Case Study: Digester Deep Clean – 800+ Tonnes Removed for UK Food Industry Client
Over 800 tonnes of solids removed
TheDigester Deep Clean – 800+ Tonnes Removed for UK Food Industry Client
Client Overview
A leading UK food manufacturing facility required a full internal clean of a large anaerobic digester tank. The digester had not been fully emptied in several years, resulting in heavy accumulation of solids that were impacting efficiency and capacity.
The Challenge
The tank contained over 800 tonnes of compacted organic solids, primarily settled sludge and fibrous food byproducts. Due to the confined nature of the space and the hazardous atmosphere inside the vessel, the job presented multiple challenges:
- Entry and operations in a confined space environment
- Removal of a large volume of solids with minimal water use
- Safe access via manways with restricted and working at height
- Maintaining compliance with health, safety, and environmental regulations throughout
Our Solution
Celvac deployed a specialised team with experience in confined space operations and anaerobic digester cleaning. The operation included:
- Initial site survey and risk assessments in coordination with the client’s safety team
- Deployment of confined space teams equipped with line-fed breathing apparatus (BA) systems
- Installation of a mobile screening unit to separate and reduce water content from the extracted material, cutting disposal costs and improving efficiency
- Continuous air monitoring and rescue team presence on standby
- Use of high-powered vacuum tankers and jetting equipment to mobilise and remove built-up solids
Implementation Timeline
Phase | Duration | Activities |
Planning & Prep | 1 week | Surveys, permits, H&S briefings |
Mobilisation | 1.5 days | Equipment setup, team orientation |
Cleaning Ops | 4 weeks | Digester clean, material screening, waste removal |
Final Checks | 1.5 days | Post-clean inspection and client sign-off |
Results & Metrics
- Over 800 tonnes of solids removed
- Project completed within 4 weeks, ahead of projected 5-week timeline
- Water use reduced through on-site screening
- Zero incidents or safety breaches during confined space entry
- Client experienced improved gas and operational efficiency post-clean
“Just a quick side note to say thanks for a great job, the team worked really hard to get this one done. The crew was exemplary. They always hard working and willing to do extra hours etc and his communication throughout the job was really good. They really are a credit to your company.
Kind regards, Kevin.
Plant Manager”
Key Points
- Specialist confined space entry teams can safely manage high-risk digester cleans
- In-line screening dramatically reduces the volume of liquid waste and disposal costs
- Regular full cleans restore operational efficiency and improve digester performance
- Strong planning and HSE coordination are essential for food industry environments
Contact Us
Have a digester or high-solids tank that needs professional cleaning? Get in touch with Celvac today to arrange a free site consultation and discover how we can help you reduce costs, minimise risk, and improve plant efficiency.
