By Andi Anderson
A major collaboration between Michigan State University AgBioResearch and MWC, a large dairy processing facility in St. Johns, has created a successful model for sustainable food processing. MWC processes billions of pounds of milk each year, leaving very little room for operational errors.
Even small disruptions in wastewater treatment can risk production levels, environmental compliance, and the livelihoods of dairy farmers who rely on the facility.
MWC, which opened in 2020, is a joint venture between Glanbia, Dairy Farmers of America and Select Milk Producers. The facility handles approximately 2.9 billion pounds of milk annually. Since opening, it has produced 1.3 billion pounds of block cheese — an amount that would stretch nearly 7,000 miles if cut into 40‑pound blocks.
To support this scale of production, MWC operates a $25‑million wastewater treatment system that includes anaerobic digestion and membrane filtration.
This system is designed to recover water from cheese processing and protect local water resources. However, shortly after opening, the facility began to experience major operational instabilities. pH levels fluctuated, aerobic sludge activity declined, and routine operation became difficult to maintain.
“We fundamentally weren’t tracking the correct key performance indicators,” said David Holmberg Jr., maintenance director at Glanbia. “Multiple issues were occurring simultaneously, creating instability in the wastewater treatment operation.”
Seeking a long‑term solution, MWC partnered with MSU’s Anaerobic Digestion Research and Extension Center (ADREC), led by Professor Wei Liao. Instead of treating the issue as a standard consultation, the MSU team incorporated it into a hands‑on engineering capstone project.
Students, led by then‑senior Carter Monson, worked directly with MWC staff to study performance data, assess microbial activity, and design a plan to stabilize the system.
The collaboration succeeded, and the wastewater process has remained stable ever since. Monson shared, “They gave us access to data, samples and operations, which allowed us to develop solutions that actually worked in practice.”
With stability achieved, MSU and MWC are now focusing on creating a circular water system. Because milk is 88% water, increasing internal water recycling could greatly reduce the facility’s dependence on municipal water supplies while supporting sustainable production.
“MWC could become the example for what a fully circular water system looks like in Michigan,” Liao said.
Photo Credit: michigan-state-university-msu
Categories: Michigan, Sustainable Agriculture