A beverage bottling company in Brandenburg required a temporary solution for treating its industrial wastewater. The site is located near Berlin. PPU Umwelttechnik supplemented the existing infrastructure with a mobile, multi-stage wastewater treatment plant on a rental basis, designed for 800 cubic metres per day. An existing aerated tank serves as the transfer point, feeding wastewater into the additional treatment system.
The rental system combines physico-chemical treatment, biological treatment and sludge management in a coordinated overall process. PPU undertook the design, supply, installation and commissioning of the system under a rental arrangement for at least 18 months. This provides the operator with additional treatment equipment for a clearly defined period, initially under a fixed-term agreement.
The containerised design shapes the entire layout, with ten FBBR container modules forming the biological treatment stage. These are complemented by flotation, secondary clarification, sludge tanks, and the control and dewatering equipment. On site, the individual modules form a continuous treatment process, with interfaces adapted by PPU to the existing site conditions. Pipework, pumps and electrical connections link the stages. The layout also provides access for operation, inspection and maintenance.
The project required several treatment steps. Solids separation alone cannot address dissolved organic loads, while biological treatment itself produces sludge. The project therefore required a combination of processes covering both wastewater treatment and the sludge generated.
These interfaces require careful coordination, as flotation separates removable constituents from the wastewater and thereby reduces the load on the downstream biological stage. Microorganisms then carry out further biological degradation of organic matter. Secondary clarification subsequently separates biological sludge from the treated water. Both sludge streams, in turn, require a common solution for collection, transfer and dewatering.
Hydraulic distribution also plays a central role, as the ten FBBR container modules supplied in parallel require balanced influent distribution to operate as a single biological treatment system. At the same time, pumps, pipework and secondary clarification must convey the wastewater through the entire plant. Considering individual modules in isolation is therefore insufficient.
The temporary deployment imposed additional requirements, as the operator needed a plant that would integrate with the existing infrastructure and allow for subsequent dismantling and removal. The proposal also specified a short lead time, so PPU coordinated the equipment, connections and work on site. The project also called for straightforward operation to support routine inspections and communication with operating staff.
PPU implemented a complete containerised plant with coordinated wastewater and sludge treatment stages. Treatment begins with dissolved air flotation. The DAF stage is designed for up to 52 cubic metres per hour and includes automatic pH control and coagulant and flocculant dosing. Chemical conditioning produces separable flocs. Fine air bubbles carry these to the water surface, where the plant collects and removes the flotation sludge.
In the treatment trial, COD was reduced from 4,800 to 1,500 mg/l. The supplementary BOD values, calculated as estimates, are 2,400 mg/l before treatment and 750 mg/l after treatment.
The process was documented during commissioning. After more than eight and a half hours of operation, the flow rate remained around 33 cubic metres per hour, temporarily reaching 43 cubic metres per hour. The commissioning engineer checked chemical dosing and compared samples taken before and after flotation. The effluent sample was visibly clear, with no discernible flocs. This observation describes solids separation during commissioning.
The system then distributes the pretreated wastewater to ten ClearFox® FBBR container modules. Each container contains submerged fixed-bed media that provide surfaces for microbial growth. Fine-bubble diffusers supply oxygen to the biomass, while bacteria break down dissolved organic matter, thereby reducing chemical oxygen demand. Within the containers, the wastewater passes through several fixed-bed stages, with carrier media offering different specific surface areas to support biological degradation.
Secondary clarification follows biological treatment. It collects settleable sludge and separates it from the clarified water. Small pumps transfer the biological sludge to two large collection tanks. Flotation sludge is also fed into these tanks. A recirculation pump circulates the sludge and distributes it between the two tanks.
The sludge screw press then performs mechanical dewatering. It combines thickening, filtration and compression. Fixed and moving rings clean the filtration zone during operation, while the screw conveys and compresses the sludge. A discharge screw conveyor removes the dewatered sludge from the container. This reduces the sludge volume for disposal. During the demonstration, the press filtrate also appeared very clear, despite a few small flocs.
A central control system brings together the plant functions and supports the monitoring of operating parameters through remote access. The service package also includes regular visits, technical inspections and communication with staff on site. The treated water is ultimately returned to the customer’s production area. PPU thus combines wastewater treatment, sludge management and operational support in a modular rental system for the industrial site.
Yes. PPU Umwelttechnik designs each ClearFox® rental plant to suit the wastewater volume, influent load, effluent requirements and local site conditions. The modular design is suitable for temporarily expanding existing plants, covering refurbishment periods and meeting additional treatment demand as production volumes increase.
PPU first determines the daily wastewater volume, peak flows and relevant influent parameters. These include COD, BOD₅, solids, pH and temperature. Wastewater analyses and treatment trials support process selection. On this basis, PPU determines the number, size and arrangement of the treatment modules.
PPU considers existing tanks, pipework and connections during the planning stage. In the Brandenburg project, an existing aerated tank serves as the transfer point to the mobile treatment system. The additional modules supplement the existing infrastructure to create a continuous treatment process.
Flotation sludge and biological sludge are fed into two shared collection tanks. A recirculation pump circulates the sludge and distributes it between the tanks. The sludge screw press then mechanically dewaters the sludge, reducing the volume for storage, transport and disposal.
PPU agrees the operational support arrangements with the customer as part of the service package. In the Brandenburg project, this includes regular visits, technical inspections and communication with operating staff. A central control system with remote access also supports the monitoring of operating parameters.
PPU agrees the rental period to suit the planned duration of use. In the Brandenburg project, the rental term is at least 18 months. At the end of the contract, arrangements can be made to return the plant, extend the rental period or purchase the equipment.
