Johanna Farms Flemington Plant Upset Causing Huge Odor Problems
Johanna Farms, Flemington NJ Plant - didn't smell Dairy Fresh
Woke up to a spectacular crisp and cool morning after the 100 degree heat and humidity broke. I felt so good I thought I’d boogie up the road to Flemington for a bagel and coffee.
Just as I hit the Flemington border on Rt. 31 I was overcome by a strong rank odor.
Leaving the bagel store, I met a man who worked for the Raritan sewer authority and asked him if his plant was having problems.
He laughed and said they were getting hundreds of complaints, but it wasn’t them – it was Johanna Farms just down the road (behind the car dealers on the western side of Rt. 31).
The Johanna Farms plant has a history of plant upsets that have caused major sickening odor and air problems. They discharge yogurt and juice waste residuals to on site disposal lagoons. They process the sludge and ship it off site for disposal on agricultural lands. Land application of this sludge on farmland has created local controversies due to strong odors, including in my town of West Amwell. (and this)
The Johanna plant also uses extraordinarily hazardous chemicals, and is regulated under the DEP Toxic Catastrophe Prevention Act permit program.
The smell was so disgusting, I called the DEP Hotline (877-WARNDEP) to report a violation of the NJ Air Pollution Control Act. That law prohibits nuisance odors beyond the facility boundary.
In this case, the air for miles around was polluted with the stench of anaerobic decaying organic matter. I assume there must be similar local health laws regulating odors from this facility that need to be enforced.
Not confident that DEP would do anything to enforce the law and DEP air and water permits, I decided to take matters into my own hands.
I drove to the plant and asked at the security gate for a meeting with the plant environmental manager.
I was given the phone number of  Plant Environmental Compliance Manager Joe Saracini (908-788-2385). I called Joe. Shortly after  he returned my call and I was able to get a good half hour discussion with Joe and the Company VP. [Correction - it is Tony Saracini. - I got his name mixed up with VP Joe (see comments for contact info). Thanks for comments John - that's what they're there for!!]
Initially, Joe tried to give me a BS story to downplay the problem.
Joe  claimed that 1) the problem was natural and caused by the heat wave; 2) that they were simply treating yogurt and juice byproduct in lagoons with swimming pool chemicals; and 3) that they were in compliance with all permits and laws.
[Update: to clarify, Johanna's  claims are flat out false: 1) the problem is not natural, but is caused by a waste treatment process at an industrial plant; 2) the lagoon contents are not "byproducts" they are regulated wastes. The "pool chemicals" used to treat these wastes are hazardous (NaOH); and 3)  the facility is in violation of state law, DEP regulations, DEP permits, and perhaps local health ordinances.]
I called them on that and in so doing I learned that they were experiencing an upset in the pre-treatment process and waste lagoons. The lagoons had gone or were going anaerobic and were not responding to aeration and chemical treatments to stabilize the pH.
After persistent questioning, they conceded that they made a $5 million investment in a new pre-treatment, aeration, and lagoon processing system 10 years ago in response to DEP requirements after a catastrophic tank collapse, followed by a power outage. That event created anearobic conditions and severe odor problems.
They also admittted that they had odor problems last year and that the most recent problem was ongoing and had begun last week.
The odors caused numerous complaints from nearby residents that led to plant insections but no enforcement actions by the Hunterdon County and Flemington Health Departments. They said that DEP has not been to the facility to inspect or enforce.
I requested that they give me a specific plan to remedy the problem and a schedule – they refused to provide this info but said they had retained engineering consultants to answer those questions.
I thanked them for their cooperation and then called DEP Air enforcement to relay this information and request inspection and enforcement action.
I gotta tell you, their seeming inability to understand and appropriately manage a biological process in a lagoon did  not inspire confidence that they can safely handle extraordinarily hazardous chemicals that can kill nearby residents.
We will keep you posted in terms of DEP and local enforcement response and whether the problem gets fixed quickly.
I really feel bad for anyone that lives nearby that stench.
thats a groundwater monitoring well in the foreground and construction and demolition waste (illegal) storage in the background. Let's hope DEP inspectors cite them for this violation.
Dairy Fresh?
view from the security gate - tanks in background
