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When Kingsley Beverages decided to install a new can line they contracted Stolle, a global supplier of can manufacturing equipment and plants for a turnkey project in South Africa. In turn, Stolle subcontracted AllWater Technologies to conceptualise, design, create, oversee, and manage the build of the entire water treatment system.

The Challenge

The water treatment system required a reliable system to produce water of <10μS/cm for production and a wastewater treatment solution to consistently achieve local discharge consent limits, including low levels of Fluoride.

Requirements:

RO water quality: <10 μS/cm
RO serviceable water rate: 8 cubic metres per hour
Effluent discharge rate: 10 cubic metres per hour

Infrastructure

AllWater coordinated closely with Stolle to design and build the infrastructure, including providing layout design. load bearing information and suggestions for area containment.
The layout design included a dedicated tank farm with access gantry to reaction tank area and filter press, pure water generation area with clear delineation from wastewater treatment area, ergonomic flow path reducing the need for pumping wherever possible and ease of forklift access to powder reagent make-up system.

Reverse Osmosis

To enhance water quality and increase overall system recovery, it was decided to operate two RO units in series. Twin pass RO system designed with 2 identical plants, either of which can be operated in the ‘lead’ or ‘lag’ position, or independently, offering a high-level of flexibility and operational security.
Operating the units in series ensured exceptionally good water quality and increased the overall recovery level of the system, providing maximum output and efficiency.

Wastewater Treatment

Two reception tank system, able to accommodate day-to-day rinse water, periodic discharge of higher strength concentrates and also emergency holding capacity.
Two stages of reaction tanks and settlers, all joined via gravity, in order to achieve low Fluoride discharge consent limit.
Continuous outfall monitoring including auto-divert and retreatment for out-of-specification effluent.

The Chemistry

Stage 1: Lime Dosing

Lime is dosed into the effluent stream to facilitate the precipitation of Calcium Fluoride. This process effectively reduces Fluoride levels to a reasonably low level and neutralises the acidic nature of the effluent.
Lime dosing is a cost-effective process that eliminates a large amount of Fluoride from the water.

Stage 2: Fluoride Precipitation

A specific Fluoride removal chemistry is introduced into the effluent within the reaction tank system. This proprietary targets Fluoride specifically, facilitating its removal from the effluent stream.
The addition of Fluoride removal chemistry achieves the discharge limit of <5 mg/litre Fluoride.

Further Support

An installation manager from AllWater supervised on-site activities, ensuring adherence to design specifications and quality standards.
Commissioning engineers were dispatched to the site to commission the unit, verifying that all systems met the required performance standards.
Comprehensive training was provided to the local personnel, covering all aspects of the system’s operation, maintenance, and troubleshooting.
Continuous remote support is offered to address any issues that may arise and to assist with system optimisation.

Conclusion

The successful completion of the Kingsley can factory water treatment system highlights AllWater Technologies’ capability to deliver effective turnkey solutions. By meeting stringent water quality and effluent discharge requirements through innovative design and advanced chemistry, we ensured efficient and compliant operations. Our ongoing support and thorough training empowered the local team to maintain optimal performance. This project demonstrates our commitment to excellence and our ability to handle complex water treatment challenges for clients worldwide.

"We have been very happy with AllWater’s professionalism and response times when we have needed help with the plant. The staff are all very helpful and knowledgeable and we are very satisfied with the service provided."

Jamie Davies

Turnspeed

"We needed a DI plant that is capable of producing the processing water to serve our Chemical Process lines twelve rinse tanks, 24 hrs a day, 7 days a week at a max of 20.00 μS/cm. The water plant is now consistently cleaning the water to 1.00 μS/cm."

Steve Silk MBE

Marshall Aerospace

"We have built a good relationship with AllWater and continue to enjoy service contracts with them. They know what they’re doing and we’re always happy with their service"

Andy Best

Production Director - Vertik-Al

Amelia

Production Manager

"AllWater Technologies installed their pure water system in our premises to replace our old system which went into retirement. The level of service and maintenance that AllWater are giving us will ensure that we get the quality of product and the length of service we are looking for out of our plant. Their level of service is excellent."

John Malone

excel gs ltd

"Thank you for all your support. I have to say that I am really impressed with All Water approach to provide a really good service. Thank you again."

Radu Vitanescu

Liberty Engineering

"AllWater have provided great service, specialist advice and an effective waste water treatment solution for our site."

Paul Pearcy

Warburtons

"AllWater have always delivered us a great service and are equally competent maintaining existing kit or installing new. They’re friendly and reliable and, perhaps most importantly, trustworthy."

Phil Parkinson

Joseph Holt

"AWT professional service allows our site to run with minimal downtime when unplanned breakdowns happen. AWT service is invaluable in maintaining our production lines throughout."

Adam Cook

Qsil

"The person was very polite and explained everything in detail. Report was typed and easy to understand."

Richard Fox

London and Brighton Plating

"We are more than satisfied with the level of service we receive from everyone at AWT. Excellent work, Thank you!"

Daniel Holden

Karas Plating

"AllWater Technologies provide an exceptional level of knowledge and support, and we cannot fault their service and commitment. The team consistently exceed expectations and although others may offer a cheaper alternative, we have every confidence that they could not offer better!"

Eric Allen

Albumedix LTD

"By using AWT we know that our plant and equipment is being maintained to the highest standard using the expertise and knowledge that we find second to none. When issues arise it is paramount that we can resolve these issues promptly; AWT are always there to support us."

Allen Staunton

Creganna Medical

"Using All Water Technologies has been a breath of fresh air. Their attentive service from the first call through to delivery completion, has made the management of our water treatment plant very easy indeed. We wash over 2.5 million items of tableware for the event industry every year, working at some of the UK’s most prestigious events, so having peace of mind over our washing operation is essential. I would recommend AWT to anyone’"

Joe Nisbet

Jongor Hire

"AWT offered Rimex a bespoke solution to our water softening and storage requirements. They took charge and managed the project efficiently and effectively from the very beginning. I am delighted with the outcome and I will continue to use AWT for preventative maintenance and any other future projects."

Daniel Meakin

Rimex Metals

"All went very well with the plant being well finished, installation being of a high standard and all works being completed on time and to specification."

Dom Oughton

Optimum

"We’ve been working with the AllWater team for eight years and they have always been attentive to our needs. AllWater redesigned our borehole system, transforming it into a robust and reliable plant whilst helping us improve water recovery and achieve significant water savings. We’ve depended on this system and their technical guidance for many years now and will continue to do so. Their work helps give us confidence and they are a partner we know we can trust."

Stephen Shields

Huntapac - Technical & Sustainability Director

"At Butcombe, AllWater Technologies have been servicing the water treatment systems in our brewery for over 10 years. They are always at hand when we need them and all very friendly to deal with, and callouts are always made in a very timely manner. They have kept our beer flowing having never let us down. A great company with a quality reliable service."

Simon Court

Brewer - Butcombe Brewing Co.

Get in Touch with AllWater Technologies

We’re here to help with all your water treatment needs. Whether you have questions about our services, want to discuss a project, or need support, our team is ready to assist you. Fill out the form for general enquiries, or you are welcome to email direct or give us a call.

AllWater House

Unit 2, 
Cheddar Business Park, 
Wedmore Road, 
Cheddar 
BS27 3EB

Opening hours

Mon-Fri: 08:30-17:30 (GMT)

Immediate assistance

+44 (0) 1934 751333
enquiries@allwatertech.co.uk

Water Treatment Solutions to Overcome New REACH Prohibition of Hexavalent Chromium, Negotiate Space Constraints and Maintain Production Output

Project Overview

Vertik-Al, a leading provider of vertical and horizontal Aluminium powder coating for the architectural Aluminium industry, faced a critical challenge when European regulations (REACH) prohibited the use of Hexavalent Chromium in their pre-treatment process. To comply with regulations while maintaining consistent production efficiency, Vertik-Al needed a reliable water supply with stringent quality requirements.

INDUSTRY: Multi-industry Powder Coating Manufacturing
PROBLEM: Transition from Hexavalent Chromium to Chromium-Free Pre-Treatment
IMPLEMENTED SOLUTION: Water Supply with <30 μS/cm Quality

The Problem

The transition from a Hexavalent Chromium to a Chromium-free process required a large volume of water with a quality level below 30 μS/cm to ensure effective pre-treatment. Restrictive space at VertikAl’s facility posed significant hurdles for installing the required water treatment systems. Additionally, maintaining uninterrupted production during the transition was crucial for Vertik-Al to meet customer demands and ensure operational continuity.

The Result

The integrated water treatment system provided by AllWater enabled Vertik-Al to meet stringent purity standards for Chromium-free processes, ensuring compliance with REACH regulatory requirements whilst enhancing operational efficiency. Despite space constraints and existing infrastructure limitations, the seamless integration of the new water treatment system allowed Vertik-Al to maintain uninterrupted production, eliminating downtime and sustaining productivity. By leveraging AllWater’s expertise and innovative solutions, Vertik-Al successfully navigated the transition to Chromium-free manufacturing processes, demonstrating a commitment to regulatory compliance and operational excellence.