Sorry for the long delay in response.. As it turns out, the float switch on our transfer station was gummed up (probably by the defoamer residue) and allowed the transfer station to get behind (backing up the gravitational flow of the wash system). Once the water height was above the wash level, the water had no where to go in a hurry and the water spilt over.. Luckily, we have a spill-trap surrounding the wash which captured the 'leaking'.
Since then, we've setup our wash to use a little of the fresh water (filter/recycled) in the wash modules --rather than just in the final rinse. This required a balance with a slight amount of direct draining into the transfer-station. The result has been positive as we are seeing clearer water (no foam) in the pre-wash and wash modules. The filtration system is able to provide the required final rinse pressure and volume --while refilling the wash tanks (as long as the transfer station can keep up).
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