Sustainability-Driven Wastewater Treatment at Thomas Foods International, Murray Bridge
Thomas Foods International (TFI), a leading Australian meat processor, has committed to embedding sustainability across its operations. As part of its new state-of-the-art processing plant in Murray Bridge, South Australia, TFI required a wastewater treatment solution that would not only ensure compliance but also reduce environmental impact and deliver long-term operational savings.
Hydroflux designed and constructed a comprehensive wastewater treatment facility incorporating both primary treatment and renewable energy generation. Key elements included:
- Screening of red and green streams and fat removal via a HyDAF HD-200V Dissolved Air Flotation system, optimised for downstream anaerobic digestion
- A 28 million-litre anaerobic pond with double heavy-duty liners, designed and built by Hydroflux, converting organics into biogas for energy reuse onsite
- Biogas collection and handling system with drier and over 200 m of pipework to supply the factory boilers
- HUBER Q440 screw press for dewatering primary sludge, stormwater solids, and waste anaerobic sludge
- Paunch handling and dewatering with fan presses
- Heat exchangers for steriliser water, reducing heating energy demand
- Stormwater treatment and reuse systems integrated into the facility design
Hydroflux engineered the treatment plant to balance efficient solids removal with optimised biogas generation, ensuring maximum energy recovery. The anaerobic pond (100 m x 80 m x 8 m) was constructed with concrete anchor trenching to secure the double liner system, ensuring long-term containment and environmental protection. The plant was built to integrate seamlessly with the facility’s sustainability objectives.
The Results
The wastewater treatment system has delivered:
- Up to 4,700 m³ of renewable biogas generated per day, reused as boiler fuel
- Significant OPEX savings through reduced fossil fuel consumption
- Efficient solids and sludge handling with HUBER screw presses and fan presses
- Reduced energy requirements via heat recovery from steriliser water
- Treated effluent suitable for irrigation of surrounding farmland
Sustainability in Action
The Murray Bridge facility demonstrates how advanced wastewater treatment can drive both environmental and economic outcomes. By integrating biogas recovery, solids handling, and water reuse, Hydroflux has delivered a state-of-the-art solution that supports TFI’s long-term sustainability strategy while reducing reliance on fossil fuels.
