JELD-WEN GLASS AUSTRALIA WATER RECYCLING PROJECT

PROBLEM

A glass manufacturer needed a cost-effective water recycling solution to reduce consumption and meet compliance.

SOLUTION

Waterform installed an UltraReuse Water Recycling System with advanced filtration, clarification, and remote monitoring.

OUTCOME

The system cut freshwater use by 80%, improved efficiency, ensured compliance, and lowered operational costs.

Glass Manufacturer - UltraReuse Water Recycling System

Project Information

ultraReuse™ Industrial Biological Nutrient Removal (BNR)Wastewater Treatment Plant and Advanced Water Treatment Plant (AWTP)

Industry

Glass Manufacturer

LOCATION

Australia

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Poultry Feed Manufacturer - Barrier-FB Advanced Water Treatment Plant

PROBLEM

A prominent glass manufacturer in Australia was facing challenges related to the high water consumption and wastewater management at its facility. The company’s glass processing equipment, particularly the Forvet cutting and cooling systems, required significant amounts of water. This resulted in rising operational costs and concerns regarding the sustainability of their water use.

In addition to high water consumption, the company needed to address several other challenges:

Environmental Compliance: The company had to ensure that its wastewater discharge met strict environmental regulations to avoid compliance issues and potential fines.
Sustainable Water Management: The company sought a solution that would reduce reliance on mains water, lower its water procurement costs, and improve overall water reuse efficiency.
Equipment Efficiency: The accumulation of suspended solids and contaminants in the process water was affecting the efficiency and performance of the Forvet machinery, leading to maintenance challenges and reduced equipment lifespan.

To address these issues, the company engaged Waterform Technologies for a comprehensive water recycling solution that would enhance operational performance, ensure regulatory compliance, and reduce environmental impact.

SOLUTION

Waterform Technologies designed a Barrier-FB Advanced Water Treatment Plant, which provided a turnkey solution for treating water to meet the ADWG compliance standards while ensuring operational efficiency.

The plant’s key components included:

Coagulation & Clarification:
The system incorporated a lamella clarifier with automated sludge removal and a high-speed mechanical mixing chamber to optimise flocculation and improve solids separation.
Ultrafiltration (UF) System:
The system featured 5 x 60m² INGE Multibore UF membranes to ensure efficient pathogen removal and consistent water quality. Automatic membrane integrity testing and backwashing, along with chemical-enhanced backwashing, were implemented to maintain system performance.
Granular Activated Carbon (GAC) Filtration:
To improve the taste and odour of the water, an automatic backwashing GAC filtration system was integrated into the treatment process.
Chlorination & Residual Disinfection:
An automated flow-paced chlorine dosing system was included for continuous microbial control, along with online monitoring of free chlorine residuals to ensure regulatory compliance.
Reverse Osmosis (RO) for Boiler Feed Water:
The system used 9 x Hydranautics ESPA 8040 RO membranes, achieving more than 80% recovery. The reverse osmosis system also featured an automated Clean-in-Place (CIP) system to optimise performance.
Smart Automation & Remote Monitoring:
The system was integrated with SCADA PLC controls for automated operation and fault detection. iSiteControl provided 24/7 remote monitoring to optimise system performance and enable real-time adjustments.
Infrastructure Enhancements:
A custom-designed containerised plant was chosen for space efficiency. An integrated backup system ensured continuous operation during maintenance and unforeseen disruptions.

This comprehensive, automated solution was designed for low operator involvement, high reliability, and seamless integration into the existing facility infrastructure.

OUTCOME

The successful installation of the UltraReuse Water Recycling System at the facility led to numerous operational, financial, and environmental benefits:

80% Reduction in Freshwater Consumption:
The system significantly reduced the company’s dependence on mains water by reclaiming process water, lowering water procurement costs, and reducing the environmental impact of water usage.
Enhanced Equipment Performance:
The consistently cleaner water produced by the system improved the lifespan and operational efficiency of the Forvet machinery, leading to reduced maintenance costs and improved productivity.
Regulatory Compliance:
The system ensured that the company’s wastewater discharge met all required environmental standards, reducing the risk of regulatory non-compliance and associated penalties.
Cost Savings:
By lowering water procurement and disposal costs, the company achieved long-term financial savings, contributing to its bottom line and sustainability goals.
Minimal Operator Intervention:
The fully automated system, coupled with remote monitoring, minimised the need for manual intervention, reducing labour requirements and optimising system performance.
Future-Proof Design:
The scalable design of the system allows for increased capacity as production demands grow, ensuring that the company can continue to meet its water treatment needs in the future.

Through this partnership, the company established a sustainable, efficient water recycling system that not only improved operational efficiency but also demonstrated its commitment to environmental responsibility and long-term sustainability.

PROBLEM

In addition to high water consumption, the company needed to address several other challenges:

Environmental Compliance: The company had to ensure that its wastewater discharge met strict environmental regulations to avoid compliance issues and potential fines.
Sustainable Water Management: The company sought a solution that would reduce reliance on mains water, lower its water procurement costs, and improve overall water reuse efficiency.
Equipment Efficiency: The accumulation of suspended solids and contaminants in the process water was affecting the efficiency and performance of the Forvet machinery, leading to maintenance challenges and reduced equipment lifespan.

SOLUTION

The plant’s key components included:

Coagulation & Clarification:
The system incorporated a lamella clarifier with automated sludge removal and a high-speed mechanical mixing chamber to optimise flocculation and improve solids separation.
Ultrafiltration (UF) System:
The system featured 5 x 60m² INGE Multibore UF membranes to ensure efficient pathogen removal and consistent water quality. Automatic membrane integrity testing and backwashing, along with chemical-enhanced backwashing, were implemented to maintain system performance.
Granular Activated Carbon (GAC) Filtration:
To improve the taste and odour of the water, an automatic backwashing GAC filtration system was integrated into the treatment process.
Chlorination & Residual Disinfection:
An automated flow-paced chlorine dosing system was included for continuous microbial control, along with online monitoring of free chlorine residuals to ensure regulatory compliance.
Reverse Osmosis (RO) for Boiler Feed Water:
The system used 9 x Hydranautics ESPA 8040 RO membranes, achieving more than 80% recovery. The reverse osmosis system also featured an automated Clean-in-Place (CIP) system to optimise performance.
Smart Automation & Remote Monitoring:
The system was integrated with SCADA PLC controls for automated operation and fault detection. iSiteControl provided 24/7 remote monitoring to optimise system performance and enable real-time adjustments.
Infrastructure Enhancements:
A custom-designed containerised plant was chosen for space efficiency. An integrated backup system ensured continuous operation during maintenance and unforeseen disruptions.

This comprehensive, automated solution was designed for low operator involvement, high reliability, and seamless integration into the existing facility infrastructure.

OUTCOME

The successful installation of the UltraReuse Water Recycling System at the facility led to numerous operational, financial, and environmental benefits:

80% Reduction in Freshwater Consumption:
The system significantly reduced the company’s dependence on mains water by reclaiming process water, lowering water procurement costs, and reducing the environmental impact of water usage.
Enhanced Equipment Performance:
The consistently cleaner water produced by the system improved the lifespan and operational efficiency of the Forvet machinery, leading to reduced maintenance costs and improved productivity.
Regulatory Compliance:
The system ensured that the company’s wastewater discharge met all required environmental standards, reducing the risk of regulatory non-compliance and associated penalties.
Cost Savings:
By lowering water procurement and disposal costs, the company achieved long-term financial savings, contributing to its bottom line and sustainability goals.
Minimal Operator Intervention:
The fully automated system, coupled with remote monitoring, minimised the need for manual intervention, reducing labour requirements and optimising system performance.
Future-Proof Design:
The scalable design of the system allows for increased capacity as production demands grow, ensuring that the company can continue to meet its water treatment needs in the future.