Polymer Processors created an economical washwater reuse solution in its plastics recycling plant with Aerofloat.

Aerofloat’s wastewater treatment system provides superior wash-water that can be reused within the factory processing.

The Need

Polymer Processors required a solution to reuse its wash-water within the factory, for both economic and environmental reasons.

The Solution

Aerofloat provided a wastewater treatment system utilising its patented Dissolved Air Flotation (AeroDAF) and patent pending Moving Bed Biofilm Reactor (AeroMBBR) technology. The high quality of the wastewater discharged by the Aerofloat system meant Polymer Processors could re-use its wash water in its plastics processing without any offensive odours present.

The Benefit

The solution provided a huge economic impact for Polymer Processors and also helped the company achieve its environmental goals.


Making a positive impact on both the environment and local community is a priority for Australian-owned and operated plastics recycling company, Polymer Processors.

The company collects, cleans and recycles a significant variety of post-consumer and post-industrial plastic waste and processes it in a facility in Braeside, Victoria.

Expanding its plastic recycling business meant the installation of a new wash-water plant for Polymer Processors. This led to an increase in the soluble organic contaminants in the recycled wastewater. Being able to re-use the large volumes of water required for the washing process was vital to the economic and environmental impact of the business. The treated wastewater therefore had to be of a high quality to avoid any odours in the plastics being produced.

The Aerofloat Solution

Aerofloat’s engineers spent time with the Polymer Processors team designing a solution that would best suit its needs.

Aerofloat’s patent-pending Moving Bed Biofilm Reactor (AeroMBBR) and patented Dissolved Air Flotation (AeroDAF) technology proved the right choice for Polymer Processors. Aerofloat installed two AeroMBBRs and two AeroDAF M400s (featuring an automatic push-off mechanism).

So how does the technology behind Aerofloat’s design work?

The process starts in a large plastic tank, where the heavy grit materials are allowed to settle and the contaminated wash-water gravitates into an inlet pumping station. This leads on to a vibrating screen, the AeroMBBRs ( two 46,500L AeroMBBRs to break down the soluble contaminants) and two AeroDAF M400s (to separate the biosolids produced). The biosolids then fill the sludge tank where the sludge continues to thicken, and the clear supernatant reaches the inlet pumping station. The treated effluent is recycled to the wash-water tanks for further washing of plastic materials.

As part of the new wastewater treatment installation, Aerofloat also installed a remote monitoring system. The remote monitoring system allows Polymer Processor’s staff to remotely log onto the system, monitor the performance and changes in real time, and make any required adjustments. Staff can also request that Aerofloat’s engineers log on and make recommendations based on the system trends and performance.


Since installing the Aerofloat system, Polymer Processors has successfully reused its wash-water – without any offensive odours present.

Keeping the environment healthy and the local community alive is at the very heart of what Polymer Processors want to achieve. The long-term effect of the Aerofloat wastewater system ensures the company’s goals are realised – and the environment welcomes the updates too.

Download Polymer Processors Case Study

After Care Service

Aerofloat can help you maintain optimal performance of your wastewater treatment system long after installation.

Servicing – Chemical Supply – Sampling & Analysis – System Automation & Remote Monitoring

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