Managing High Turbidity and Membrane Fouling Risks
A Victorian dairy manufacturer faced severe process water challenges after heavy rainfall caused its shallow surface catchment to deteriorate. The resulting high turbidity and colloidal solids led to persistent membrane fouling, threatening production reliability. The dairy required a robust pre-treatment and ultrafiltration upgrade to stabilise water quality, maintain compliance, and ensure continuous supply for critical production processes - without relying on polymer additives that could worsen membrane performance.
Delivered an Integrated Pre-Treatment and Ultrafiltration Solution
FILTEC designed, built, and commissioned a new water treatment facility comprising a 4.8 MLD lamella clarifier (later expanded to 6.8 MLD) and ultrafiltration system. The lamella clarification unit utilised the patented Ecoflow plates to achieve over 90% suspended solids reduction using only existing site chemicals. Downstream, the UF membranes, complete with tanks, instrumentation, and control systems, provided fine filtration and ensured high-quality process water suitable for food manufacturing.
Ensured Continuous Operation During Plant Expansion
Following the initial installation of a 4.8 MLD pre-treatment and ultrafiltration system, FILTEC was later commissioned to expand the facility’s capacity to 6.8 MLD to meet increased water demand. During this upgrade, the dairy manufacturer needed to maintain full water supply and avoid production downtime. FILTEC achieved this by sequencing works to keep the existing system online throughout construction. Even during a severe storm event that pushed raw-water turbidity above 200 NTU, the plant remained operational, maintaining recovery rates above 90% through process optimisation and controlled backwash adjustments.
Ongoing Servicing and Performance Optimisation
FILTEC continues to provide monthly service and performance reviews of the treatment facility. These include membrane permeability analysis, transmembrane pressure checks, sonic fibre testing, and analyser calibration. Periodic clean-in-place (CIP) and productivity assessments ensure the UF and lamella systems operate efficiently, sustaining reliable water quality and supporting long-term plant resilience.
Reliable Water Quality Through Ultrafiltration and Pre-Treatment
The upgraded 6.8 MLD facility now delivers consistent, high-purity water for dairy operations, withstanding variable raw water conditions and significant solids loading. Integration of ultrafiltration and lamella clarification has strengthened the site’s resilience and reduced membrane fouling risks, while maintaining compliance with process water standards. FILTEC’s ongoing service and performance monitoring ensure continued reliability and efficient operation for the dairy manufacturer.
