VENTORA GLASS MANUFACTURER CASE STUDY

PROBLEM

A glass processing facility faced high water consumption, wastewater discharge, and maintenance issues, leading to increased costs and compliance risks.

SOLUTION

Waterform installed an UltraReuse Water Recycling System to reclaim and treat wastewater for reuse, reducing consumption and ensuring compliance.

OUTCOME

The system reduced water usage by 70 kL/day, lowered operating costs, improved equipment performance, and ensured compliance, with scalability for future growth.

Glass Processing Facility

Project Information

ultraReuse Water Recycling System

Industry

Glass Processing Facility

LOCATION

Australia

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Glass Processing Facility: ultraReuse Water Recycling System

PROBLEM

A leading glass processing facility, specialising in grinding and polishing operations, faced challenges with excessive water consumption and high levels of wastewater discharge. This led to rising operational costs and environmental concerns. The existing water management system was inefficient, requiring frequent maintenance and posing a risk to regulatory compliance.

Key issues included:

High levels of suspended solids in wastewater (~2,100 mg/L)
Excessive water wastage due to ineffective recycling
Increasing costs associated with wastewater disposal and freshwater usage
Potential risk of equipment wear and downtime due to poor water quality
Compliance with sustainability goals and regulatory standards

Recognising the need for a more sustainable and cost-effective water treatment solution, the facility engaged Waterform Technologies to develop an advanced water recycling system.

SOLUTION

Waterform Technologies designed and implemented an UltraReuse Water Recycling System, a tailored, state-of-the-art solution, to reclaim and treat wastewater for reuse in the glass grinding and polishing machines. This system aimed to reduce overall water consumption while ensuring compliance with operational requirements.

Key components of the solution included:
• Raw Water Collection: A suspended trash pump with level switch automation to collect wastewater from the existing pit.
• Flocculation & Coagulation: A high-speed mechanical mixing chamber with precision dosing to enhance sedimentation and particle separation.
• Ceramic Ultrafiltration Membrane: Advanced filtration down to 0.04 microns, ensuring complete removal of fine particles and contaminants.
• Filtered Water Storage & Distribution: Integration with existing water storage tanks, including automated level sensors and a mains water top-up system to ensure uninterrupted production.
• Chemical Dosing System: Grundfos dosing pumps for coagulants, pH correction, and membrane cleaning, maintaining optimal system performance.

The system was designed with scalability in mind, allowing for future upgrades to accommodate increased water demand as the business grows.

OUTCOME

The implementation of the UltraReuse Water Recycling System has delivered significant benefits to the glass processing facility, including:

Reduction in Water Consumption: The plant now reclaims up to 70 kL/day of water, significantly decreasing reliance on fresh water.
Lower Operating Costs: By reducing wastewater disposal and freshwater intake, the company has achieved substantial cost savings.
Enhanced Equipment Performance: High-quality recycled water minimises equipment wear, reducing maintenance and downtime.
Regulatory Compliance: The system ensures compliance with environmental regulations and sustainability targets.
Future Scalability: The modular design allows for additional treatment capacity as production demands increase.

With this solution, the facility has reinforced its commitment to sustainability while achieving operational efficiencies, cost reductions, and improved production reliability.

PROBLEM

Key issues included:

High levels of suspended solids in wastewater (~2,100 mg/L)
Excessive water wastage due to ineffective recycling
Increasing costs associated with wastewater disposal and freshwater usage
Potential risk of equipment wear and downtime due to poor water quality
Compliance with sustainability goals and regulatory standards

Recognising the need for a more sustainable and cost-effective water treatment solution, the facility engaged Waterform Technologies to develop an advanced water recycling system.

SOLUTION

The system was designed with scalability in mind, allowing for future upgrades to accommodate increased water demand as the business grows.

OUTCOME

The implementation of the UltraReuse Water Recycling System has delivered significant benefits to the glass processing facility, including:

Reduction in Water Consumption: The plant now reclaims up to 70 kL/day of water, significantly decreasing reliance on fresh water.
Lower Operating Costs: By reducing wastewater disposal and freshwater intake, the company has achieved substantial cost savings.
Enhanced Equipment Performance: High-quality recycled water minimises equipment wear, reducing maintenance and downtime.
Regulatory Compliance: The system ensures compliance with environmental regulations and sustainability targets.
Future Scalability: The modular design allows for additional treatment capacity as production demands increase.

With this solution, the facility has reinforced its commitment to sustainability while achieving operational efficiencies, cost reductions, and improved production reliability.