Aerofloat deemed ‘top of the list’ when it comes to wastewater treatment by Beak & Johnston.
Beak & Johnston needed a solution to process production-specific waste that was high in grease, fats and oils
Aerofloat installed its stainless steel Aero V-DAF 30 system to meet high flows and ensure compliant effluent
Aerofloat was able to accommodate last-minute space availability changes at the site without compromising on results
“It was an easy process with Aerofloat. Their team are very professional and easy to get along with, nothing is ever a problem.
- Daniel Sciffer, Beak & Johnston
Large ready-meals manufacturer Beak & Johnston’s enlisted Aerofloat to provide a wastewater treatment solution at its newest $100 million food production facility.
The state-of-the art 10,500 sqm facility boasts Aerofloat’s Aero V-DAF 30 system, with 30,000L/hr treatment capacity. Aerofloat constructed a complete stainless system to ensure a long-life, robust solution; including the balance tank, sludge tank, reaction tanks, V-DAF and pipework.
Michael Anderson, GM of Engineering and Projects at Aerofloat, said Aerofloat’s previous experience in the ready-meals space gave it insight into the variability and seasonal requirements of the industry to ensure Sydney water compliance.
Aerofloat undertook its usual hands-on approach to ensure a custom-fit for Beak & Johnston.
“We conducted due diligence on the wastewater based on the products City Kitchens would be producing,” he said.
Daniel Sciffer, Group Project Engineer for Beak and Johnson said Aerofloat were very professional across the lifetime of the project and took the time to understand Beak & Johnston’s specific wastewater needs to inform the system design.
“Aerofloat were very thorough in their design process, ensuring they understood the types of waste that would be going down our system,” said Sciffer.
“We pump out 50-80 dollies of food waste per day.”
That waste includes food waste high in grease, fats and oils and the specific chemical waste and machine oils that are a biproduct of running a production industry.
Aerofloat’s stainless steel V-DAF 30 system was custom built to fit the needs of Beak & Johnston.
“Not long after project initiation, Beak & Johnston needed to change the footprint of the available space for the plant which considerably shrunk the available space for the DAF plant,” said Anderson.
Sciffer said that Aerofloat responded to the change without hesitation and was able to adjust the design to allow for the reduced space.
“Despite throwing this curveball at Aerofloat, the whole project came off without missing a beat,” said Sciffer.
Aerofloat’s engineers were able to accommodate other equipment in the designated space, like fire suppression pumps.
Aerofloat’s solution included a pump station for wastewater collection, a treatment room where large food particles are screened out, a balance tank for mixing, aeration, and pH correction, and a reaction tank for coagulation and flocculation.
“This leads to a dissolved air flotation system, using our newly developed stainless steel Aero V-DAF 30 system with 30,000L/hr treatment capacity,” said Anderson.
Aerofloat’s design was cost-effective and compact and ensured compliant wastewater, with the option for growth down the track.
The system can process to the 200-litre per minute speed or can slow it down as required.
“The whole plant was a custom solution, including the wastewater plant layout and all mechanical, electrical, and process components,” said Anderson.
“Added benefits like Aerofloat’s patented scum removal and its unique self-cleaning double hopper design that doesn’t require mechanical scrapers, reduces maintenance time for Beak & Johnston.”
Sciffer said the system met the brief however Aerofloat’s support has gone well beyond the project end point.
“The team further supported us for another six months following project completion – not many companies do that,” he said.
“I was impressed by how they still took ownership of the plant so we could focus on ensuring production got set up and running in the main factory. It meant we could focus on our bread and butter, which is getting meals out of the factory and into store.”
Beak & Johnston appreciated Aerofloat’s end-to-end support.
“It was an easy process with Aerofloat. Their team are very professional and easy to get along with, nothing is ever a problem,” said Sciffer.
“The Aerofloat team still offer engineering support and get online to our remote system to understand issues and support us when we need it.”
“If anyone asked me who I’d use for chemicals or trade waste, Aerofloat would definitely be at the top of the list.”
CASE STUDY Aerofloat was contracted to provide an upgrade to the existing plastics recycling wastewater treatment facility to meet growth at the site. The Need
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