Waterform Technologies provided a state-of-the-art UltraReuse Water Recycling System that optimised water usage, reduced operational costs, and met the company’s sustainability and compliance goals. The solution was designed to integrate seamlessly with the existing infrastructure, offering a plug-and-play setup with pre-assembled skid-mounted units.

The key components of the system included:

• Coagulant & Flocculant Dosing Systems:
  The system incorporated a Pin Floc dosing system with Grundfos pumps to effectively separate solids from the water, improving water quality for reuse in the production process.
• Lamella Clarification Unit:
  The unit included high-efficiency plate settlers with a conical sludge collection base and automated sludge removal, ensuring the efficient removal of suspended solids.
• pH Correction & Monitoring:
  An inline dosing system with automatic flow-paced control was implemented to maintain optimal water chemistry, ensuring effective filtration and compliance with environmental standards.
• Prism Si4 Media Filtration Bank:
  The filtration system utilised multi-stage filtration with an automatic backwash mechanism to remove fine particulates, ensuring high-quality water for reuse in the manufacturing process.
• Electrical Control & Automation:
  The system was equipped with a SCADA-integrated PLC system for real-time monitoring and system optimisation, ensuring seamless operation and minimising manual intervention.
• Smart Automation & Remote Monitoring:
  iSiteControl, a 24/7 remote monitoring system, was implemented to track system performance in real-time, providing operators with alerts for any required maintenance or performance issues.
• Integrated Mains Water Backup:
  To ensure continuous operation during system downtime, a backup mains water supply was integrated into the system.

This comprehensive water recycling system was designed to reduce the facility’s reliance on freshwater, improve process water quality, and minimise the environmental impact of the manufacturing operations.

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.