South Africa – The upgrade of the Signal Hill effluent treatment plant has reached an advanced stage, with specialist industrial water solutions provider Tecroveer announcing significant progress on the project at the Signal Hill Beverages facility.
The upgrade centres on a 60% increase in anaerobic treatment capacity, achieved through the installation of two Aqana DACS® (Down-flow Anaerobic Carrier System) reactors, a PA tank, a Condi tank, and expanded front-end treatment infrastructure. Tecroveer notes that the dual-reactor configuration improves operational flexibility, process stability, and system redundancy.
DACS® technology: a departure from conventional systems
The project leverages DACS® technology, which differs fundamentally from conventional anaerobic systems. Instead of relying on sludge granulation – a process that can be disrupted by fluctuations in effluent quality – the system retains biomass on carrier material. This design reduces sensitivity to process fluctuations and enhances reliability when treating high-strength industrial wastewater .
The technology is developed by Aqana, a Netherlands-based company specialising in anaerobic wastewater treatment solutions for industrial applications. DACS® reactors operate on a downflow principle, with wastewater passing through a bed of floating plastic carriers where anaerobic biomass attaches primarily to the interior of the carrier structure. Biogas rises naturally to the top of the reactor, providing gentle mixing without the need for complex internal mechanisms .
Biogas integration supports circular economy goals
A key benefit of the upgrade is the integration of biogas production. During treatment, organic waste is converted into renewable biogas, enabling energy recovery that reduces the operational carbon footprint of the facility. This approach aligns with global industry trends toward energy-positive wastewater treatment plants, where facilities generate more energy than they consume .
Tecroveer’s broader portfolio includes biogas management and anaerobic digestion solutions, with applications across the food, beverage, paper, chemical, and pharmaceutical sectors .
South Africa’s growing DACS® footprint
According to Tecroveer, South Africa now hosts the highest number of DACS® reactors currently in operation globally. This reflects growing confidence in advanced anaerobic systems and increased adoption of circular water technologies across local industry, supported by collaboration between technology providers and South African engineering firms .
The milestone comes as South Africa faces persistent wastewater infrastructure challenges. Government reports indicate that poorly functioning wastewater treatment plants and ongoing sewerage spillages continue to contribute significantly to water pollution in several municipalities, with aging infrastructure and capacity constraints placing pressure on both municipal systems and receiving water bodies . Industry reports suggest that 56% of wastewater treatment works were in poor or critical condition as recently as 2022, with private-sector investment increasingly seen as essential to bridge infrastructure gaps .
Strategic value for beverage manufacturers
For beverage manufacturers, the Signal Hill upgrade delivers clear operational and sustainability advantages. The expanded capacity supports adherence to strict wastewater discharge regulations while handling higher effluent volumes without compromising performance. Energy recovery through biogas offsets operational costs, while strengthened water stewardship credentials support environmental, social, and governance (ESG) reporting requirements.
The project builds on Tecroveer’s established track record in the beverage sector. The company has previously delivered design-build-operate-maintain effluent treatment services for industrial clients including AB InBev and Distell, with a focus on integrating existing infrastructure into new designs to optimise capital and operational expenditure .
Outlook
The Signal Hill effluent treatment plant upgrade sets a benchmark for industrial water projects across Africa, demonstrating how advanced anaerobic treatment, resource recovery, and scalable engineering solutions can transform wastewater from a liability into a valuable resource.
With engineering expertise from Tecroveer and process technology from Aqana, the project illustrates the potential for collaborative partnerships to deliver high-performance wastewater treatment systems that achieve both operational efficiency and sustainability goals, while supporting regulatory compliance, reducing environmental risks, and strengthening long-term water security for industrial operations across the region.
