Webster Griffin Ltd
Brooklands Park
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Crowborough,  TN6 2JD
England (UK)

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> Home > Case Studies > Sewage Sludge and Compost
Sewage Sludge and Compost
  Bag Filling and Packing Systems for dry and wet sludge, organic fertilizer and composted green waste  
Form Fill Seal Bagging Machine for Fertilizer

Sewage Treatment Works

 
bulk bag filler for sewage sludge pellets

form fill seal bagger for composted green waste


robot palletizer for bags of organic fertilzer and composted green waste


bulk bag filler for wet and dried sludge

bulk bag filler for dried sludge

Automatic bagging machine for organic fertilizers and composted green waste

Robot palletizer for bags of fertilizer and composted material

Palletized and Stretch Wrapped Bags

form fill seal bagging unit for bags of fertilizer

sewage works

Sewage Treatment Works

pallet magazine

Robot palletizer hand for bags of composted material

Palletized stack of bags on the Okura robot palletizer

 

 

Webster Griffin has developed many solutions packing sewage sludge, treated effluent, ash and composted green waste into big bags and sacks.

Over 30 systems supplied in Europe and Middle East - click here to see list

Our scope of supply includes:-

Doha North STW - Keppel Seghers

Webster Griffin have won US $800,000 contract to supply two fully automatic bag packing and palletising lines for the new sewerage treatment works in Doha, Qatar in the Middle East.

The sludge treatment plant in the Doha North facility will be the only sludge treatment plant in Qatar, it will receive and treat sludge from Waste Water Treatment Plants all over Qatar and the treated sludge can be used as a supplementary green source of energy or as a pelletised organic fertilizer which will be packed into 10kg plastic bags on a new hi-tech Form Fill Seal (FFS) bagging machinery and robot bag palletising system from Webster Griffin.

Webster Griffin will act as subcontractor to TSL Engineering PTE Singapore. Webster Griffin’s scope includes detail design, engineering, testing, installation, start-up and training co-ordinated from Webster Griffin’s service centre in Dubai.

Singapore company Keppel Seghers is the main contractor for this Landmark International Waste Water Treatment and Water Re-use project, they have forged a partnership with the public works authority of Qatar to develop Doha North Sewage Treatment works (Doha North STW).

When completed in 2011 this project will be the largest Greenfield waste water treatment, water re-use and sludge treatment plant in the Middle East. With peak design capacity to treat waste water of up to 439,000m3/day Doha North STW will serve a projected population of over 900,000 in the year 2020.

Doha North is a model project for the International Water Community, incoming water will be treated to International standards for safe disposal and for re-use, solid waste is treated, dried and converted into a slow release organic fertilizer which is a used as a soil conditioner for planting purposes.

This is the third project of this kind which Webster Griffin has been awarded in the region and follows their installations at Saudi Aramco Dhahran STW (Sewage Treatment Works) and for Dubai Municipalities new sewage treatment works in Jebel Ali where Enpure and Al Ahmadiah Aktor are the main contractors.

  

Millbrook Wastewater Treatment and Recycling Centre, United Kingdom

Southern Water's Millbrook Wastewater Treatment and Recycling Centre was completed in 1999.

The plant currently treats wastewater from 138,000 people in the Southampton area and sludge from an additional 112,000, which is imported from the region's smaller WWTPs. A total of 14,000t of sludge is converted into 10,000t of fertiliser per year, which is sold to a variety of outlets for beneficial land use.

Work to upgrade the Millbrook site to provide a regional sludge treatment centre began in May 1997, and was completed in early 1999 at a project cost of around £20 million. The work involved providing enhanced facilities for sludge screening, thickening and de-watering, together with upgraded anaerobic digestion incorporating biogas collection and heat recovery systems.

SLUDGE PELLET BAGGING SYSTEM - HIGH SPEED BULK BAG FILLING SYSTEM

Webster Griffin supplied the big bag filling system for the dried pelleted sewage sludge.

The dried sludge pellets or organic fertiliser is bagged and distributed for beneficial agricultural / land applications under the name "Bestway".

 The European waste water industry needed a convenient, clean, economical method of packing or bagging dry pelletised sewage sludge for transportation from sewage works to disposal sites.

Webster Griffin provided the answer with its high speed IBC-PF2 Bulk Bag Weigh Fill System. This machine packs 10-25 x 800-1000kg big bags of FIBC's (Flexible Intermediate Bulk Containers) per hour (10-40 m3 per hour).  The IBC-PF2 is available as a static machine or mobile bagging unit. 

The bags or jumbo bags are sealed at the neck and provide a convenient, clean method of containing dried sludge for transportation while protecting it from damp.

The bulk bag filler machine weighs and fills dried sludge pellets into supersacks or bulk bags which are made from tough woven Polypropylene fabric and have a loose P.E. inner liner bag.

The Webster Griffin bag filling machinery is built to operate 24 hours per day in arduous conditions, the equipment is PLC controlled and includes load cell weighing technology which totalises the tonnage of sludge handled whilst providing up to the minute production data to the plants central control computer - or SCADA system.

For traceability every bag can be identified by a unique number which is printed onto a ticket with additional production data, and inserted into a pocket on the side of the big bag. An operator starts the filling cycle by applying an empty bag and pressing 'start'. Once filled, bags are automatically released from the weigh-fill station and discharged onto a length of accumulation conveyor.

Webster Griffin are specialists in bag filling machinery for powder and granular materials, ash, waste and composted products and will handle all aspects of the packing installation in a turnkey basis, including all hardware and software,  supervision of installation and on-site commissioning.

Moray Coast Wastewater, Treatment Project, Scotland, United Kingdom

The updating of storm water arrangements in Whitehills in the spring of 2004 signalled the final stage of a radical modernisation of wastewater treatment along the Moray Firth which had begun three years earlier.

The work - under a Scottish Water contract awarded to the Catchment Consortium - was chiefly driven by the demands of the EU Urban Wastewater Treatment Directive. Pre-existing arrangements had principally relied on direct discharge into the sea.

The project involved the construction of three new wastewater treatment plants providing a combined capacity of nearly 60,000m³/d, a sludge treatment works and a network of new sewers, serving 55,000 residents and local industry.

SLUDGE TREATMENT AND DISPOSAL - SLUDGE PELLET BAGGING SYSTEM

Webster Griffin were awarded the contract to supply a mobile bulk bag filling unit for the treated dry pelleted sludge.  The bag filling machine complete with operators platform and control panel, can be moved to a new bagging location by fork truck.  Compressed air and power connections are of the quick release 'plug-in' type.

Although the Oakenhead Wood plant at Lossiemouth is the centre for sludge treatment and disposal - dealing with some 10,000m³/d - each of the works has its own three-belt press for sludge thickening.

This equipment has a pre-thickening first belt, driven independently of the other two, which dewater. Allowing the optimum speeds to be selected for these separate operations enables the press to handle a very dilute influent, whilst producing a solid cake product. This makes it well suited to the thin sludges produced, especially since material from Macduff and Buckie must be transported to Lossiemouth.

The 17% TDS cake, together with other sludge brought in by Scottish Water, is put through a high temperature dryer running at 220°C and pelletised to form a Class A product suitable for fertiliser use on agricultural land. The finished pellets, now with a TDS of around 92%, are bagged on the Webster Griffin bulk bagging machinery and then  stored at the works for up to six months before being distributed in single loop bulk bags. The material is subject to thorough analysis and any which does not comply with the required standard is landfilled at a licensed site.

No charge is made to the farmers involved, but this part of the operation is highly regulated. The receiving soil must be of suitable type, only permitted amounts may be spread and only then at given times of the cropping cycle. Careful records are also required for each batch of sludge.

 

Sukomi Waste Management Lebanon (Bagging System for Composted Green Waste)

Form Fill Seal Bagging Line for Composted Green Waste.  Sukomi are part of the Averda group of companies covering the collection, treatment, recycling of municipal solid waste in the Middle East.

Sukomi encompasses 3 divisions, Sukomi Waste Treatment for the sorting and composting operations, Sukomi landfill projects for sanitary land filling and the centre for the Environmental Research and Testing (CERT).

Sukomi employs state of the art technology, waste treatment starts at the sorting plants where waste is segregated into 4 main categories:-

  • Recyclable material (glass, PET, PE, wood, aluminium, paper, cardboard, tins)
  • Organic (green waste)
  • Reject and bulk material

The organic material is processed into compost - an excellent soil enhancer - which is sold in bulk to farmers and packed into 50 litre sacks on the Webster Griffin bagging equipment for distribution to the public.

The composted green waste is loaded into the system by a tip dumper truck or 'front end loader', then an inclined trough belt conveyor feeds the composed material into the automatic product dosing system, which discharges 10-50 litre charges of product into the high speed FFS  (form fill seal) bagging machine.  With FFS the bags are automatically made on the bagging machine from a roll of flat plastic film which is converted into a tube and then filled with compost, before being welded closed by a heat seal across the top.  FFS is a well proven, low cost method of packing compost, fertilizer and chemicals into 10kg, 25kg and 50kg bags at high speed.  After filling the bags are rotated 1800 and then squeezed between two belt conveyors to remove excess air in order to provide a solid block which is convenient for palletizing, handling and transport.

Dubai Municipality STP (Sewage Treatment Project) Jabel Ali

SLUDGE PELLET BAGGING AND PALLETIZING SYSTEM - Automatic Bagging System for Organic Fertilizer / Pelleted Sewage Sludge

The sludge pellet bagging system from Webster Griffin Ltd was designed and supplied on a turnkey basis for Enpure Ltd.  Webster Griffin have been awarded the contract to supply a fully automatic bag filling, bag palletizing and pallet wrapping line, dust extraction/vapour control and filtration is also part of Webster Griffin's scope.  The bag filling line employs the most modern equipment and latest technology including an Okura robot palletizer - which was chosen for its versatility, minimal moving parts and reputation for reliability in inhospitable environments.

The automatic pellet bagging line is composed of the following 3 main elements:-

i) fertilizer weighing and filling into 25kg bags, bags are picked up from a magazine and automatically applied to the filling spout, after filling bags are closed by sewing
ii) Palletizing, after the full bags have been flattened and shaped for palletizing, an Okura robot palletizer picks up and stacks the bags onto wooden pallets
iii) Wrapping, the loaded pallets are conveyed to an automatic pallet stretch wrapper which also applies and 'wraps-in' a plastic sheet on the top of the load in order to give the palletized stack of bags stability and protect it from dust and rain.

All main elements of the line are connected by conveyors and operate as one integrated fertilizer packing unit.

Dhahran Sanitary WWTP (Wastewater Treatment Project) for Saudi Aramco

This plant is located in Eastern Region of the Kingdom of Saudi Arabia.

BAGGING DRIED SLUDGE PELLETS

Webster Griffin were awarded the contract to supply the Automated Screens Bagging System by Al Suwaidi Industrial Services.  The bagging line will receive and pack processed wet sludge into 800-1000kg four loop bulk bags.  All machinery is built to operate outside in inhospitable, humid high temperature environment.

Project Details:-

  • Product - wet thick sludge
  • Self Contained Automated Bagging Unit
  • Stainless Steel Product Contact Parts
  • Automatic pallet dispenser and pallet conveyors for full bag handling
  • Contractor - MS Al Suwaidi Industrial Services Ltd, Jubail Industrial City Kingdom of Saudi Arabia

Afan Waste Water Treatment Works

The project was to construct a new waste water treatment works and sludge treatment facility for a population of 135,000 in Neath, Port Talbot and surrounding areas. The project, valued at some £30 million, commenced in August 1998 and was completed by April 2000. The aim of the project was to improve the quality of the bathing water at Aberavon Beach, achieving "Blue Flag" status at the beach in 2001.

Webster Griffin Ltd supplied the complete system for filling dried sewage pellets into bulk bags/big bags.  After being filled the full bags are accumulated on conveyors for removal by fork truck.  The bulk bag filler can deliver a throughput of upto 30 bulk bags/hour, therefore, a total days production can be bagged in a one hour campaign - this strategy is employed to reduce labour required to operate the state of the art sewage processing facility.

 Doha North Sewage treatment works

Sewage treatment works

form fill seal bagging system for composted green waste

sewage treatment works

 Big bag filling machine for pelleted sewage sludge

Inside a Webster Griffin control panel for a big bag filling system for sewage sludge

Push button controls for a Webster Griffin jumbo bag filling machine for pelleted sewage sludge

 form fill seal loader for composted green waste

Building a new sewage treatment works in the Desert

 Sewage treatment works in the Desert

Pelleted Sewage Sludge

Jumbo bag filling machine for wet and dried sludge

Filling spout for a bulk bag filling machine for wet and dried sewage sludge

Sewage Treatment Works

Pallet Stretch Wrapper for Bags of Composted Waste and Organic Fertilizer

Form fill seal bagging line for composted green waste

form fill seal bagger / baler for composted green waste