Wastewater Treatment Plant Control System Upgrade

Suffolk, December 2019

The Challenge

A wastewater treatment facility at an apple juice, cider, and vinegar producer in Suffolk was in desperate need of an upgrade. Their control system was no longer suitable and they required a reliable solution to ensure the treatment of up to 200 cubic metres of wastewater every day. When the client approached us at Elmleigh, we knew exactly how we could help.

The Solution

Our proposal included the design, assembly, and electrical installation of an upgraded control panel system. Using a Siemens S7-1500 PLC and Siemens Touch Comfort 15” HMI with Siemens G120C VSD, and a fibre optic link between the existing system and new AD plant, Elmleigh increased the water treatment capacity at the plant. The original aeration tank and plant room container were also retained with our new control panel adopting and integrating into the existing remaining equipment. We were also able to implement remote access for troubleshooting and diagnostics.

The Outcome

Utilising existing plant wherever possible, we were able to provide a total treatment rate of 200 cubic metres per day as required. The project covered design engineering, software and hardware through to control panel assembly, installation, and commissioning enabling us to complete the project to the client’s expectations. Taking just 8 weeks from start to finish, the team were able to finish the project with minimal disruption to the site’s manufacturing and processing requirements.

Dan Connor, Project Engineer, comments: “This project was very challenging, not only because of the number of trades onsite but the fact we were installing a new system alongside an old system whilst the old system was still running! This meant organising the shutdowns out of hours to transfer everything over into our new panel with minimal disruption. The logistics of getting the 4-metre panel into a container and across rough ground, with only 2 days to get the old cables into the new panel and up and running proved challenging but the team at Elmleigh sailed through. Everyone did a great job, completing the project to a very high standard.”

If you’d like to discuss an electrical installation project with Elmleigh in more detail, contact our office today and we’ll be happy to help. Alternatively, have a look through our full scope of services to find out more about how we can help upgrade your business.


Value £100K
Client UK Apple Juice, Cyder and Vinegar Producer
Location Suffolk
Time 8 Weeks

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