Romtec Utilities designed and supplied a food process lift station for a $40 million facility expansion by a spice manufacturer in South Bend, Indiana. The upgraded infrastructure supports a new production line and handles complex chemical and solid waste streams for food manufacturing.

Jedson Engineering Inc. led the facility’s engineering, procurement, and construction management and brought Romtec Utilities into the project. F.A. Wilhelm was the general contractor and previously worked with Romtec Utilities on a different project.

Romtec Utilities managed the complete lift station scope, providing:
• Design and engineering of a complete packaged pump station.
• Prefabrication and delivery of all mechanical, structural, and electrical components.
• On-site advisory services during installation and start-up.
• Warranty and performance assurance for all supplied equipment.

Romtec’s involvement began with a formal request for proposal and continued through multiple rounds of RFIs, bid revisions, and scope clarifications. The final design was approved after extensive collaboration with Jedson Engineering, ensuring all specifications aligned with the facility’s operational needs.

The South Bend Cardinal Lift Station was engineered to handle wastewater generated from process washdown and clean-in-place operations. These streams include:
• Acidic and caustic cleaning solutions
• Sanitizers with hypochlorite
• Organic waste from sauce production (e.g., pepper mash, vinegar)
• High salt concentrations (up to 35%)
• Temperatures ranging from 65°F to 185°F
• Solid debris such as pepper chunks, seeds, zip ties, and plastic fragments

Romtec Utilities designed the food process fiberglass lift station to accommodate these variables, ensuring durability, corrosion resistance, and clog prevention. The pumps and piping were selected to withstand chemical exposure and high temperatures, while trash baskets were included to capture solids before they could damage equipment.

The lift station features a triplex pump configuration, alternating operation to balance wear and extend equipment life. Key specifications include:
• Peak inflow: 225 GPM
• Pump rate: 75 GPM per pump
• Total Dynamic Head (TDH): 156.3 feet
• Wet well: 8-foot diameter, 20-foot depth
• Active volume: 112.5 gallons
• Power supply: 480V / 3-phase

Romtec supplied three Goulds vertical sump pumps, each with stainless steel columns and discharge piping. The system includes radar level sensors as the primary sensing device, backed by eight float switches for redundancy. The control panel, housed in a NEMA 4X stainless steel enclosure, features fiber optic communication for integration with the facility’s control systems.

Orenco created the fiberglass wet well, which was a critical structural component to the lift station. Its corrosion-resistant design and compatibility with food process wastewater made it ideal for this industrial application.

Romtec Utilities prefabricated the food process fiberglass lift station components to the furthest extent possible prior to shipment. This included:
• Structural components such as the wet well and valve skid
• Mechanical assemblies including pumps, valves, and piping
• Electrical equipment including the control panel and level sensors

Delivery was coordinated to align with the construction schedule, and Romtec provided advisory support during underground installation. An installation adviser was present on-site to oversee component placement and ensure proper installation procedures were followed.

Romtec Utilities supported the system startup and owner training. A start-up technician provided two days of on-site service, verifying system performance and training designated personnel on operation and maintenance. Romtec supplied a comprehensive O&M manual, including:
• Submittal documentation
• Parts lists
• Maintenance guides
• Electrical schematics

While primary system controls were provided by others, Romtec ensured its supplied components functioned correctly and met performance expectations.

The South Bend Cardinal Lift Station is a critical component of the facility’s expansion. South Bend, located in northern Indiana, has a reputation as a hub for manufacturing and industrial innovation. It is historically known for automotive and heavy machinery production, but has increasingly diversified into sectors like food processing, logistics, and advanced manufacturing.

The region has a robust infrastructure with access to rail and highway networks, and a skilled workforce, making it an attractive location for large-scale industrial investments. South Bend is strategically located in the Midwest, less than 3 hours from Chicago (Illinois), Indianapolis, Detroit (Michigan), Fort Wayne, Toledo (Ohio), Grand Rapids (Michigan), and Milwaukee (Wisconsin).

Romtec Utilities’ ability to design and deliver a pumping system tailored to the unique chemical and physical properties of food manufacturing waste demonstrates its expertise in custom lift station solutions.

This project highlights Romtec’s role not just as a supplier, but as a strategic partner in complex infrastructure development. From initial design to final startup, Romtec Utilities provided the engineering, support, and reliability needed to ensure the success of this high-impact project.