Pilot-Scale Evaluation of a Filter Prototype for Bacterial Inactivation in Agro-Food Processing Wastewater

The processing of freshly cut fruits and vegetables represents an important niche for implementing circular economy principles, particularly through the reuse of washing water. This is especially relevant as post-wash water is often treated as wastewater and discarded without reuse. One promising research avenue is the use of plant-derived extracts in water sanitation processes. Their antimicrobial properties offer a natural alternative to conventional disinfectants while reducing the formation of harmful disinfection by-products. The aim of this study was to evaluate the effectiveness of different filter bed configurations in removing pathogens from water. These configurations included a hydrogel saturated with natural plant extracts, an ion exchange resin layer, and an activated carbon layer. The most effective composite was also tested using real process water from a fruit washing line. The test materials included concentrated extracts from oak bark (Quercus robur), willow (Salix alba), birch (Betula pendula), raspberry shoots (Rubus idaeus), tea leaves (Camellia sinensis), and linden flowers (Tilia cordata), all immobilized in hydrogel, along with activated carbon and ion-exchange resin. Water samples were artificially inoculated with six opportunistic pathogens and collected process water was also used. Samples were analyzed microbiologically at six time intervals. The composite filter (hydrogel–resin–carbon) achieved a reduction of over 2 log10 in heavily inoculated water (~108 CFU mL−1) and maintained at least a 1 log10 reduction in real process effluents. The proposed solution supports blue water footprint reduction strategies (as the system aims to decrease the demand for freshwater resources through the reuse of treated wastewater) and aligns with the principles of green processing.