A large-scale UK milk processing facility faced increasing BOD load from expanded production. Reynolds & Bauhm designed and commissioned a DAF-based treatment train that achieved consent compliance within 12 weeks.
A dairy processing facility in the East Midlands producing fluid milk, cream, and cheese expanded throughput by 40%, pushing daily effluent BOD from 1,200 to 2,800 mg/L — far above their discharge consent of 250 mg/L BOD, 100 mg/L SS, and 50 mg/L fat. The existing dissolved air flotation unit was sized for the old production volume and was hydraulically overwhelmed during cleaning-in-place (CIP) peaks.
Reynolds & Bauhm completed a rapid site assessment and proposed a phased solution using our modular DAF platform to fit within the existing plant room footprint. The existing unit was retained as a duty standby for the first CIP equalisation stage.
| Stage | Equipment | Function |
|---|---|---|
| 1 | Curved screen (1 mm aperture) | Fibre and solid removal |
| 2 | 2,500 m³ equalisation tank with mixer | Flow and load balancing |
| 3 | Rapid mix chamber with pH correction | pH 6.5–7.0; coagulant dosing |
| 4 | Flocculation chamber (3-stage baffled) | Floc growth; polymer dosing |
| 5 | 250 m³/h dissolved air flotation unit | Fat, protein, SS removal |
| 6 | Float cream collection hopper → tanker | By-product recovery |
| 7 | Sub-surface discharge monitoring | BOD, SS, fat continuous measurement |
Discharge BOD achieved 35–60 mg/L (consent: 250 mg/L). SS: 18–35 mg/L (consent: 100 mg/L). Fat: <5 mg/L (consent: 50 mg/L). Enforcement notice withdrawn at week 14.
Reduction in trade effluent charges of. Cream recovery output of. Project benefits achieved within 26 months.
DAF unit sized for further 25% production increase with no modification. Equalisation volume provides headroom for extended CIP cycles during cleaning campaigns.
Complete commissioning within 4 weeks including hands-on operator training, SOP documentation, and performance guarantee sign-off.
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