NEUTRA grease separators for vege table and animal fat in compliance with EN 1825 and DIN 4040-100 Separating technology
A problem that should not be underestimated: Fat in wastewater All vegetable and animals oils and fats represent a considerable additional load on our sewer system and wastewater treatment plants. It can cause pipes to clog up, accelerate corrosion, lead to unpleasant odors and make the operation of sewage treatment plants more difficult. For this reason, the law requires the installation of grease separators in accordance with the polluter pays Grease separators for all requirements Grease separators provide the answer to fat problems simply, quickly and environmentally appropriate. Depending on the intended use, NEUTRA grease separators are manufactured from reinforced concrete, plastic or stainless steel. We also build customized plants to meet individual requirements. For underground installation, NEUTRAtip and NEUTRAsept are available as a separate system for standard operation, while NEUTR - Abasic and NEUTRAtec are provided for free-standing installation. Note on standards EN 1825 parts 1 and 2 and DIN 4040-100; both standards may only be applied together. principle. With its NEUTRA products, Mall offers matured, economical solutions for all requirements. Mall customers benefit from a distribution and service network that covers all of Germany. 2 NEUTRA Grease separator
Components and functions The grease separator plants comprise three components:. NEUTRA sludge trap Heavy soil particles will settle in the sludge trap.. NEUTRA grease separator Owing to their low density, fats will remain on the surface and form a separate layer.. NEUTRA sampling manhole For taking representative waste - water samples from the flowing wastewater. Disposal Disposal intervals must be scheduled such that the storage capacities of the sludge trap and the separator are not exceeded. In accordance with EN 1825 and DIN 4040-100, both these components should be emptied completely, cleaned and refilled with fresh water, preferably every two weeks but at least once a month. The following items must not be discharged into grease separators:. Wastewater containing oil and fat of mineral origin Sewage containing fecal matter. Rainwater. Washing, rinsing and cleaning agents, as well as disinfection agents, must be separator-friendly and must not form stable emulsions. The use of products containing enzymes to convert the substances or for self-cleaning purposes is not permitted Grease separator applications In accordance with EN 1825 and DIN 4040-100, grease separators must be installed by all companies producing wastewater with a fat content. These include:. Commercial kitchens, canteens and refectories Hotels and restaurants. Care homes and homes for the elderly. Roadside service areas and snack bars/takeaways Oil mills, edible oil refineries. Factories for margarine and food preserves Ready meal producers Chip producers, peanut roasters Poultry slaughterhouses. Grilling, roasting and deep-fat frying kitchens. Fresh and cold meat factories, butchers. Slaughterhouses and installations for the disposal or recycling of animal carcasses and animal waste Operating mode of a grease separator system Wastewater Fat Sludge NEUTRA Grease separator 3
Design and installation: Mall offers the optimal solution for all requirements Operation All Mall products are designed for ease of installation, easy handling using durable, mature technology. This keeps the costs for operating the units as low as possible. Dimensions / sizing The sizing of grease separators is carried out individually to make sure that your operational processes are matched with the right unit. Once the required volumes are established, a grease separator is selected from one of several nominal sizes (NS). In accordance with EN 1825 and DIN 4040-100, grease separators must be sized according to the type and quantity of the wastewater to be treated. Sizing parameters:. Maximum wastewater outflow Q s. Density of the fats and oils to be separated f d. Temperature of the wastewater f t. Effect of any rinse aids and cleansing agents f r Mall provides an online sizing program in order to help you conduct the sizing quickly and easily. If you need further information or assistance for design and technical realization we are very happy to discuss your solution personally. Installation underground. No other material is as well-suited to underground construction as concrete is.. In compliance with applicable standards, concrete as a building material is designed for a service life of at least 50 years.. Installation by local contractor, no specialist contractor required. Can be adapted to existing drainage pipes. The outside location allows for natural ventilation. Optimum accessibility for maintenance and disposal. High load capacities both statically and dynamically (60 t HGV), and can be driven over. Dense and flexible pipe connection suitable for plastic pipes. No additional load transfer panels required. Can in most cases be installed without additional buoyancy protection Free-standing installation in a frost-proof room. The system can be moved if necessary Slender shape. Low in weight. Also fits through narrow doors and stairwells. Does not require much space. Can be fitted to existing drainage pipes. No earth works required for installation. An optional viewing panel is available to control the layer of fat 4 NEUTRA Grease separator
NEUTRAsept and NEUTRAtip for installation underground Generally, the best and most expedient solution for installing a grease separator is underground. No specialist contractors are required work can be carried out by local contractors. The space of the instal - lation remains usable for vehicular circulation or as a parking space. There are no problems with access to the plant for disposal purposes. The odor nuisance during disposal is reduced to a minimum.. Quality-controlled precast reinforced concrete construction without joints. Type-tested structure Characteristics:. Internal coating in accordance with the relevant standards. Stainless steel components corrosion-proof. Flexible pipe joints with multiple seals for plastic pipes. No additional adapters required NEUTRAtip In the NEUTRAtip reinforced concrete grease separator, the sludge trap unit and the grease separator are arranged side-by-side without separating partition. The performance of the separator has been tested in practice and documented in accordance with EN 1825 and DIN 4040-100. NEUTRAsed and NEUTRAsept For special requirements it is also possible to supply the sludge trap and the separator as separate units. NEUTRAcheck sample-removal manhole. The sample must be taken from the flowing wastewater in the plant. The volume of the sample-removal container must be greater than the sample volume. The sample removal log also contains a record of the operating state while the sample was taken, as well as a record of the data on site Options. PE-HD plastic inliners resistant to fatty acids instead of the inner lining compliant with the standards. The wax-like surface prevents incrustation and accelerates the cleaning process. The polyethylene is highly resistant against all operational hazards. Suction device NEUTRA Grease separator 5
NEUTRAbasic and NEUTRAtec for free-standing installation Grease separator and sludge trap in one unit Where the available space outside is limited, or where the plant is part of an upgrade in existing rooms it is possible to opt for free-standing versions. The installation can be inside any existing rooms that are frost-proof. These rooms must have ventilation (air inlet and discharge). Owing to the slender shape and low weight of the plant it will fit even through narrow stairwells and can be installed in small rooms. NEUTRAbasic and NEUTRAtec In the standard versions, the covers are opened manually. The suction hose used for disposal is taken through the building to the place where the plant is installed. Then the separator is manually cleaned with a water jet and re-filled with fresh water. For improved operating convenience we offer a range of options, depending on customer requirements. Upgrading with well-designed options We offer special disposal mechanisms in order to allow for more convenient maintenance and disposal processes. These do not require the separator to be opened for disposal. Disposal is achieved from the outside via a suction pipe (to be installed by others). The layer of fat can be controlled via a vision panel. The odor nuisance during disposal is reduced to an ab - solute minimum. With this solution it is not necessary to pull a suction hose through the building. Further options include fill and sample-taking devices. Quality assurance for the drainage technology The Professional Association for Drainage Technology Quality Assurance (GET) guarantees that the high quality standards will be met, and that safe operation is therefore assured all year round. Advantages of the GET guidelines. Specification of additional quality criteria beyond the standard for drainage technology products. GET guidelines close gaps created by European harmonisation. Consumers have the opportunity to describe the required quality standards precisely by referring to the GET guidelines. Monitoring certificates document the maintenance of these increased standards. External monitoring of the production processes. Special stability certificates Quality features. Documented quality management by the association. Ongoing updates of the technical condition of the products Type testing and national certification. Internal monitoring of production by the manufacturer 6 NEUTRA Grease separator
Services and accessories General inspection, maintenance and disposal Prior to commissioning and after five years of operation, a general inspection including a leak test must be conducted by a specialist. The annual maintenance can be conducted by a specialist, or directly by the plant operator, provided that a specialist training programme with instructions on site has been completed in accordance with EN 1825 and DIN 4040-100. The intervals between disposals must be determined in such a manner that the storage capacity is not exceeded. We recommend full emptying of the sludge trap and separator system every two weeks. The internal monitoring, maintenance and inspection, as well as the disposal of removed substances, must be recorded in the operation log. All these services can be provided by Mall. NEUTRAproof manhole sealing system Innovative manhole system for manholes with standard, displace - ment-proof bearing rings according to DIN V 4034-1. The system consists of a subsequently installed compression seal which is pressed through a stainless steel tension ring. The sealing sleeve is tensioned inside the manhole, thus pressing the rubber from the inside onto the compensation rings. No chemical adhesives, binding agents or mineral plaster are used. Backwater-proof installation of a grease separator Separator systems with a static water level below the backwater level must be drained via a downstream lifting station. According to the standard, it is not permitted to fit an anti-flooding valve. A pump station to be installed downstream of the separator system is to be designed in accordance with DIN EN 12056 und DIN EN 752. NEUTRAtip grease separator system Grease separator system with integrated sludge trap EN 1825 and DIN 4040-100 Sample-removal manhole Pump shaft NEUTRA Grease separator 7
Project report Grease separators McDonald s and Mall Planners Online Tip Carry out project planning with Mall's help You ll find the NEUTRAplan online sizing program for grease separators and light fluid separators under www.mall.info The initial situation The first German McDonald s restaurant opened on 4 December 1971 in Munich. McDonald s and its franchisees now employ almost 60,000 staff in 1,333 restaurants throughout Germany. McDonald s Germany is a market leader in the catering industry. McDonald s produces fatty wastewater every day in its kitchen areas, which cannot be discharged into the sewage system without pre-treatment. The solution Here grease sepa rator systems from Mall ensure that the kitchen wastewater is cleaned efficiently. In this respect a common standard was stipulated: all separators are supplied with a PE-HD inner lining and the sample-removal manhole is supplied with fibreglass composite cladding. This ensures the durability of the systems, enabling them to withstand the aggressive fatty acids. The advantages at a glance System parts with certification. Uniform standard for Germany agreed with the customer Accessibility of the system parts. Delivery with crane. Implementation of the general inspection. Everything from one source; combination with rainwater use, wastewater treatment and lifting systems. Grease separator systems for installation indoors or containerin-container Client McDonald s Germany Design Construction department, McDonald s Germany Year of construction ongoing Products Grease separator and NEUTRAtip NS 4-800 sludge trap, NEUTRAcheck sample-removal manhole FO-0214 WO 06/10 Subject to technical modifications without notice. Hüfinger Straße 39-45 78166 Donaueschingen Phone +49 771 8005-0 Fax +49 771 8005-100 Grünweg 3 77716 Haslach i. K. Phone +49 7832 9757-0 Fax +49 7832 9757-290 Industriestraße 2 76275 Ettlingen Phone +49 7243 5923-0 Fax +49 7243 5923-500 Roßlauer Straße 70 06869 Coswig ( Anhalt) Phone +49 34903 500-0 Fax +49 34903 500-600 Oststraße 7 48301 Nottuln Phone +49 2502 22890-0 Fax +49 2502 22890-800 info@mall.info www.mall.info Ident-No. 092003