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Case

Groundwater management

Industrial water treatment

Urban water management

+3

Upgrading Wastewater Treatment Capacity Without Expanding Land Use.

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

Many regional wastewater treatment plants are under pressure to increase capacity while operating within strict space, budget, and environmental constraints.
At the Lower Cleeve Wastewater Treatment Plant in the UK, the existing crossflow filter media was reaching the end of its service life and could no longer meet treatment requirements. At the same time, expanding the facility by building new assets was not a viable option, as it would require additional land use and exceed the available budget.

Solution

Instead of constructing a new facility, the project team chose to refurbish the existing filters using BIO-BLOK® fixed film filter media, developed by EXPO-NET.
BIO-BLOK® made it possible to significantly increase treatment capacity within the existing infrastructure. Thanks to its open mesh helical design, BIO-BLOK® provides a much larger active surface area than conventional crossflow media, allowing the same performance to be achieved with approximately three times less filter media volume than originally installed crossflow media.

The BIO-BLOK® units were prefabricated offsite and delivered ready for installation, enabling a fast and efficient, highly cost-effective refurbishment process without the need for specialist lifting equipment.

Result

The refurbishment delivered a highly effective and future-proof solution with clear environmental and operational benefits.

Key results include:

  • Refurbishment of both 25 mtr. diameter filters completed to budget
  • Significantly better treatment performance and greater plant capacity installed
  • No additional land use, as the existing plant footprint was maintained
  • 80% BOD plus ammonia 36% removal rates, exceeding operational requirements due to having excess BIO-BLOK media installed to fill physical volume of the refurbished filters
  • Excess installed media volume had the added environmental benefit of reducing the ammonia impact downstream
  • Faster installation, enabling a plant downtime of only 14 days
  • Lower operational energy use and reduced maintenance needs
  • Extended lifetime, with installed additional capacity of the existing wastewater asset