Integration of Failure Mode and Effects Analysis and Full‑Scale Treatment Plant Monitoring for the Management of Dairy Wastewater: Evidence from a Case Study

Dairy wastewater (DWW) contains very high levels of fats and oils (FAO), organic compounds, and other nutrients. These components pose a danger to the biological processes of wastewater treatment plant (WWTP) and may also affect the effluent’s quality. This study focuses on the combined approach of conventional Failure Mode and Effects Analysis (FMEA) and monitoring of a WWTP treating mainly DWW. After some actions were implemented to reduce the risk, the qualitative variation of the DWW was assessed and FMEA has been updated. The results highlighted that the WWTP has lower performance on organic matter than expected probably due to the low biodegradability of wastewater and the high concentration of FAO that could have limited the diffusion of oxygen in the bioreactor. However, this last aspect remains speculative and warrants further investigation to exclude other causes. The actions implemented after the FMEA help to limit the identified risks and reduces the amount of FAO discharged from the factory by 39.5%. These findings can be beneficial for both the scientific community and technical operators, highlighting the importance of integrating FMEA with large-scale WWTP monitoring and providing useful information for the management and treatment of industrial wastewater, not limited to the dairy sector.