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Thinking outside the box leads to excellent solutions

Aerfloat's wastewater solutions are flexible and robust.

When it comes to wastewater treatment plants, Aerofloat has a proven track record of being able to overcome unforeseen restrictions to install the best wastewater treatment for its clients. Food & Beverage Industry News reports.

Aerofloat, experts in wastewater solutions, has recently installed a low-maintenance wastewater treatment system at a Meyer Food Co. site, formally Bryopin, as part of the company’s expansion.

Meyer Food Co. is one of Australia’s largest dedicated sous vide foods manufacturer. The meat-based production processes required lots of water; therefore, Meyer Food Co. needed a robust wastewater treatment solution to ensure compliance and support
its growth.

Aerofloat’s design included its patented AeroDAF, which applies modern engineering to traditional dissolved air flotation technology.

Dissolved Air Flotation is a method in which suspended solids, fats, oils, and grease are removed from wastewater, so that it can be safely put back into
the sewer.

Some of the benefits and features of the wastewater solution include the patented scum removal system, which reduces maintenance time, coupled with a unique double hopper design that is self-cleaning, eradicating the need for mechanical scrapers.

This also creates a more cost-effective solution for food and beverage manufacturers and producers.

Michael Anderson, director, Aerofloat, said the project came after a long consultation period to ensure the design and installation met the needs of both the Meyer Food Co. and local regulations and standards
around wastewater.

“The client asked us to design a wastewater treatment plant that would fit a specific area of the plant,”
said Anderson.

Despite some restrictions created by the layout of the site, Aerofloat was able to utilise its 3D modelling to come up with a viable solution that created additional benefits for the client.

“We collaborated with Meyer Food Co. to capitalise on the split-level space in the facility. We were able to add equipment to the upper level, such as the control panel. And hydraulically we were able to put the screen on that upper level,”
said Anderson.

“The client was happy we were able to work with the space and come up with a successful outcome for them.”

Aerofloat’s AeroDAF is already compact in design, making it easier to fit into a small footprint, saving space to produce goods for the client.

Because the wastewater solution had to be installed across two levels the Aerofloat team used gravity to ensure a correct flow.

“Essentially, you need some things elevated and we are big fans of minimising the number of pumping systems in a process train. Using gravity is an easy way to create a more energy efficient wastewater treatment plant,”
said Anderson.

“Anywhere we can cascade from one process to the next is clever design.

“We look to do that when we can and with this split level set up, we gained access to certain equipment on that second level while using the hydraulics through the fall of the system to
our advantage.”

Even without the use of gravity as an added benefit to the two-level solution, AeroDAF’s come in capacities of 100 & 200 l/min litres per minute, with the Meyer Food Co. solution being a
200-litre solution.

Being a meat processor, the Meyer Food Co. required a solution which could separate fats, solids, and grease from the wastewater before it was pH corrected and then discharged into the local sewer.

Because of the tight space the installed tanks had to be tall, with a 200-litre per minute, or 12,000 litres per hour, capacity. Future proofing the solution was also important to Aerofloat and Meyer Food Co.

“Selecting the right product is key, we have three types of DAF’s that we sell in the small flow to large flow ranges,”
said Anderson.

“Different clients require different DAF’s, depending on their requirements and we take pride in doing our due diligence to provide the best wastewater treatment solution.

“We look at data around waste streams and gain a deep understanding of a client’s internal processes, and we use that sound wastewater data to select the right DAF.

“We can process to the 200-litre per minute speed, or we can slow it down. This system is ideal because it creates a lot of room for expansion alongside the company, without having to be replaced any time soon.”

They also had to provide 600mg/l meet local standards. All of which were achieved by the team from Aerofloat.

The installation falls under Sydney Water’s jurisdiction, meaning it must meet the standards set out by Sydney Water, something it has not only met, but exceeded.

Another aspect of the Meyer Food Co. installation, which is becoming more common across the industry, is the automated plant which allows Aerofloat engineers to monitor the system remotely and contact a client if data indicates an issue with the system.

This significantly reduces downtime for the client, and travel time for Aerofloat engineers. While also preventing a smaller issue turning into a much larger one before being discovered.

Wastewater standards vary from state to state. With a vast number of projects in the food and beverage industry completed and multiple new projects underway, Aerofloat always has its pulse on the regulations that are specific to each state.

Aerofloat can apply the required standards and regulations to each job, no matter where in the country it is, to ensure its clients not only meet, but exceed the requirements.

This is helped along by the company ensuring its engineers assist in both the de-sign and construction of water treatment plants using a variety of options for clarification, filtration,
and disinfection.

Anderson says it’s important to consider incoming feed quality, which will dictate the water treatment design, along with the best way to integrate other systems into the design.

“Our team undertakes extensive consultation with a client to ensure the design is the best one for the space and requirements, namely ensuring treatment systems will run effectively, are future proofed, and produce effluent that meets discharge requirements,” said Anderson.

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