Closed-loop wash water recycling system for Novelis UK

Project summary

The cleaning of a fleet of forklift trucks at Novelis UK’s Warrington recycling facility required substantial water use, leading to higher operating costs. To address this, Kirton Water Treatment Services developed a customer-engineered closed-loop water treatment system that improves cleaning efficiency, lowers maintenance expenses and supports environmental compliance.

The background

Novelis UK, a leading aluminium beverage can and automotive recycling facility based in Warrington, operates a fleet of forklift trucks and similar industrial vehicles to support its daily operations. While these vehicles operate only on roads, they are still subject to soiling from weather and road conditions. The Warrington site did not have a water reclamation system in place, resulting in higher water usage and associated costs.

Dust and debris build-up on the vehicles was identified as a contributor to avoidable maintenance issues, affecting productivity and increasing service costs. At the same time, environmental compliance standards required improved water usage efficiency. A practical, sustainable approach was needed to reduce water waste, enhance system reliability and support the company’s environmental objectives.

The challenges

The site did not have an existing water reclamation system, and the project took place during a period of significant site expansion alongside regular recycling operations. As a result, around 300 heavy goods vehicles and multiple contractors using excavation vehicles had to be safely managed on-site at the same time.

The solutions

Kirton Water Treatment Services built a custom-engineered closed-loop water treatment system so that it could be tailored to the specific needs of the Novelis Warrington site. Full-width ramps and protective screens were used to build a reverse-on washing platform. Water run-off was diverted into the closed-loop system with coagulation and settlement stages, cyclonic separation, particulate media filtration and absorption media filtration. Continuous water quality monitoring via a system turbidity probe and controller ensured effective reuse of water.

The impact

The closed-loop water treatment system has transformed vehicle maintenance at Novelis’s Warrington site. Recycling and reusing the water have led to a significant reduction in water consumption, and the reduced run-off has enhanced environmental compliance. The reduced water usage has also reduced operational costs at the site.

The reverse-on system has made it easier and faster to wash down vehicles. This has facilitated improved vehicle reliability by preventing dust and debris build-up, fewer vehicle repairs and improved site hygiene from effective vehicle cleaning.

Because the system was installed with careful planning, ongoing site operations were not interrupted. The Warrington site now benefits from a cleaner and more reliable approach to water management.