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Winemaking Facility – CAL System Refurbishment

PROBLEM

A large winemaking facility needed to refurbish its aging CAL system to maintain efficiency, compliance, and methane capture while minimising disruption.

SOLUTION

Waterform upgraded the CAL system with a new geosynthetic cover, improved biogas flare, and structural enhancements for minimal downtime.

OUTCOME

The refurbishment improved methane recovery, extended system lifespan, ensured compliance, and supported sustainable winemaking practices.

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Winery

Winery Estate

LOCATION

Australia
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Winery Estate: Covered Anaerobic Lagoon (CAL) Refurbishment

PROBLEM

A leading winemaking company, located in a renowned Australian wine region, was operating a Covered Anaerobic Lagoon (CAL) system at their facility to manage and treat wastewater generated from their winemaking processes. As time passed, the existing CAL infrastructure began to show signs of aging and deterioration, leading to reduced operational efficiency and potential risks to environmental compliance. The system’s ability to capture methane for sustainable energy use was also affected.

The key challenges that the company faced included:

  • Ageing Infrastructure: The geosynthetic cover had deteriorated, requiring replacement to ensure continued functionality and methane capture.
  • Inefficient Biogas Management: The existing biogas management system was underperforming, reducing the efficiency of methane recovery.
  • Structural Concerns: The supporting ring beam structure was showing signs of weakness, which could jeopardise the system’s stability.
  • Minimising Disruption: Refurbishing the CAL system needed to be done with minimal disruption to winery operations to avoid production downtime during the busy winemaking season.

In response to these challenges, the winemaking company sought a reliable and experienced water solutions provider capable of refurbishing the CAL system while meeting operational, environmental, and regulatory requirements.

SOLUTION

Waterform Technologies delivered a comprehensive CAL refurbishment solution that addressed all of the client’s operational and environmental needs. The project was managed using Waterform’s “Solve, Deliver, Sustain” methodology, ensuring both short-term success and long-term system performance.

Key components of the solution included:

  • Geosynthetic Cover Replacement: Waterform coordinated with suppliers to install a high-performance cover designed to optimise methane capture and improve the system’s durability. The new cover provided increased reliability and resistance to harsh weather conditions, ensuring the system’s longevity.
  • Biogas Flare System Upgrade: Waterform designed, supplied, and installed a BEF-500i Biogas Flare system, which included:
    • An automatic stainless-steel flare for methane combustion
    • A Siemens PLC-controlled operation system, featuring built-in safety monitoring
    • High-efficiency flame control with UV sensors and temperature monitoring
  • Structural Improvements: Waterform performed a detailed assessment of the ring beam system and carried out necessary refurbishments to enhance its structural integrity, ensuring the system could withstand operational stresses.
  • Comprehensive Commissioning & Safety Assurance: The refurbishment process included onsite testing and commissioning of the CAL system and the biogas flare. A HAZOP (Hazard and Operability) review was conducted, and safety sign-off was completed. Final performance validation and compliance certification ensured that all systems met regulatory standards.

Throughout the process, Waterform managed all aspects of the refurbishment, coordinating closely with key suppliers and the client to ensure minimal disruption to winery operations.

OUTCOME

The successful refurbishment of the CAL system has provided the following operational and environmental benefits for the client:

  • Enhanced Biogas Recovery and Sustainability: The new system now captures methane more efficiently, improving the sustainability of the winery by reducing greenhouse gas emissions and supporting the company’s energy generation needs.
  • Extended Infrastructure Longevity: With the installation of a new geosynthetic cover and structural upgrades, the system’s reliability has been greatly improved, ensuring reduced maintenance costs and a longer operational life.
  • Regulatory Compliance Assurance: The refurbishment process has ensured that the system now complies with all environmental and safety regulations, including meeting EPA standards. This helps the winery maintain its commitment to responsible environmental practices.
  • Minimised Operational Disruption: The refurbishment work was carried out with minimal impact on the winery’s operations, ensuring that the winemaking process continued without significant interruptions.

By partnering with Waterform Technologies, the winery has ensured that its anaerobic wastewater treatment system is future-ready, reinforcing its commitment to sustainable winemaking practices and operational excellence.

PROBLEM

A leading winemaking company, located in a renowned Australian wine region, was operating a Covered Anaerobic Lagoon (CAL) system at their facility to manage and treat wastewater generated from their winemaking processes. As time passed, the existing CAL infrastructure began to show signs of aging and deterioration, leading to reduced operational efficiency and potential risks to environmental compliance. The system’s ability to capture methane for sustainable energy use was also affected.

The key challenges that the company faced included:

  • Ageing Infrastructure: The geosynthetic cover had deteriorated, requiring replacement to ensure continued functionality and methane capture.
  • Inefficient Biogas Management: The existing biogas management system was underperforming, reducing the efficiency of methane recovery.
  • Structural Concerns: The supporting ring beam structure was showing signs of weakness, which could jeopardise the system’s stability.
  • Minimising Disruption: Refurbishing the CAL system needed to be done with minimal disruption to winery operations to avoid production downtime during the busy winemaking season.

In response to these challenges, the winemaking company sought a reliable and experienced water solutions provider capable of refurbishing the CAL system while meeting operational, environmental, and regulatory requirements.

SOLUTION

Waterform Technologies delivered a comprehensive CAL refurbishment solution that addressed all of the client’s operational and environmental needs. The project was managed using Waterform’s “Solve, Deliver, Sustain” methodology, ensuring both short-term success and long-term system performance.

Key components of the solution included:

  • Geosynthetic Cover Replacement: Waterform coordinated with suppliers to install a high-performance cover designed to optimise methane capture and improve the system’s durability. The new cover provided increased reliability and resistance to harsh weather conditions, ensuring the system’s longevity.
  • Biogas Flare System Upgrade: Waterform designed, supplied, and installed a BEF-500i Biogas Flare system, which included:
    • An automatic stainless-steel flare for methane combustion
    • A Siemens PLC-controlled operation system, featuring built-in safety monitoring
    • High-efficiency flame control with UV sensors and temperature monitoring
  • Structural Improvements: Waterform performed a detailed assessment of the ring beam system and carried out necessary refurbishments to enhance its structural integrity, ensuring the system could withstand operational stresses.
  • Comprehensive Commissioning & Safety Assurance: The refurbishment process included onsite testing and commissioning of the CAL system and the biogas flare. A HAZOP (Hazard and Operability) review was conducted, and safety sign-off was completed. Final performance validation and compliance certification ensured that all systems met regulatory standards.

Throughout the process, Waterform managed all aspects of the refurbishment, coordinating closely with key suppliers and the client to ensure minimal disruption to winery operations.

OUTCOME

The successful refurbishment of the CAL system has provided the following operational and environmental benefits for the client:

  • Enhanced Biogas Recovery and Sustainability: The new system now captures methane more efficiently, improving the sustainability of the winery by reducing greenhouse gas emissions and supporting the company’s energy generation needs.
  • Extended Infrastructure Longevity: With the installation of a new geosynthetic cover and structural upgrades, the system’s reliability has been greatly improved, ensuring reduced maintenance costs and a longer operational life.
  • Regulatory Compliance Assurance: The refurbishment process has ensured that the system now complies with all environmental and safety regulations, including meeting EPA standards. This helps the winery maintain its commitment to responsible environmental practices.
  • Minimised Operational Disruption: The refurbishment work was carried out with minimal impact on the winery’s operations, ensuring that the winemaking process continued without significant interruptions.

By partnering with Waterform Technologies, the winery has ensured that its anaerobic wastewater treatment system is future-ready, reinforcing its commitment to sustainable winemaking practices and operational excellence.

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