Danger! Danger! High Voltage!

When Meadow Foods faced the prospect of spending £0.5M on a new effluent tank—at a time when future expansion plans were still uncertain—FLI CAP Technology stepped in with a far more economical solution.

The existing 1,250m³ tank was operating with an outdated, inefficient 110kW blower system that was no longer delivering sufficient aeration due to repeated breakdowns. Extending the life of this tank by at least two to three years meant that any new aeration or mixing equipment would have to be installed while the tank remained in full operation, with no backup capacity.

Adding to the complexity, overhead 11kV power lines made it impossible to use cranes for installation.

Chris Woods, Divisional Director at FLI CAP Technology, recalled: “Our first reaction—if we’re being honest—was something along the lines of, ‘How on earth are we going to do this?’”

After considering several lift-out aeration grid options that could utilise the existing floor space, the team selected Landia’s AirJet system. “We knew from past experience that Landia equipment is extremely reliable, and their engineers offer a wide range of installation options—even in very demanding situations,” Woods said.

At the same Meadow Foods site, Landia AirJet and JetMix systems had already been operating trouble-free for seven years on a large balancing tank. The JetMix design recirculates liquid and uses strategically positioned nozzles to deliver even mixing throughout the tank, while also providing intensified mixing zones when required.

Woods continued: “We worked closely with Landia to plan the ‘live and full tank’ installation. Because the tank had to stay full, and had no flange connections, external placement of the pumps wasn’t an option. Landia solved this by supplying spike-bottomed guide rails for the chopper pump venturi nozzles, meaning the AirJet could be installed without mounting anything inside the tank.”

These guide rails could be lifted over the tank wall without major lifting equipment, and the units can be removed easily using a winch for maintenance.

FLI CAP Technology installed three 18.5kW Landia units—less than 60kW in total—replacing the old 110kW blower. The resulting energy savings are substantial. With automated controls, the system can operate on just two mixers during periods when effluent targets are met, with no loss of aeration performance.

Costs had been escalating for Meadow Foods not only due to high energy usage but also because more than half of the insufficiently treated effluent had to be tankered off-site due to its high strength.

“The old tank might not win any beauty awards,” Woods said, “but with the right approach, we’ve shown how to extend the life of an asset. Our customer is back in compliance, no longer needs expensive tanker removal, and has dramatically reduced energy consumption. The Landia AirJet has given them a highly efficient, extremely reliable system that provides real peace of mind.”

Dave Hutchinson, Engineering Manager at Meadow Foods, added: “Having worked with Chris Woods before, we were confident he’d find a cost-effective solution. We were very pleased to be offered Landia equipment, as their systems have previously delivered excellent results on site. The equipment quality and installation management were outstanding from start to finish. FLI CAP Technology and Landia delivered a high-quality solution with impressive energy savings.”