FlocFormer – the best floc for every dewatering task

A process for high dewatering performance through targeted flocculation

The standard procedure for preparing sewage sludge for dewatering is through chemical conditioning using polymers. The conditioning technology has to create flocs with optimal dewatering qualities for the constantly changing sludge and process parameters. This is not possible using conventional technology. In addition, each dewatering unit requires a specific flocculation process in order to achieve optimal dewatering. Thus, the dewatering results are only as good as the conditioning used!

Our solution :

FlocFormer200The internationally patent-protected FlocFormer flocculation unit for polymer-initiated separation processes can be optimally adapted to the sludge and process conditions. Four degrees of freedom allow varying volume and flow rates to be treated and enable a high degree of adaptability towards different sludges and dewatering machines. The unit for controlling the degrees of freedom is an integral part of the system. The parameters can be set and monitored using the touchscreen. Industry-standard data interfaces to higher-level control systems are used to integrate the FlocFormer into the process sequence.

The Performance:

In the FlocFormer, the flocculation agent is first added to the sludge in a high-speed mixer. This results in high-volume flocs with low shear stability. These flocs are then targeted for erosion and compacted for improved shear stability in a modified flocculation reactor. The polymer can reach its full potential and the polymer volume is significantly reduced.

Your benefits:

The application of FlocFormer improves dewatering results, irrespective of whether the FlocFormer is combined with a chamber filter press, decanter, belt filter or other dewatering unit. The higher dry solid content in the dewatered sludge reduces disposal costs. The filtrate quality improves considerably and the loads on the waste water treatment plant are reduced. Polymer consumption is reduced and operating costs decrease accordingly.

Advantages of the process:

  • Reduced disposal costs due to reduced sludge volumes and higher dry solid content.
  • Reduced polymer consumption leading to lower operating costs.
  • Improved process stability.
  • Improved filtrate quality leading to lower loads on the waste water treatment plant.
  • Plug and play concept.
  • Short amortisation period.
  • Can be used in combination with all standard separation processes.
  • When upgrading existing processes: Simple integration into the existing process thanks to compact design.

Visual comparison of sewage sludge after separation (with and without FlocFormer)

TrockenschlammvergleichPlant: Sewage treatment plant (municipal waste water)
Method: Dewatering with decanter
Initial value without FlocFormer: 20 % dry solid content
Initial value with FlocFormer: 24 % dry solid content (+20 %)
Initial value with FlocFormer: 25 % dry solid content (+25 % – optimised)
These images were taken in a treatment plant with an installed FlocFormer. In the plant, a 25% improvement in dewatering was reached when using the FlocFormer. The amortisation period was one year.
Visits to the plant are available on request.

A manufacturer-specific design for simple integration of the FlocFormer system into existing dewatering and separation plants is available on request.

Some striking results

These are just some of the results from our many tests and installations:


We would be happy to show more examples on request.

Inside the FlocFormer (Model, Compacting of flocs)

FlocFormer animiert