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Case

Groundwater management

Industrial water treatment

Urban water management

+4

Improving Wastewater Treatment Performance While Reducing Costs and Footprint.

16 April 2026

Solution provider

EXPO-NET Danmark A/S

Experience in high-tech plastic net production since 1959. We stand for quality, delivered on time. Our modern production processes are based on a range of techniques ideally suited to the manufacture of custom-designed products used across a wide variety of industries. We are flexible and always ready for dialogue on the design of new extruded net types.

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Challenge

The Sandbach Wastewater Treatment Works in Cheshire, England, needed to increase treatment capacity to support regional population growth.
The key challenge was to deliver higher performance within a limited site footprint and budget. Using traditional crossflow filter media would require larger structures, longer construction time, and significantly higher costs, making the project difficult to deliver within existing constraints.

Solution

Working closely with Cougar Wastewater, EXPO-NET delivered an alternative biological filtration solution using BIO-BLOK® fixed filter media.
BIO-BLOK® enabled the design of a compact nitrifying filter system capable of handling increased loads within the existing site boundaries. The modular BIO-BLOK® units are lightweight, self-supporting, and easy to install by hand, which significantly reduced both installation time and complexity.

This approach made it possible to deliver a higher-performing solution without increasing the plant footprint.

Result

The project delivered strong, well-documented environmental and economic benefits:

Key results include:

  • 40% improvement in wastewater treatment performance
  • Overall project cost savings of approximately £500,000.-
  • 50% smaller asset footprint compared to traditional crossflow solutions
  • 40% reduction in overall build time, minimising plant downtime
  • Low-maintenance operation due to self-cleaning filter media
  • Improved compliance with environmental discharge standards