Reverse Osmosis Wastewater Filtration Plant: Fonterra Edendale

Reverse Osmosis Wastewater Filtration Plant: Fonterra Edendale

Tetra Pak - Fonterra Edendale, Southland, New Zealand

The Client

Tetra Pak is a world-leading supplier of processing and packaging solutions for food.

In this project, Tetra Pak was contracted by Fonterra to design, manufacture and manage the installation of a new milk dryer at their largest milk processing plant, Edendale.

The Brief

Tetra Pak developed and managed the installation of the ED4 which, with a processing capability of 100 litres of milk per second, is the world’s largest and most efficient milk powder dryer.

As part of the project Tetra Pak included a reverse osmosis plant to filter all used water so it could be recycled.

The reverse osmosis plant cleans the water by forcing it through micro-porous membrane filters. The plant consists of two trains of 100 cubic metres per hour capacity membrane filters with automatic back-flush cleaning and chemical dosing facility.

Tetra Pak commissioned EIS to carry out all of the on-site electrical installation and PLC automation for this treatment plant.

The Solution

EIS developed custom PLC automation specifically for the reverse osmosis plant.

This design included Functional Descriptors (FDs), Process Logic Controllers (PLC) and Human Machine Interfaces (HMI), which are all networked together with the Variable Speed Electric Drives (VSD).

These allow the plant to be fully automated and operated remotely from the ED4 control room.

Upon completion of the installation, EIS provided electrical testing and certification, assisted with commissioning the plant and trained the Fonterra operation staff.

The Challenges

There were two levels of client interaction on this project; EIS was directly responsible to Tetra Pak to deliver the contracted services but also had responsibility to Tetra Pak’s client Fonterra, as the end user of the plant. This meant that comprehensive project management and effective communication with all stakeholders was crucial to achieve a successful outcome.

Fonterra had recently introduced a requirement for structured batch automation programming to meet the S88 standard, and so the PLC software and programming developed for the automation of the reverse osmosis plant had to comply with this.

The Results

EIS exceeded all Tetra Pak and Fonterra standards for safety and quality for the electrical and automation design, installation and testing.

The reverse osmosis plant has been operating successfully since January 2012, ensuring that all waste water from Dryer 4 meets the environmental discharge standards for turbidity.

What the Client Said

EIS was the ideal on-the-ground partner for us to work with on this project. We could count on them to always work in a timely, cost effective manner and of the highest quality - this was essential as their work contributes to our reputation in the eyes of our client.

Dan Dirks, Senior Electrical/Automation Engineer

Tetra Pak