FLI CAP Technology delivered a new Membrane Bioreactor (MBR) system for Recordati’s pharmaceutical manufacturing facility in Ringaskiddy, Cork, as part of a wider wastewater treatment plant upgrade programme.

Following a significant increase in production capacity and the introduction of new BAT (Best Available Technology) requirements, the existing sequencing batch reactor (SBR) system required upgrading to meet future treatment demands and compliance requirements.

Working alongside WEW Engineering, FLI CAP Technology was selected to design, supply, install and commission a new membrane separation system as part of the overall treatment plant improvement project.

Project Scope

The project included:

• Detailed process and mechanical design
• Equipment supply
• Mechanical and electrical installation
• Commissioning of the complete MBR system

A dual-chamber prefabricated stainless steel membrane tank was installed to house two Alfa Laval MFM-120 membrane cassettes. Located separately from the biological aeration process, the system provides a peak membrane filtration capacity of 5 m³/hour while consistently achieving treated effluent suspended solids concentrations of less than 10 mg/l.

The installation also incorporated:

• Duty/standby inlet basket strainers
• Membrane scour blower system
• Automated CIP cleaning system
• Activated sludge return pumps
• Instrumentation and automated process controls
• New PLC control panel with touchscreen HMI

To minimise site installation time, key process equipment was assembled and tested off-site on a prefabricated skid complete with pipework and electrical cabling.

Delivering During COVID-19

The installation was completed during the height of the COVID-19 pandemic, requiring strict compliance with both Government and site-specific safety protocols.

A prefabricated installation approach significantly reduced the duration of on-site works and associated project risks. Due to travel restrictions, commissioning was successfully completed remotely through close collaboration between FLI CAP Technology, on-site contractors and WEW Engineering.

Project Outcome

The completed MBR system was delivered on programme and within budget, achieving all agreed performance targets while providing Recordati with a robust, future-ready wastewater treatment solution capable of supporting continued site growth and compliance requirements.