Innovation provider

Abbelen Fleischwaren GmbH & Co. KG


Kempener Strasse 20
Mr. Clemens Louven
47918 Tönisvorst
Tel.: +49 (0)2156 / 97 89 35
Fax : +49 (0)2156 / 97 89 33

Effizienz-Agentur NRW
Dr.-Hammacher-Straße 49
47119 Duisburg
Tel.: +49 (0)203 37879-30
Fax: +49 (0)203 37879-44


The production of the extensive range of meat products – for example, some 375 t of rissoles are produced each week – requires an appropriately flexible job-order production system.
Market success, the high quality and hygiene standards in production also saw a rise in operating costs in the field of process water and process energy. As a consequence, in 2004 Abbelen initiated the PIUS Check (for details please see section “Toolbox” on the SPIN Hompepage) by Effizienz-Agentur North Rhine-Westphalia with the aim of lowering the overall use of water, chemicals and energy, taking into consideration the high requirements of food hygiene.
An analysis was undertaken of the internal value added (goods-in, meat preparation, portioning, frying line, frosting, packaging and contract cleaning). Improvements in the process, incorporating the employees, enabled process water consumption to be significantly reduced by 0.32 m3/t of product, for example via a drier pre-cleaning process.
 After this, the waste water containing fat, meat residue, brine
and marinade enters a cleaning system comprising a pre-separator and post-separator for fats. It did not prove possible to solve the problem of the lipophilic substances released by large quantities of hot cleaning water using standard fat separators.
 Abbelen therefore turned to ASR (aerobic sludge reactor) technology with downstream ultra-filtration (UF) and reverse osmosis, comprising the following stages:

  • Mechanical cleaning via sieves and rotors

  • Biological cleaning with the activated sludge process

  • Sludge separation via ultra-filtration

  • Water treatment via reverse osmosis

  • Partial recycling to the cooling towers



By switching to ASR water treatment technology, considerable improvements could be achieved compared to the formerly installed fat separator. Wastewater values thus developed as follows:
COD:                                          7669 mg/L down to 150 mg/L
Lipophilic substances:           1400 mg/L down to 10 mg/L
Settleable substances:          614 mg/L down to 5 mg/L
Total phosphorus:                   48 mg/L down to 10 mg/L
Total nitrogen:                          238 mg/L down to 25 mg/L

Innovative aspects (ecologic, social and economic)

A pump initially brings the waste water for solids removal from a collector shaft through a rotating filter in a mixing and equalising reservoir. Here there is sedimentation of coarse material, temperature equalisation and automatic correction of the pH value via the addition of caustic soda. The concluding biological treatment is undertaken by an aerobic sludge reactor, with the separation of reusable biomass from the treated waste water performed by downstream ultra-filtration. The sludge accrued is drained using a solid-bowl screw-type centrifuge (decanter) with integrated press.
The cleaned process water is used exclusively in the cooling towers with a share of 25 % as supply water.
The result is a closed cooling water circuit with water savings of
10,000 m3 per year.

Application examples


Following the PIUS Check EFA conducted PIUS financing consulting. EFA drew up a financing recommendation for the investment to the amount of 1 million Euros. The project was subsidised with a grant from the NRW Ecological and Sustainable Water Management Initiative aid programme, funding area 1.1 (2000 - 2006), of the NRW Ministry of Environment.


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National Contact Point

Daniel de Graaf
Wörlitzer Platz 1
06844 Dessau-Roßlau

Tel. +49 (0)340 21033407
Fax. +49 (0)340 21043407