Hydroflux’s Sustainability Driven Water Treatment Technology at TFI’s Murray Bridge Meat Processing Plant

Thomas Foods International (TFI) is a leading Australian meat processing company that has made significant strides in sustainability in recent years. One of its recent major projects is the construction of a new processing plant in Murray Bridge, South Australia which features a state-of-the-art sustainability driven wastewater treatment plant.

The wastewater treatment plant was designed and built by Hydroflux, featuring a robust primary wastewater treatment system and paunch handling facilities and 28 million litre anaerobic pond which is used to convert organics to biogas. The captured biogas is treated and reused as an energy source within the factory, reducing the facility’s reliance on fossil fuels and helping to offset its carbon footprint. The project also included treatment and collection of storm water, solids handling and dewatering, and heat exchangers are being used to cool the sterilizer water and transfer heat to incoming mains water, reducing energy requirements for heating.

By implementing this innovative wastewater treatment project, TFI has been able to significantly reduce its environmental impact, while also achieving significant OPEX savings.

The primary treatment plant involves screening of the red and green streams followed by fat removal in a HyDAF HD-200V dissolved air flotation system designed to operate in a way that optimises the efficiency of the anaerobic pond for biogas generation. The anaerobic pond measures 100 m x 80 m and 8 m deep and the design and construction of the pond was conducted by Hydroflux utilising double heavy-duty liners sealed in a concrete anchor trench. At full capacity, the system is designed to generate 4700 m³ of biogas per day and the biogas handling system comprises a drier and over 200 m of pipework to deliver the gas to the boilers.

A HUBER Q440 screw press is installed to dewater primary sludge which is automatically removed from the surface and base of the DAF system. The screw press also has the capacity and facility to handle solids collected in the storm water retention basin and waste anaerobic sludge when required. Fan presses are being used to dewater the paunch.

The treated water from the anaerobic pond is transferred to aerobic ponds to further reduce the concentration of organics and nutrients before being irrigated on surrounding farmland.

About Hydroflux

The Hydroflux Group consist of eleven specialist companies that aim to deliver the highest level of engineering and scientific know-how to the emerging issues of sustainability, climate adaptation and environmental protection with a specific focus on water and wastewater.

As part of its vision and mission, Hydroflux has always taken its climate responsibility seriously. In 2022, Hydroflux became Australia’s first water treatment and technology company to achieve Climate Active carbon neutral certification for its organisation and products. It knows that partnering with customers and clients is the most significant impact it can have in its journey.

The Group employs over 100 staff and operates throughout Australia, New Zealand and the Pacific Islands, with office locations in Sydney, Melbourne, Brisbane, Perth, Auckland, Suva and Portsmouth.