6 Signs Your Wastewater Equipment Needs Upgraded

Wastewater treatment is essential to both public and ecological health because it prevents high amounts of nitrogen, phosphorus, metals, herbicides, pharmaceuticals, and even pathogens such as COVID-19, hepatitis A, and salmonella from polluting rivers, waterways, and public drinking supplies.

Because the quality of wastewater treatment directly impacts public and ecological health and is influenced by the facility’s equipment, it’s critical that field supervisors and facility managers frequently perform inspections, identify signs of potential failure, and replace or upgrade equipment as needed.

In this article, we’ll cover specific scenarios that indicate when an upgrade is needed.

1. You’re Spending Too Much on Maintenance

If you’re frequently repairing your equipment, replacing worn-out components, or experiencing unexpected breakdowns, those are clear signs that your equipment is unable to handle your facility’s current demands. This could be due to new materials being introduced into wastewater (which we’ll cover later), increased flow due to higher populations in your municipality, or frequent inclement weather.

Some older equipment may also require specialized parts or components that have since been discontinued, which makes it harder (and more expensive) to procure replacements. At some point, you have to ask yourself if the recurring maintenance is worth it or if it’s time to invest in something better.

2. Flow Has Increased or Exceeded the Permitted Daily Average

Every municipality has an average daily flow based on factors like time of year (month) and weather (dry versus wet). This average could significantly increase due to population growth, urban expansion, changes in industrial activities in your area, or new stormwater patterns caused by climate variability (such as the increase in hurricanes and flooding in Southeast United States).

When wastewater systems face higher volumes, older equipment can be pushed beyond their intended capacity, leading to inefficiencies, equipment strain, and even permit violations if untreated wastewater is discharged.

That’s why it’s so important to inspect your equipment—what is the existing flow rate of your facility and the capacity of your equipment? Can it handle any changes or increases in flow and volume? If not, it’s time to upgrade to something with a higher capacity.

3. New Materials Are Being Introduced Into Wastewater

 

 

Wastewater equipment manufacturers can’t predict the various types of materials the public will be using (and disposing of) in the future. It’s no secret that people will throw away anything, including paper towels, wet wipes, dental floss, cat litter, and food. If these items make their way into wastewater treatment plants, older equipment may not be able to effectively process them, especially if the equipment was designed during a time when certain materials (like wet wipes) weren’t readily available on the market. Wipes and rags, in particular, present a significant challenge. Because they are tough and fibrous, they can reweave with hair, fats, oils, and grease, resulting in “ragballs” that cause damaging clogs.

If your grinders aren’t designed to handle tough materials, you should upgrade your cutter stacks (if possible) or invest in a newer grinder.

4. Effluent Quality Has Approached Permit Limits, or Effluent Standards Have Changed

Effluent quality permit limits are becoming increasingly stringent. Modern standards require advanced treatment capabilities to reduce contaminants to levels that older systems may struggle to meet. Failing to comply with these new standards can result in severe monetary consequences (fines), as well as more extreme consequences like public health issues and environmental damage.

For example, meat and poultry processing facilities are now subject to updated effluent guidelines to reduce their contributions to nutrient and organic loads in wastewater. These changes not only impact these industrial facilities but also place additional strain on municipal treatment plants tasked with managing the discharge.

5. You’ve Noticed Reduced Efficiency or Performance

As equipment ages, critical components, like cutters, screens, and filters, experience wear and tear, potentially reducing overall equipment performance. A decrease in performance and efficiency can lead to solids bypassing the system, clogging downstream processes, or increasing the load on other equipment. Outdated equipment also tends to consume more energy as it struggles to maintain operational capacity, driving up costs.

Upgrading to more energy-efficient and higher-performing equipment will not only reduce energy and operational costs but also prevent frequent manual intervention and reduce risks associated with public and ecological health.

6. You’re Expanding Your Facility

Lastly, if you’re planning to expand your facility, you’ll need to evaluate your equipment to ensure it can meet the needs (flow and capacity) of your newly expanded facility and comply with any new restrictions. It’s also important to ensure existing equipment can fit into the new facility layout without causing space constraints.

When to Retrofit Versus Replace

Retrofitting or upgrading specific components in equipment (adding cutters or installing better motors, etc.) can be a cost-effective and less disruptive option. However, it has its limitations, and in some cases, a complete replacement may be the best solution.

First, if the equipment is nearing the end of its intended lifecycle, it’s important to look at the costs (both upfront and long-term) of replacing specific components versus the entire unit.

Second, if the equipment is frequently breaking down, it’s also important to evaluate the impact a retrofit would have versus a replacement. Would it stop breakdowns entirely or only slow them down throughout the year? If the chance of failure is still high or more likely to happen, a replacement might be the better option over a retrofit.

Lastly, if there are new regulations or restrictions to consider, there could be a very real possibility that your equipment wasn’t designed to handle some of the newer technology or components required to meet these regulations. For example, membrane bioreactors and advanced chemical dosing systems for phosphorus precipitation are becoming a more common need for wastewater facilities. If older equipment wasn’t designed to handle these additional treatment steps, facilities must find equipment that can be better integrated into newer processes.

How JWC Environmental Can Help

JWC Environmental is an industry-leading wastewater equipment manufacturer specializing in both municipal and industrial solutions, including our powerful Muffin Monster® and HYDRO grinders that can effectively reduce the most challenging solids. We further support wastewater treatment facilities by offering extensive services, including retrofitting, technology upgrades (on our existing equipment), and field rebuilds.

If you’re experiencing operational inefficiencies, please contact us today to speak with one of our representatives. We have representatives across the United States and Canada, each familiar with their region’s current challenges and regulations. Whether you need retrofitting advice or help selecting new products, our reps are ready to help.