Project Overview

Butler Manufacturing Services (BMS) Ltd. worked with a busy service station in Cork to design, manufacture, supply and commission a Recyclone Water Recycling System capable of treating and recycling used wash water from car/van/SUV washes by both a high-volume brush wash and jet wash facility.

The site processes approximately 4,000 litres of water per hour, generating significant volumes of wastewater containing detergents, suspended solids, hydrocarbons and persistent soap foam. With limited available space and increasingly stringent discharge requirements from Cork County Council, the client required a compact, efficient and environmentally compliant solution.

The BMS Recyclone System was selected for its ability to provide high levels of water recycling while effectively managing heavy foam generation within a compact footprint. The installation significantly reduced freshwater consumption, enabled compliance with local authority discharge requirements and delivered long- term operational savings term operational savings

The design remit was to design, manufacture, install and commission a compact car/truck wash water recycling system as follows:

• Treating used wash water/wastewater generated from both a commercial brush wash and jet wash.

• Processing used wash water flows of approximately 4,000 litres per hour.

• Managing large volumes of detergent foam generated during daily operation.

• Meeting Cork County Council discharge consent requirements.

• Maximising water reuse to significantly reduce potable water consumption.

• Providing a solution that could be installed within the site's restricted plant space with minimal disruption to ongoing operations.

The Recyclone being loaded for delivery. It can also fit in a standard container for easy shipping by sea.

Project Value

The client operates one of Cork's busiest service station vehicle wash facilities, serving a continuous flow of customers throughout the day, washing cars, vans, SUVs etc., with two wash systems operating simultaneously, water consumption and wastewater production had become a significant operational cost.

The existing system also struggled with excessive detergent foam and the business needed to ensure compliance with evolving environmental regulations governing wastewater discharge.

Due to limited plant room and service yard space, any solution needed to deliver maximum performance within a compact footprint while requiring minimal operator intervention.

Solution & Delivery:

Working closely with the client, Butler Manufacturing designed a bespoke Recyclone water recycling system specifically tailored to the site's operational demands.

The solution included:

• Detailed assessment of wash water volumes and wastewater characteristics.

• Design of a compact treatment system to suit the restricted installation area.

• Integration of Butler Manufacturing's Recyclone technology to separate solids, oils and contaminants while effectively controlling excessive soap foam.

• Installation of an automated water recycling process allowing the majority of wash water to be reused within the vehicle wash operation.

• Final commissioning and optimisation to ensure compliance with Cork County Council discharge requirements.

• Operator training and system handover.

The compact nature of the Recyclone system allowed installation without major alterations to the existing wash equipment or disruption to the site's day-to-day trading.

By recycling the majority of process water, the system has substantially reduced mains water demand while providing consistent water quality for vehicle washing operations.

Operation/Maintenance Details: 

The Recyclone can be maintained by on site staff. At this site BMS will visit on a monthly basis to ensure optimal functioning of the Recyclone. BMS offer maintenance contracts throughout the island of Ireland. 

Results

Following installation, the client achieved several significant operational and environmental benefits:

• Significant reduction in freshwater consumption through continuous water recycling.

• Ability to process approximately 4,000 litres of wash water per hour.

• Effective management of high detergent foam levels generated by both wash systems.

• Compliance with Cork County Council wastewater discharge requirements.

• Reduced wastewater disposal volumes.

• Lower operating costs through reduced water charges.

• Compact installation requiring minimal site footprint.

• Reliable, automated operation with minimal maintenance requirements.

Actual Recyclone Results from Inlet to Outlet

BMS have an unrivalled 40 years of experience manufacturing and installing surface water and wastewater management systems in Ireland, the UK and 60+ countries around the world.

BMS offer complimentary custom design consultations and project designs. Please contact us to discuss your project.