FRC’s MBBR system uses floating biofilm media in aerated tanks to reduce BOD, nitrogen, and phosphorus with no need for RAS or MLSS monitoring. , FRC, Biological, MBBR, FRC Systems » Products Moving Bed Biofilm Reactor MBBR System Biological Treatment System for High-Rate BOD and Nutrient Removal Features & Specs FAQ Photos All Products FRC’s MBBR system uses floating biofilm media in aerated tanks to reduce BOD, nitrogen, and phosphorus with no need for RAS or MLSS monitoring. FRC’s Moving Bed Biofilm Reactor (MBBR) is a high-rate biological treatment system that supports dense microbial growth on suspended carrier media. The result is a compact, self-regulating process that efficiently removes BOD, nitrogen, phosphorus, and COD without the operational burden of traditional activated sludge systems. The MBBR process uses specialized plastic carriers suspended in an aerated tank to provide a high surface area for biofilm growth. As wastewater flows through the tank, bacteria living on the carrier media consume organic contaminants (BOD/COD) and nutrients such as nitrogen and phosphorus. Aeration keeps the carriers in motion and supplies oxygen. Excess biomass naturally sloughs off and is removed in downstream treatment. No sludge return or manual wasting is required, allowing for hands-off operation. Product Sheet (PDF) Request More Info Key Features High surface area media for elevated biomass concentration No Return Activated Sludge (RAS) or MLSS monitoring required Automated, low-maintenance biological treatment Compact footprint with scalable tank design Durable stainless-steel or concrete tank construction Compatible with DAF or clarifier solids removal Specifications Fill Volume: 30 – 70% of tank with carrier media Construction: Stainless-steel or concrete tanks Operation: Fully automated, no RAS or MLSS management Options High-efficiency aeration blowers and diffusers Carrier media (see MBBR Media section) DO, ORP, pH, and temperature instrumentation SCADA-ready control panels Catwalks, platforms, and retrofit kits Applications Industrial BOD/COD removal Municipal wastewater and decentralized plants Nutrient reduction for nitrogen and phosphorus Plant upgrades and retrofits with space constraints Why choose an MBBR system? FRC’s MBBR offers robust performance with minimal operator input, making it the ideal solution for biological wastewater treatment in modern, space-conscious plants. MBBR FAQ Q: Why use MBBR instead of traditional activated sludge? A: MBBR doesn’t require RAS return or MLSS monitoring, resulting in lower operational complexity and cost. Q: Can I expand my MBBR system later? A: Yes. You can scale up treatment simply by adding more carrier media and aeration capacity. Q: What contaminants does MBBR remove? A: It removes BOD, COD, ammonia, nitrogen, and phosphorus, depending on design. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC’s stainless-steel belt press reduces sludge volume with stacked dewatering zones and continuous belt cleaning for low-maintenance operation. , FRC, Dewatering, Belt Press, Sludge FRC Systems » Products Belt Filter Press Sludge Dewatering System Compact Solution for Automated Sludge Dewatering Features & Specs FAQ Photos All Products FRC’s stainless-steel belt press reduces sludge volume with stacked dewatering zones and continuous belt cleaning for low-maintenance operation. The FRC Belt Filter Press is a high-throughput, automated dewatering system designed to reduce sludge volume and handling costs in industrial and municipal wastewater treatment. With a compact, vertically stacked design, this press delivers consistent, dry sludge cakes with minimal operator intervention—making it ideal for facilities processing oily, fatty, or particulate-rich sludge. Conditioned sludge enters the belt press and moves through a series of dewatering zones. It first passes through the gravity drainage zone, where free water drains out. Then it moves into a wedge zone and is gradually compressed between two belts. In the final stage, high-pressure rollers extract the remaining water, producing a dry sludge cake. The belts are continuously cleaned with automated spray bars, allowing for consistent, unattended operation and reduced maintenance. Product Sheet (PDF) Request More Info Key Features Vertically stacked gravity and pressure zones for space efficiency Continuous dewatering with automated belt cleaning Stainless-steel construction resists corrosion in harsh environments Available in widths from 0.5 to 3.0 meters Integrated control system with HMI and PLC Compatible with flocculators, polymer systems, and wash water modules Specifications Flow Capacity: Up to 350+ GPM (79.5 m³/h) Effective Belt Width: 24” – 120” (600 – 3,000 mm) Effective Dewatering Area: 35 – 388 sq. ft. (3.3 – 36 m²) Construction: Stainless steel (304, 316, duplex) Components: Sludge inlet, thickening belts, roller assembly, spray bar, cake discharge chute Applications Municipal wastewater sludge Food and beverage plant residuals Pulp and paper processing Industrial and chemical manufacturing DAF float and clarifier sludge dewatering Why choose a belt filter press? FRC’s belt press is a proven, efficient solution for high-volume sludge dewatering. It combines compact footprint, robust construction, and fully automated operation—minimizing water, energy, and labor costs while delivering consistently dry sludge cakes. Belt Press FAQ Q: What type of sludge is the belt press best for? A: It’s ideal for oily, fatty, or particulate-rich sludges from food & beverage, municipal, and industrial treatment systems. Q: How is belt cleaning handled? A: The system includes automated spray bars for continuous belt cleaning during operation. Q: Is this system scalable? A: Yes, with widths from 0.5 to 3 meters and full auxiliary system compatibility, it scales easily to match sludge volume. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC Systems offers advanced wastewater treatment solutions in the United States, including DAF systems, sludge dewatering, and biological treatment. Contact us today. Wastewater Treatment Solutions Advanced wastewater treatment systems engineered for efficiency and reliability. From solids and FOG removal to full-scale biological treatment, FRC designs and manufactures custom solutions that meet regulations, cut costs, and solve real-world challenges. Our Products Project References FRC Systems Trusted Wastewater Solutions At FRC Systems, we understand the complex challenges of industrial and municipal wastewater treatment . With decades of experience, our engineers design advanced, customized systems for solids removal, FOG separation, BOD and COD reduction, and phosphorus control —all engineered for compliance and efficiency. From targeted process upgrades to complete wastewater treatment solutions , we partner with you from concept to commissioning to deliver reliable, long-term results. Total Suspended Solids (TSS) Removal Fat, Oil & Grease (FOG) Removal Biological Oxygen Demand (BOD) Removal Sludge Dewatering Phosphorus & Algae Control Pilot & Rental Equipment System Upgrades Learn more about... DAF Systems Sludge Dewatering Systems Biological Removal Systems Food & Beverage Industry FRC wastewater treatment systems are used throughout the food and beverage industry because of their ability to remove Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), Biochemical Oxygen Demand (BOD), and Total Phosphorus (TP). Explore General Manufacuring Industry Our systems are custom designed to combat the harsh environments often found in industrial manufacturing environments. FRC’s engineers will create a system optimized to treat the wastewater’s specific composition in your industry. Explore Meat Processing Industry FRC designs customizable wastewater treatment systems with durable equipment, including DAF units, rotary drum screens, MBR and MBBR treatment, CWAS systems, and sludge dewatering for reliable industrial and municipal performance. Explore Municipal Wastewater Industry FRC municipal DAF units improve wastewater treatment by removing algae, phosphorus, and industrial inputs, or thickening WAS—delivering robust, compact, cost-effective systems with low chemical use and operating costs. Explore Oil & Gas Industry FRC provides mobile and central DAF systems for oil and gas wastewater, treating produced water, flowback, and stormwater runoff—custom-engineered for upstream or downstream needs, enabling injection, reuse, or discharge in compact, efficient systems. Explore INDUSTRIES News & Updates The FRC Difference With nearly 50 years of industry experience and thousands of Dissolved Air Flotation (DAF) installations across the globe, FRC Systems is dedicated to leveraging our extensive application expertise in industrial wastewater treatment solutions to benefit you. We’re committed to offering ongoing support and innovative wastewater solutions for the future. About FRC Systems Meet Our Team Almost 50 Years of Industrial Wastewater Treatment Solutions Thousands of Worldwide Installations Application Experience and Endless Knowledge Client Focused. Solutions Based. Results Guaranteed. Testimonials FRC Systems transformed our wastewater treatment process. Their expertise and innovative solutions have significantly improved our plant’s efficiency. We’re grateful for their ongoing support and highly recommend their services. Chief Product Officer Food & Beverage Company The installation of FRC Systems’ wastewater treatment solution was seamless and professional. Their team’s knowledge and dedication have made a noticeable difference in our operations. We couldn’t be happier with the results. Facilities Design Manager Health & Beauty Company Choosing FRC Systems for our wastewater treatment needs was a game-changer. Their system is reliable, and their customer service is exceptional. We’ve seen a marked improvement in our environmental compliance and operational costs. Plant Operations Director Oil & Gas Company

Step-by-Step Guide to Aeration Control This instructional video demonstrates how to set and balance the aeration controls on an FRC Dissolved Air Flotation (DAF) system. The goal is to generate stable, high-quality whitewater. Whitewater—the air-saturated recycle stream—is essential for effective solids flotation. Key Steps for Setting Aeration Controls Set Aeration Valves : Begin by adjusting the aeration valves on the DAF tank to 50% open. Ensure that all ports are uniform. Open Manifold Valves : Next, open the manifold valves to 100%. This action engages the recycle pump. Monitor Pump Pressure : It is crucial to check that the recycle pump discharge pressure remains below 90 psi. This ensures the system operates within safe limits. Adjust Pressure Regulator : Set the pressure regulator to 10 psi higher than the recycle pump. This adjustment helps maintain optimal performance. Fine-Tune Aeration Valves : Finally, fine-tune the aeration valves to achieve the target recycle pump pressure. This step is vital for optimal system performance. With these adjustments, the DAF system produces consistent microbubbles that spread across the tank surface. Fully saturated water takes on a “skim milk” appearance, signaling optimal whitewater conditions. This leads to reliable separation, lower operating costs, and consistently cleaner effluent. Understanding the Importance of Whitewater Whitewater plays a crucial role in the efficiency of a DAF system. It enhances the flotation process, allowing for better separation of solids from liquids. The quality of whitewater directly impacts the overall performance of wastewater treatment systems. When whitewater is properly generated, it leads to improved treatment outcomes. Facilities can achieve regulatory compliance more easily and reduce operational costs. This is particularly important for industrial and municipal facilities that face stringent environmental regulations. Benefits of Effective Whitewater Generation Enhanced Separation : Properly aerated whitewater improves the flotation of solids, ensuring they rise to the surface for removal. Cost Efficiency : By optimizing the aeration process, facilities can lower energy costs and improve the overall efficiency of their wastewater treatment systems. Regulatory Compliance : High-quality effluent is essential for meeting environmental regulations. Effective whitewater generation helps facilities stay compliant. Conclusion In summary, mastering the aeration controls of a DAF system is vital for producing high-quality whitewater. By following the outlined steps, facilities can enhance their wastewater treatment processes. This leads to better separation, lower costs, and compliance with environmental standards. For more detailed guidance, check out the instructional video below.

During the project development process, you will eventually narrow down a list of potential dissolved air flotation (DAF) system manufacturers. At this stage, the critical task is to determine which manufacturer and system best meet your specific needs. How Should You Choose? Whether you are an engineer specifying equipment for a client, a plant owner addressing wastewater treatment challenges, or someone seeking a deeper understanding of wastewater process equipment, this guide aims to provide a comprehensive understanding of key DAF system design considerations. By exploring mechanical and process design elements in this series, you will gain valuable insights to evaluate DAF systems effectively. This knowledge will enable you to identify superior designs and, most importantly, make an informed purchasing decision. Given the significant investment, selecting the right DAF system is essential. 1. Aeration System: The heart of the DAF unit. The aeration systems are the central component of a DAF, representing one of the largest capital and maintenance expenses. Therefore, understanding its design and functionality is crucial. Below is a breakdown of common pump types used in DAF aeration systems and their respective advantages and limitations. Multistage Impeller Pumps These pumps are often referred to as "whitewater pumps".  They draw atmospheric air (or compressed air) into the pump, where impellers mix/shear the air with water to create micron-sized bubbles that dissolve into the solution. While effective in generating whitewater, multistage impeller pumps pose several challenges in wastewater environments: Low Solids Tolerance : These pumps are prone to failures when handling oily, stringy, or gritty materials, which are common in wastewater applications. Cavitation/Airlock : In general, these pumps are not designed to handle entrained air.  Air can collect at the eye of the impellers which can cause loss of flow (airlock) and binding.  Air being introduced to the pump for “white water” generation can cause cavitation leading to increased energy usage, increased noise/vibration, and in more extreme instances cause damage to seals, bearings and impellers. Dependency on Manufacturer-Specific Components : These pumps tend to be “special order” or made in low quantities. Typically, these pumps must be sourced directly from the manufacturer which can lead to high replacement cost and extended downtime due to limited availability or long lead times. Multistage impeller pumps can generate quality “white water”; however, they lack the robustness in a wastewater environment where solids, grit and oily materials are prevalent.  With the high associated maintenance costs and lower reliability, most DAF manufacturers have moved away from the Multistage Impeller Pump.   Regenerative Turbine Pumps Regenerative turbine pumps are another type of pump often marketed as "whitewater pumps". These pumps are often characterized as providing high discharge pressures associated with positive displacement pumps with the versatility of a centrifugal pump.  They utilize a turbine-like impeller with radially oriented blades/vanes to draw in atmospheric or compressed air and mix with water to create microbubbles.  When choosing a Regenerative Turbine pump for a DAF application it is important to consider: High Pressure Capability : These pumps can generate high pressures and low flows in a compact design.  They can operate at discharge pressures of 90-120 psi in DAF applications while being resistant to cavitation and other ill effects of air entrained fluids. Clean Liquid Requirement : Due to tight internal clearances, these pumps typically require liquids with minimal abrasives or solid content, limiting their suitability for wastewater treatment. Limited Parts Availability : Popular models, such as those manufactured by Nikuni, often have very small supplier networks, leading to limited options in accessing quick replacement parts. Several manufactures utilize regenerative turbine pumps for “whitewater generation” on their DAF units, and their compact footprint make them a popular choice for upgrades of older Multistage technology.   Tight tolerances and poor solids handling make them less suitable for certain wastewater environments and care should be taken to ensure proper application. End-Suction Centrifugal Pumps End-Suction Centrifugal pumps are produced by many pump manufacturers and are available in a variety of materials and configurations that can be adapted to a wide variety of applications.  Due to the large variety in available pumps, there is a high degree of versatility across various industries, including food processing, oil refining, and chemical manufacturing.  As with any pump selection, application is important.  Here are some important considerations when evaluating a system using an end suction centrifugal pump. Simplified Whitewater Generation : In most DAFs that use an end-suction centrifugal pump for “whitewater” generation, the pump is utilized only for the pressurization of the recycle stream.  The air and water are mixed in a separate vessel or saturation tube, meaning the pump is only doing what it was design for (pumping).  This ensures that the pump can be selected for high efficiency and reliability.  In some designs, manufacturers will use the pump in a similar manner to the Multistage pump where atmospheric air (or compressed air) is injected at the pump suction and the pump is used to dissolve the air.  When the pump is utilized in this manner, it is prone to the same Cavitation/Airlock issues as the Multistage Pump. Adaptability : These pumps can be selected based on the application to handle a wide variety of liquids (with or without solids) and can be fitted with various materials and alloys for corrosive environments. Manufacturer Choice : Unlike specialized whitewater pumps, the end-suction centrifugal pump is typically not mixing the air in water.  This allows more choice in manufacture and style of pump.  Some DAF providers can work with the end user to select a pump that aligns with their preferred manufacturer/plant standard providing improved access to parts and service.    By assigning the task of whitewater generation to a static tube or vessel, end-suction centrifugal pumps focus solely on pressurization, enhancing reliability and efficiency. When evaluating DAF systems, the aeration system reflects the manufacturer's design philosophy. Prospective buyers should inquire about the reasoning behind the selected pump type and its suitability for their specific wastewater treatment needs. 2. Controls and Automation: Enhancing Operational Simplicity The operational efficiency of a DAF system often hinges on its control and automation features. A well-designed system should be intuitive and user-friendly, akin to the seamless functionality of modern smartphones. Unfortunately, some DAF systems rely on overly complex operational procedures and have limited automation to reduce costs.  This typically leads to increased labor, frustration, and hidden expenses. Often these systems require frequent operator intervention and manual procedures which take more time and require more knowledge from the operator: Start/Stopping the system based on incoming flow. Make regular adjustments to the DAF aeration system to achieve “whitewater” generation. Manually adjust chemical dosing rates based on changing flows and/or pH. Check the system for faults and evaluate performance based on visual inspection. In contrast, a well-automated system streamlines operations significantly by: Automatically starting and stopping the treatment system as determined by incoming flow and tank levels. Automating the aeration features such as low-pressure detection, system warm-up and off-cycle air purging. Automatically adjust chemical dosing rates based on flow rate to the system and pH. Report and alarm system faults and provide warnings for reduced system performance. Trend and store data for system flows, tank levels, pH turbidity, chemical consumption, and alarms. When considering a DAF system, request details its operating procedure and automation. This will provide insights into its usability and the time/labor necessary to operate it.  A system with intuitive controls not only saves time but also reduces operational errors and long-term costs.

Dairy processors, especially ice cream manufacturers, face some of the toughest wastewater challenges in the food industry. High levels of fats, oils, and grease (FOG), fluctuating pH from constant product changeovers, surging TSS, and residue from syrups, fruit pastes, nuts, and chocolate make treatment both complex and costly. Clean‑in‑Place (CIP) cycles only amplify the problem, sending large bursts of organics down the drain multiple times a day. CIP changeovers also cause extreme variability in COD, TSS, BOD, and pH , which is traditionally managed using large equalization (EQ) tanks , metal‑salt coagulants, organic flocculants, and DAF systems. While this conventional strategy can meet discharge goals, it comes with major drawbacks: very large EQ tanks needed to homogenize COD/TSS/pH risk of fermentation and odor generation  in both the EQ tank and DAF sludge DAF float that can’t go to rendering  due to high free fatty acids sludge unsuitable for return to the food chain because of metal salts rapid fermentation inside the DAF if flows pause for even a few hours One major ice cream facility, producing up to 1.1 million gallons of wastewater per day , struggled with these exact issues. Instead of investing in massive EQ tanks, stainless steel pumps, aeration systems, and odor‑control systems, the facility partnered with FRC Systems to engineer a more elegant, cost‑effective solution. The Breakthrough: Acidulation as a Pretreatment Strategy FRC introduced an acidulation‑based treatment process  that directly resolves the weaknesses of traditional chemistry‑heavy treatment. By dropping the wastewater pH to 3.9 using sulfuric acid , two natural events occur: milk proteins coagulate  (ideal pH range: 4.1–4.3) fat emulsions crack  at pH ≈ 3.9 This eliminates dependence on metal‑salt coagulants such as alum, ferric chloride, ferrous sulfate, and magnesium chloride —reducing cost, simplifying chemical handling, and eliminating metal contamination in the sludge. Even better, maintaining the flow at pH 3.9 prevents the rapid fermentation otherwise common in dairy wastewater. Acidulation is performed inline (pipe flocculator, sump, or small EQ tank), followed by polymer addition and then DAF treatment. After solids removal, the flow is neutralized. Why Acidulation Solves Problems Traditional Systems Can’t The acidulation process offers significant advantages over conventional dairy wastewater treatment: 1. No large EQ tank needed Only a small EQ tank is used for hydraulic buffering—not for balancing TSS, COD, or pH. This represents a major footprint and CAPEX reduction. 2. Dramatically reduced odor potential Keeping pH at 3.9 prevents fermentation in both: the EQ tank DAF sludge (which otherwise ferments rapidly at neutral pH) 3. Cleaner, more usable sludge Because no metal salts are used, the DAF float: is easier to dewater contains no metal contamination has 50% less sludge volume  due to higher dry‑solids content 4. Greater process stability Even if the DAF stops briefly, low pH prevents the rapid fermentation and solids generation that normally plague dairy plants. These enhancements align perfectly with the benefits observed in the Unilever ice cream facility’s full‑scale system. Inside the Treatment System FRC Systems - Flocculator The integrated treatment train includes: Screening   for coarse solids Acidulation flocculation  (acid → polymer → neutralization) PCL‑Series DAF  with plate pack and sludge dewatering grid Belt filter press  for sludge handling The new content from the acidulation process overview reinforces exactly why this configuration works so well. Real‑World Performance: High Removal Efficiency After installation, the system achieved: 91.5% reduction in TSS 94.3% reduction in FOG Consistent compliance with pH discharge limits And critically, the system has operated successfully since 2014 , with no issues related to odors, fermentation, or chemistry instability. Conclusion: A Smarter Path Forward for Dairy Wastewater The acidulation‑DAF approach offers dairy producers a simplified, more reliable, and more cost‑effective treatment strategy by replacing metal‑salt chemistry and oversized EQ tanks with a predictable, stable low‑pH pretreatment method. FRC’s acidulation process delivers: lower operational and chemical costs reduced sludge volume (50%+ less) elimination of noxious odors simpler, automated operation cleaner sludge with no metal salts It’s an approach that not only handled the ice cream plant’s extreme variability—it fundamentally transformed their wastewater program.