Off-sewer corrugated packaging plant adhered to strict New Zealand environmental guidelines.

A robust wastewater treatment solution from Aerofloat achieved outstanding results against stubborn ink waste.

The Need

Visy’s installation of a new $100m off sewer corrugated packaging plant required a wastewater treatment system to treat the ink waste, starch solution and boiler water to a standard suitable for irrigation or reuse.

The Solution

Aerofloat’s wastewater treatment system utilised a range of technologies to ensure the wastewater could be reused within the processing plant or irrigated around the site.

The Benefit

The Aerofloat solution allowed the plant to adhere to the strict environmental guidelines set out by the EPA.


In 2017/18 Visy built a new $100m corrugated packaging plant in New Zealand.

The off-sewer plant delivered a significant increase in capacity for the packaging company and used leading technology to ensure sustainability was at the core of its design. The wastewater from the plant contained a mixture of ink waste, starch solution and boiler blowdown water. The plant was not connected to the mains sewer, therefore Aerofloat focused on finding an environmentally sensitive and suitable treatment solution.

The Aerofloat Solution

Aerofloat was engaged to do extensive design and planning of the wastewater treatment system for the site.

Aerofloat’s team of engineers used 3D modelling to refine the plant design prior to being awarded the project. This ensured a polished and detailed design was presented with an all-inclusive price, that meant no surprises for the packaging giant. Aerofloat’s custom solution used the following technologies:

  • Patented dissolved air flotation (AeroDAF)
  • Patent-pending features in its moving bed biofilm reactor (AeroMBBR) process
  • Sand filtration
  • Ultra-filtration
  • Reverse osmosis (RO)

The clever Aerofloat design enabled the treated wastewater to be 100% recycled within the corrugated box plant, whereby:

  • RO permeate can be used for boiler makeup water
  • RO reject can be used for starch makeup water


Aerofloat’s solution produced an effluent quality such that 100% of the treated wastewater could be recycled back for reuse within the corrugated packaging plant.

The plant operator also had the choice to irrigate the treated water to the surrounding grounds. The final effluent quality achieved for SS, BOD, COD, N, P, TDS and SAR were all below discharge limits set by the local water authority/EPA. This ensured the packaging plant achieved and maintained its commitment to the local New Zealand environment.

Download Off-Sewer Packaging 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

  • ARP White Logo
    4 pines logo
    Visy White Logo
    Norco White Logo
    carlton united breweries logo
    Astron White Logo
    ANK White Logo
    Ballina White Logo
  • sanitarium logo
    B&E White Logo
    Cordina White Logo
    Cupitt's White Logo
    Devil's White Logo
    Fyna White Logo
    Goodman White Logo
    Italia White Logo
  • Jewel White Logo
    Marsden Brewhouse White Logo
    Monte Fresco White Logo
    Murray Princess White Logo
    North Coast White Logo
    Pope White logo
    Proud Mary White Logo
    Rawbone White Logo
  • Ruby & Roys White Logo
    Specialised Chickens White Logo
    Sunfresh White Logo
    Tip Tip NZ White Logo
    U-Sonics White Logo
    Westlands White Logo