• Active fragrance manufacturing plant with complex combination of compounds
• Odor complaints prompted regulatory enforcement
• Extensive investigation and pilot study.
• Several remedial action alternatives analyzed
• Complex permitting process
• Noise mitigation investigation and design
• Construction management
• Stack testing and reporting for odor mitigation system
A confidential New Jersey fragrance manufacturer produces up to 4,000 blends monthly using more than 3,000 chemical compounds. Despite operational and ventilation improvements, emissions affected ambient air, generating neighborhood odor complaints and regulatory citations.
Challenge
The challenge was developing a reliable treatment system for a highly variable mixture of compounds, often present at very low volatile organic compound concentrations, while achieving the New Jersey Department of Environmental Protection’s required destruction efficiency of more than 90 percent.
Solution
GZA conducted a comprehensive odor investigation at the site that included baseline evaluations, indoor air screening, source and exhaust-stack sampling, downgradient sampling, and dispersion modeling. After evaluating seven remedial alternatives for effectiveness, reliability, constructability, community impacts, sustainability, and regulatory compliance, GZA recommended a regenerative thermal oxidizer. A 26-week pilot study, incorporating a zeolite concentrator wheel and multiple polishing media, enabled GZA to optimize treatment parameters and design the full-scale system.
GZA provided permitting support, design calculations, drawings, specifications, contractor coordination, bid evaluation, and construction oversight. When modeling identified potential noise impacts from system fans and blowers, GZA designed a 20-foot sound barrier and insulated equipment covers; post-construction monitoring confirmed compliance with the local noise ordinance. GZA also developed stack-testing and monitoring protocols, coordinated worst-case production conditions, oversaw performance testing, and secured the final operating certificate.
Benefit
GZA’s integrated environmental, permitting, acoustical, engineering, and construction-management services delivered a compliant odor-control system while minimizing operational disruption and community impacts. Since startup, the facility has received no verified odor complaints, supporting continued production and long-term regulatory compliance.