Category Archives: RecOil

Wiltshire Dairy plant seeing major benefits from their Recoil System 28

121114 Arla Westbury Recoil5

Recoil System 28

Following the turnkey installation of our Recoil System 28 plant, at a leading Wiltshire dairy, an immediate difference was noted in their effluent plant: recovering substantial volumes of high grade (low moisture) butter fats, the effluent plant is now within discharge consent and the pre-existing DAF plant sludge has been virtually eminated. A further result of the installation has been the COD reduction within the process effluent (as a direct result of FOG removal) and while this does not happen in all food processing industries, it is an added benefit of the system when deployed in dairy facilities.

With the cost savings on sludge handling, and the ever increasing value of the recovered FOG, this site have calculated that the Recoil system will have a payback time of less than eighteen months !

2 Sisters do the Double


Location: North Lancs., UK

Installation Date: 8th August 2008

Industry Sector: Chicken Roasting (120 tonnes per week)

Pre-install Issues: The client site has a central collection pit for all effluent which was emptied utilising high shear chopper pumps. The effluent was then passed over a wedge wire screen to remove solid debris before passing to a bio nutrient plant, from where the treated effluent was pH balanced and fed through a DAF plant to remove oils and excess biomass. The high content of chicken fat present caused untold problems with all stages of the process, the screen would blind with semi solid fat causing a large proportion of the effluent to simply run into the solids collection pit (30 mі) resulting in the requirement for this to be pumped 3 times per week at a cost of Ј400 each time. The bio nutrient plant, which is designed to remove sugars present in the coatings, could not operate efficiently as the fats were clogging up the system. The DAF plant could not cope with the strength of effluent being passed through it. As a consequence the Water Authority was regularly assessing the site and applying surcharges to the normal water charges. There was also a considerable odour problem from decaying fats, as the site is adjacent to a residential area, so the site was subject to pressure from the City Council and local resident pressure groups to improve the situation. Water disposal costs were around Ј25,000 per month with tankering costs of around Ј5,000.

2 Sisters PhotoSolution: The site was fitted with a Recoil 18 system, complete with solids removal augers and low shear pump systems. Additional heat sources were utilised due to the fast solidifying nature of the chicken fat and the exposed location of the equipment.

2 Sisters PhotoResult: The effluent is now initially treated by the Recoil system which efficiently removes the solid debris before de-oiling the effluent. As a result the wedge wire screen now works as designed to remove fine solids and carbon from the ovens. The bio nutrient plant is also now fully operational with the DAF system being used solely to remove the biomass carryover at the end of the process. Consequently the site is now compliant with the effluent standards required, the smell issue has abated and the sludge haulage costs are sunstantially reduced. Moreover, the site’s water charges have reduced to Ј5000 per month with Recovered Oil sales yielding approx Ј3-4000 per month.

United Biscuits: New dawn for effluent processing


Location: Ashby de la Zouche, Liecestershire, UK

Installation Date: 17th June 2008

Industry Sector: Preformed corn and potato starch fried snacks

United Biscuits PhotoPre-install Issues: The client was trying to use a DAF plant to remove oils from their effluent but this was unsuccessful due to the high pH of the effluent (9-11), exacerbated by the caustic wash from the frying kettles. pH balancing was required before AND after the DAF plant. The client had been outside of consent for some time and had recently been fined Ј50k by the Environment Agency.

United Biscuits PhotoSolution: A Recoil 28 unit was installed to replace the aging DAF plant, there are no solids present and as result the augers were omitted. The control systems are Siemens S7 logic and feature touch sensitive user interface with manual override for all controls to enable individual maintenance functions to be accessed remotely. The pH balancing is now only performed once, after the Recoil system

United Biscuits PhotoResult: The client has removed the cost of running the DAF plant, reduced the cost of pH control and removed the requirement for any sludge to be removed from site. Total savings Ј70k per annum. On top of this the client now enjoys an income of over Ј50k per annum from the sale of the recovered sunflower oil, the recover rate is around 20 tonnes per month at up to 97%. The client is now consistently compliant with their discharge licence, FOG has been reduced from peaks of 20,000ppm to a consistent level below 100ppm. COD is reduced by 85% as are TSS. pH is also now normalised between 6 and 8.

First Recoil Unit into KTC Edibles


Location: West Midlands, UK

Installation Date: 14th November 2004

Industry Sector: Oil repackaging, blending, margarine and lard production and packaging

KTC PhotoPre-install Issues: Attempting to remove waste oils from their effluent wtih a small DAF system, the client was bearing the costs of having to tanker away large volumes of oily water from site. The Water Authority was testing the effluent weekly and the site received numerous compliance and improvement notices. The Water Authority was scheduled to close the drains unless a solution could be found. Being unable to process the effluent properly, the client was unable to keep the tank farm area free from oil. The tank farm bund was constantly full of effluent containing approx 30% oil.

KTC PhotoSolution: Following discussions with the development team at Recovered Oil Limited, this became the first installation for a Recoil unit (Recoil 18). The effluent from 5 different locations was piped to a centrally located unit, using low shear, continuous cavity pumps. The resulting separated oil is pumped to waiting IBC units. Recovered Oil were also engaged to oversee the site clean up operation to rid the various locations of years of oil build up.

KTC PhotoResult: The initial clean up and Recoil processing of the 15 acre site, including 3 grease traps and interceptors totalling around 60 cubic meters of effluent, together with the tank farm bund which contained a further 450 cubic meters of effluent, yielded 73 tonnes of marketable oils. Normal operations since then yield around 14 tonnes of saleable oils and fats each week. The client is now consistently compliant with their discharge licence and was removed from the Water Authority watch list after only 3 months of operation. Attached are the before and after Water Authority test results – click to download.

Severn Trent Water Analysis, 2 November 2004, just prior to Recoil installation.

Severn Trent Water Analysis, 1 December 2004, soon after Recoil installation.

Severn Trent Water Analysis, 20 July 2006, approx 18 months after Recoil installation.

Having removed the cost of operating the DAF plant and tankering effluent, the client now enjoys an income of around Ј2800 per week from recovered oil sales.