FDBusiness.com

Advanced 3D modelling techniques and engineering innovation led Britvic to significantly reduce wastewater discharge, far exceeding their original targets. This modified system, built around existing technology and fully integrated with their current production line, led to huge additional cost savings.

Bill Denyer of Envirogen says: “An audit had taken place of the wastewater streams at the plant and Britvic were keen to make changes to achieve their ambitious environmental goals, as well as meet their targets to improve efficiencies and drive further cost savings on site. The changes had to happen fast, with no impact on the day to day production output. This is a very successful operation with a high output with very little room for downtime; the factories are working at high capacity. However, it was important, for environmental compliance, that Britvic reduce their wastewater output.”

Detailed 3D Modelling Unlocked Environmental Potential

Denyer goes on to say: “The potential for saving and reusing water lay in the four bottle rinsing line as high quality rinse water was being sent straight to drain as wastewater. There was enormous reuse potential, but we needed to ensure that the water quality wasn’t compromised. Monitoring and further process treatment would be essential to maintain sterility.

“We drew up detailed 3D models for a sterile recapture and storage system so that this water could be fed back through to the rinse lines. The models showed how the new plant would fit with the existing machinery and, laser measuring was used to ensure that the exact proportions of the factory were incorporated into the design software.”

The final solution:

• A recapture line and pump system fitted to rinsing lines leading to a single storage tank
• Inline instrumentation to monitor the water quality as it is fed through to the tank, controlled with an HMI & PLC
• In-tank monitoring equipment with pre-set quality parameters controlling discharge and refill protocols, if quality standards reduce
• Additional UV sterilisation and 10µm and 1µm absolute cartridge filtration system using long life Envirogen brand cartridges.

Operations Development GB & Ireland at Britvic, Calvin Winch, says: “Envirogen’s expertise and knowledge enabled them to see how modifications to an existing system could bring major benefits. Envirogen project managed the whole process from design and installation to commissioning. Their attention to detail and onsite work is outstanding.”

Key outcomes:

• Significant wastewater reduction – exceeding clients targets
• Additional huge cost savings
• No operation downtime, with plant integrated seamlessly with existing equipment.