Waterform Technologies
Enquire Now
Enquire Now

Ensuring Safe, Sustainable Water for Poultry Feed Operations

PROBLEM

A poultry feed manufacturer needed a reliable water treatment system to tackle high turbidity, organics, and ADWG compliance.

SOLUTION

Waterform installed a Barrier-FB Advanced Water Treatment Plant with coagulation, ultrafiltration, reverse osmosis, and automated monitoring.

OUTCOME

The system ensures high-quality water, lower costs, minimal waste, and scalable expansion for future growth.

19

Industry

Poultry Feed Manufacturer

LOCATION

Murray River
Download Case Study

Poultry Feed Manufacturer:
Barrier-FB Advanced Water Treatment Plant

PROBLEM

A leading poultry feed manufacturer in South Australia was sourcing water from the Murray River for its feed mill operations. However, the water quality posed several challenges:

  • High Turbidity & Suspended Solids: Seasonal “Black Tide” events significantly increased turbidity, making the water unsuitable for food-grade production.
  • Fluctuating Organic Matter: Changes in organic matter levels affected water taste, odour, and posed microbial risks.
  • Compliance Requirements: The facility needed to comply with stringent Australian Drinking Water Guidelines (ADWG) to ensure the safety of its feed production process.
  • Operational Efficiency: There was a need for a low-maintenance and automated solution to reduce labour and improve system reliability.

To address these concerns, the company engaged Waterform Technologies to design and implement a reliable, high-performance water treatment solution that would ensure safe and sustainable potable water.

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 implementation of the Barrier-FB Water Treatment Plant has resulted in significant operational, financial, and compliance benefits:

  • Consistently High Water Quality:
    The plant consistently meets ADWG standards, ensuring that the water used in feed production is safe, clean, and suitable for processing.
  • Increased Operational Efficiency:
    The automated system minimises the need for manual intervention, reducing labour costs and optimising the overall efficiency of the water treatment process.
  • Sustainable Water Use:
    The system’s high-efficiency design reduces water wastage and optimises energy consumption, supporting the company’s sustainability goals.
  • Future-Proof Design:
    The plant features modular expansion capabilities, allowing for easy upgrades and the accommodation of increased water demand as production capacity grows.
  • Cost Savings:
    The system’s reduced chemical consumption, lower maintenance requirements, and improved water recovery rates contribute to significant cost savings in the long term.

With this installation, the company has secured a future-ready water treatment solution that ensures reliable, compliant water supply, while also aligning with its sustainability and operational efficiency objectives.

PROBLEM

A leading poultry feed manufacturer in South Australia was sourcing water from the Murray River for its feed mill operations. However, the water quality posed several challenges:

  • High Turbidity & Suspended Solids: Seasonal “Black Tide” events significantly increased turbidity, making the water unsuitable for food-grade production.
  • Fluctuating Organic Matter: Changes in organic matter levels affected water taste, odour, and posed microbial risks.
  • Compliance Requirements: The facility needed to comply with stringent Australian Drinking Water Guidelines (ADWG) to ensure the safety of its feed production process.
  • Operational Efficiency: There was a need for a low-maintenance and automated solution to reduce labour and improve system reliability.

To address these concerns, the company engaged Waterform Technologies to design and implement a reliable, high-performance water treatment solution that would ensure safe and sustainable potable water.

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 implementation of the Barrier-FB Water Treatment Plant has resulted in significant operational, financial, and compliance benefits:

  • Consistently High Water Quality:
    The plant consistently meets ADWG standards, ensuring that the water used in feed production is safe, clean, and suitable for processing.
  • Increased Operational Efficiency:
    The automated system minimises the need for manual intervention, reducing labour costs and optimising the overall efficiency of the water treatment process.
  • Sustainable Water Use:
    The system’s high-efficiency design reduces water wastage and optimises energy consumption, supporting the company’s sustainability goals.
  • Future-Proof Design:
    The plant features modular expansion capabilities, allowing for easy upgrades and the accommodation of increased water demand as production capacity grows.
  • Cost Savings:
    The system’s reduced chemical consumption, lower maintenance requirements, and improved water recovery rates contribute to significant cost savings in the long term.

With this installation, the company has secured a future-ready water treatment solution that ensures reliable, compliant water supply, while also aligning with its sustainability and operational efficiency objectives.

Have a water or wastewater challenge?

Submit Your Enquiry Now