• Al Goodman (CDM Smith), Dan Bena (Pepsico), Mo Haghighipodeh (Frito-Lay), Cedric Robinson (Frito-Lay) and Dick Fox (CDM Smith) accept the 2012 U.S. Water Prize.

file under: 3D/4D Design, Industrial, Design-Build, Energy, Facilities, Food and Beverage, Membranes, North America, Sustainability, United States, Water Reuse

Facility + Design-Build

Frito-Lay's Casa Grande Snack Food Manufacturing Facility Wins Distinguished U.S. Water Prize

First-of-its-kind process water recovery system underscores sustainability commitment.

March 30, 2012

CASA GRANDE, Arizona—The Clean Water America Alliance (CWAA) has awarded PepsiCo Frito-Lay a 2012 U.S. Water Prize for its Casa Grande, Arizona, USA snack food manufacturing facility. Thanks to an innovative process water reuse system and alternative energy, the facility runs almost entirely on renewable energy and recycled water while producing nearly zero waste—something the company refers to as “Near Net Zero.”

The 650,000-gallon-per-day process water recovery treatment system recycles up to 75 percent of the facility’s process water—enabling Frito-Lay to reduce its annual water use by 100 million gallons. 

CDM Smith completed the design and construction of the 650,000-gallon-per-day process water recovery treatment system, which recycles up to 75 percent of the facility’s process water—enabling Frito-Lay to reduce its annual water use by 100 million gallons. The advanced purification system includes advanced membrane treatment and disinfection to treat the effluent to U.S. Environmental Protection Agency (EPA) primary and secondary drinking water quality standards, allowing it to be reused to wash and move potatoes and corn. This is the first U.S. food processing plant that produces drinking water quality process water to be reused in food production.

The facility also freed up land, previously used for the pre-treatment and land application of wastewater, for a 5-megawatt photovoltaic solar system that produces almost all of the plant’s daytime electricity needs. CDM Smith completed the entire photovoltaic solar installation, including 36 acres of photovoltaic panels on dual-axis ground-mount systems, single-axis concentrated photovoltaic collectors, and dish collectors with Stirling© engine generators.

The Casa Grande facility was the first snack food manufacturing facility in the United States to be awarded LEED® Existing Building Gold Certification from the U.S. Green Building Council, thanks to educational elements, enhanced process layout, energy-efficient motors, and recycled construction debris. Learn more Frito-Lay's Casa Grande process water recovery system.

CWAA created and administers the U.S. Water Prize to recognize achievement and inspire action for water sustainability. According to CWAA, PepsiCo Frito-Lay is deserving of the U.S. Water Prize because of its corporate-wide stewardship on water and energy conservation.

CDM Smith provides lasting and integrated solutions in water, environment, transportation, energy and facilities to public and private clients worldwide. As a full-service consulting, engineering, construction and operations firm, we deliver exceptional client service, quality results and enduring value across the entire project life cycle.