Dual-Load Wastewater Treatment at Fonterra
Fonterra required a wastewater treatment solution capable of handling two very different wastewater streams. Typical flows carried extremely high suspended solids concentrations of around 15,000 mg/L, while at other times, higher flow rates with much lower solids loads of around 1,000 mg/L were discharged. Designing a single system to manage such variable conditions posed a significant challenge, as surface loading, recycle rates, and air-to-solids ratios differ greatly between the two scenarios.
Hydroflux was engaged to supply a HyDAF HD system with a tailored design to meet both operating conditions. The HyDAF combines:
- Robust stainless steel construction with an enclosed scraper system
- Extremely low energy footprint compared with conventional DAF systems
- Two operational configurations built into a single DAF unit, selectable via HMI controls, enabling operators to easily switch between high-solids and high-flow scenarios
The Hydroflux DAF team modelled both wastewater conditions and designed a flexible operational setup to ensure optimal performance under either loading. Collaboration between Hydroflux Industrial in Australia and Hydroflux Industrial NZ ensured local manufacturing, tailored design, and full alignment with client requirements.
The Results
The HyDAF installation has delivered:
- Reliable treatment under two distinct wastewater scenarios
- Flexible operation via HMI selection, eliminating the need for separate systems
- Low energy consumption and reduced operating costs
- Locally manufactured equipment built for long-term reliability
Technology in Action
This project demonstrates Hydroflux’s in-house expertise in DAF sizing and design, proving that the correct selection and application of technology is as important as the equipment itself. With local fabrication in both Australia and New Zealand, Hydroflux continues to provide tailored, high-performance wastewater treatment systems for the dairy industry.
Up Next
