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Discover how Dairygold's Mallow plant revolutionized its wastewater treatment with Robuschi's cutting-edge technology, achieving 25% energy savings, 20% lower noise levels, 40% less footprint, while addressing environmental and community needs at the same time.
Dairygold's Mallow plant, a cornerstone of Ireland's dairy industry, was grappling with a critical issue – its wastewater treatment system was antiquated and inefficient. The existing secondary treatment systems, reliant on attached growth and trickling filter processes, were installed decades ago and had become obsolete. These outdated systems were no longer meeting the environmental and operational demands of the plant. The challenge was heightened by the need to manage the high energy costs associated with aeration processes, a key stage in wastewater treatment that can consume up to 60% of a plant's total power usage. Additionally, the community's concerns over noise pollution from the outdoor installations necessitated a solution that was both energy-efficient and quiet.
EPS Wastewater, commissioned by Dairygold to find a suitable upgrade for the inefficient treatment systems, identified Robuschi's Robox Turbo blowers as the optimal solution. The decision to replace conventional rotary lobe blowers with Robox Turbo models was driven by several key advantages: their exceptional energy efficiency, compact footprint, and quiet operation, making them ideal for outdoor installations close to residential areas. These blowers are oil-free and utilize a direct-drive system, which means maintenance is less complex and costly, as there is no need for routine replacements of pulleys or belts. Installation was designed to be straightforward and cost-effective, thanks to the integrated Variable Speed Drive (VSD) and Programmable Logic Controller (PLC), which allow for seamless plug-and-play operation. The transition to the new blowers began in mid-2021 and was strategically split into two phases to align with Dairygold's ongoing production activities. The entire project was executed on a tight schedule, with the new infrastructure being constructed and commissioned within just eight months.
The deployment of the Robox Turbo blowers has led to a transformative outcome for Dairygold's Mallow plant. These state-of-the-art aeration units have redefined the efficiency of the wastewater treatment process, resulting in a substantial energy savings of over 20%. The modernization project not only delivered a quieter operation, addressing previous noise complaints from the local community, but also provided Dairygold with a robust and reliable wastewater treatment solution. The successful upgrade aligns with Dairygold's commitment to sustainability and environmental stewardship, ensuring that their operations remain cost-effective and compliant with stringent environmental standards. The Mallow plant now benefits from a modernized wastewater treatment system that supports its production goals while prioritizing energy efficiency and community well-being.
