Effluent Treatment Plant for Wash Water Reuse
Capacity
Removal
Rate
Overview
Our customer is a leader in plastic recycling in the UK, operating a full recycling line at their facility. Their process includes the recycling of film and plastic milk bottles, which are processed into reusable plastic pellets. An important part of their operation is the effective treatment and recycling of wash water used during the cleaning of shredded plastic materials.
We partnered with them to deliver an advanced Effluent Treatment Plant (ETP) capable of processing and recycling 125,000 litres per hour of contaminated wash water. This solution reduces freshwater demand and improves overall process efficiency.
We partnered with them to deliver an advanced Effluent Treatment Plant (ETP) capable of processing and recycling 125,000 litres per hour of contaminated wash water. This solution reduces freshwater demand and improves overall process efficiency.
The Challenge
The customer’s process generates large volumes of contaminated wash water, requiring effective treatment to allow for its reuse.
An example of some stages of their process:
- Shredding: Baled plastic materials are shredded into confetti-sized pieces.
- Washing: Shredded plastic is thoroughly washed to remove dirt, adhesives, and organic contaminants.
- Drying & Granulation: Clean plastic is dried and then granulated into high-quality pellets for industrial reuse.
The Solution
To meet the requirements of their operation, we designed, manufactured and installed a custom-built effluent treatment system with the following key features:
1. Solid Separation
Initial coarse screening and sedimentation remove large solids, protecting downstream equipment and improving overall efficiency.
2. Balance Tank
Regulates flow and homogenises effluent, ensuring stable performance for downstream treatment units.
3. pH Correction and Chemical Dosing
Automated chemical dosing and pH balancing ensure compliance with discharge regulations and optimal DAF performance.
4. Chemical Dissolved Air Flotation (DAF) Systems
- Fine air bubbles and flocculants bind suspended solids, fats, oils, and greases, floating them to the surface for removal.
- Delivers high-efficiency treatment with minimal footprint.
5. Sludge Handling and Dewatering System
Collected sludge is compacted and dewatered, reducing volume and disposal costs while maintaining hygiene and safety.
6. Storage and Water Reuse Loop
Treated water is stored in a clean water tank and recirculated to the wash line, enabling a highly efficient closed-loop water reuse system.
7. Automated Control System
Intelligent PLC-based automation allows for remote monitoring, real-time alerts, and reduced operator intervention.
The Results
- Dramatically reduce main consumption, keeping costs low.
- Lower disposal and operational costs
- Maintain a consistent, high-quality wash process
- Ensure regulatory compliance and future-proof operations
- Advance their commitment to environmental sustainability
Conclusion
Water Tecnik’s installation of the effluent treatment plant at our customer’s UK site has transformed their wash water management. The advanced, closed-loop system supports their commitment to environmental sustainability while ensuring their plastic recycling line operates with maximum efficiency.
This project is a great example of how our custom-engineered solutions can drive both economic and environmental value in industrial recycling operations.
Get in touch to discuss your project
For a chat about how we can help you reach your water treatment goals, just fill out the form on the contact us page and we’ll be in touch.