Large Personal Care Products Factory in Bydgoszcz, Poland Project Background

This factory is a globally recognized production base for personal care and household cleaning products, manufacturing items such as shampoo, body wash, and laundry detergent . With expanded production lines and an increased product range, wastewater volume continued to rise. COD concentrations exceeded the original design value by 50%, and the existing activated sludge system could no longer handle the load. The factory required that the retrofit involve no additional civil structures and that production downtime not exceed 72 hours.

MBBR Retrofit Solution

We provided a pretreatment + MBBR combined process. A dissolved air flotation (DAF) unit was added upstream of the biological system, and the existing aeration tank was converted into an MBBR system filled with our MBBR Media at a 55% filling ratio, equipped with new high‑efficiency aeration blowers.

Retrofit Results

● Design flow of 100 m³/day; COD reduced from ≤700 mg/L to ≤50 mg/L, removal efficiency 93% .

● TSS reduced from ≤330 mg/L to ≤30 mg/L, removal efficiency 91%.

● Zero civil expansion; production lines operated normally throughout the retrofit.

● Operating costs reduced by approximately 28% (lower sludge disposal costs and electricity consumption).

● Compliant with the strictest EU industrial wastewater discharge standards.