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

FRC sludge dewatering systems cut sludge volume and disposal costs. Our Belt Filter Press and Multi-Disc Screw Press deliver drier cake with low energy use and reliable performance. , FRC Systems » Products Sludge Dewatering Systems Overview Optimize Wastewater Operations Using FRC Sludge Dewatering Technologies Features & Specs FAQ Photos All Products FRC sludge dewatering systems cut sludge volume and disposal costs. Our Belt Filter Press and Multi-Disc Screw Press deliver drier cake with low energy use and reliable performance. FRC sludge dewatering systems provide cost-effective solutions for reducing sludge volume and disposal costs. Our Belt Filter Press and Multi-Disc Screw Press handle diverse sludge types, delivering drier cake with lower utility use and simple operation. Built from stainless steel with automated controls, they improve efficiency, cut hauling costs, and ensure compliance. Multi-Disc Screw Press Flocculated sludge enters a screw with fixed and moving discs. As it rotates, water drains while sludge compresses into a high-solids cake. The self-cleaning design minimizes maintenance and water use. Belt Filter Press Sludge moves through gravity thickening and pressure stages on porous belts. Rollers squeeze out water, producing a consistent, drier cake. Product Sheet (PDF) Request More Info Key Features Two proven dewatering technologies: Belt Filter Press & Multi-Disc Screw Press High solids capture rate with drier cake for reduced disposal volume Low energy and water consumption compared to conventional systems Stainless-steel construction resists corrosion in harsh environments with custom alloys available Easy integration with DAF, MBBR, or MBR wastewater systems Fully customizable system configuration including skids, catwalks, and controls Specifications Belt Filter Press Flow Rates: Up to 350+ GPM (79.5 m ³ /hr) Belt Widths: 0.5 – 3.0 meters Multi-Disc Screw Press Flow Rates: Up to 440+ GPM (100 m ³ /hr) Dry Solids Capacity: Up to 4,000 lbs-DS/hr (1,814 kg DS/hr) Construction: Stainless steel (304, 316, duplex, or custom alloys) Applications Food & Beverage wastewater treatment (dairy, meat, poultry, breweries) Municipal wastewater plants and sludge handling facilities Petrochemical, pulp & paper, and chemical industries Mining and landfill leachate treatment Any facility requiring reduced sludge hauling and disposal costs Why choose a sludge dewatering system from FRC? FRC sludge dewatering solutions deliver reliable performance at low lifecycle cost. Our Belt Filter Press and Screw Press reduce sludge volume, cut disposal costs, and provide long-term compliance savings. Sludge Dewatering FAQ Q: What is the difference between a Belt Filter Press and a Screw Press? A: A Belt Filter Press uses moving belts and rollers to mechanically squeeze water from sludge, while a Multi-Disc Screw Press uses a rotating screw with fixed and moving discs for clog-free dewatering. Both reduce sludge volume, but the screw press uses less water and energy. Q: Which sludge dewatering system produces drier cake? A: Both systems achieve high solids capture, but the Multi-Disc Screw Press typically produces a drier cake with lower water content, resulting in reduced hauling and disposal costs . Q: What industries benefit from sludge dewatering equipment? A: Sludge dewatering systems are essential in food & beverage, municipal wastewater, petrochemical, pulp & paper, chemical, mining, and landfill leachate treatment. They reduce sludge handling costs and improve overall plant efficiency. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC’s CPI Separator uses corrugated plates for gravity-driven oil and solids separation—ideal for refineries, terminals, and food processors. , Oil & Water Separators, FRC, CPI, Plate Pack FRC Systems » Products Oil-Water Separator Corrugated Plate Interceptor (CPI) High-Efficiency CPI Oil-Water Separator for Industrial and Petrochemical Waste Features & Specs FAQ Photos All Products FRC’s CPI Separator uses corrugated plates for gravity-driven oil and solids separation—ideal for refineries, terminals, and food processors. FRC’s Corrugated Plate Interceptor (CPI) is a high-efficiency oil-water separator designed to outperform traditional API separators by leveraging corrugated plate technology. The CPI system delivers superior separation of oil, water, and solids in a compact footprint with minimal operator intervention—making it ideal for industrial and petrochemical wastewater streams. Influent oily wastewater enters the CPI separator and flows across inclined corrugated plate packs that slow the flow and promote phase separation. Due to density differences, solids settle to the bottom while oil droplets rise and coalesce on the plate surfaces. Skimmers remove the oil to a recovery trough, and sludge is discharged via augers. This gravity-based method efficiently separates immiscible phases, delivering cleaner effluent without the need for high-pressure or chemical inputs. Product Sheet (PDF) Request More Info Key Features High-efficiency separation using inclined corrugated plate packs Compact design compared to traditional separators Stainless-steel construction resists corrosion in harsh environments Minimal moving parts for low maintenance Available with static or rotating oil skimmers Gas-tight cover options for volatile environments Fully customizable system configuration including skids, catwalks, and controls Specifications Flow Capacity: Up to 6,000+ GPM (1,363+ m³/hr) Free Separation Area: 5.5 – 151 sq ft (0.5 – 14 m²) Effective Separation Area: 32 – 3,101 sq ft (2.97 - 288.1 m²) Construction: Stainless steel (304, 316, duplex, or custom alloys) Applications Oil and gas production wastewater Petrochemical and refinery effluent Produced water and frac flowback Food processing and meat/dairy operations Transportation terminals and bulk handling facilities Renewable fuels and LNG plants Why choose a CPI? FRC’s CPI separator is a modern upgrade to outdated API systems—offering faster separation, better space utilization, and robust stainless-steel construction. With scalable designs and low-maintenance performance, it’s the preferred choice for reliable oil-water separation across diverse industrial applications. CPI FAQ Q: How is a CPI separator better than an API separator? A: CPI systems use corrugated plates to increase separation surface area, allowing more efficient gravity separation in a smaller footprint. Q: What types of oil can a CPI separator handle? A: It efficiently separates free-floating oils, including those in refinery effluent, food processing wastewater, and frac water. Q: Is the CPI available in gas-tight designs? A: Yes, optional gas-tight covers with nitrogen sweep and flame arrestors are available for hazardous environments. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

The FRC Multi-Disc Screw Press provides efficient, continuous dewatering with ultra-low water usage and self-cleaning discs for reliable sludge management. , FRC, Dewatering, Volute Press, Screw Press, Sludge FRC Systems » Products Multi-Disc Screw Press Sludge Dewatering System Clog-Free Screw Press for Sludge Thickening and Dewatering Features & Specs FAQ Photos All Products The FRC Multi-Disc Screw Press provides efficient, continuous dewatering with ultra-low water usage and self-cleaning discs for reliable sludge management. The FRC Multi-Disc Screw Press offers an energy-efficient, low-maintenance solution for sludge thickening and dewatering. Designed with a self-cleaning, clog-free architecture, this press combines gravity filtration and mechanical compression into one continuous process—ideal for a wide range of industrial and municipal wastewater applications. Flocculated sludge enters a flocculation tank and is directed into a screw chamber containing multiple fixed and moving disc rings. As the screw slowly rotates, sludge is conveyed and compressed toward a back-pressure plate. Water is squeezed out through the disc gaps, while the motion of the discs prevents clogging and maintains filtration pathways. The dry cake is discharged at the end, and filtrate is collected separately. Its low water and energy usage ensure efficient, hands-free operation. Product Sheet (PDF) Request More Info Key Features Clog-resistant multi-disc design with continuous self-cleaning Ultra-low water consumption: ≤5 gal/hr per screw Quiet, enclosed operation with minimal odor Stainless-steel construction resists corrosion in harsh environments Fully customizable system configuration including skids, catwalks, and controls Specifications Flow Capacity: Up to 440+ GPM (100 m³/h) Dry Solids Capacity: Up to 3,000+ lbs/hr (1,361 kg/hr) Typical Cake Solids: 20% - 35% Application Dependent Water Consumption: < 5 gal/hr (< 18.9 L/hr) per screw Construction: Stainless steel (304, 316, duplex, or custom alloys); optional tungsten carbide coating Components: Screw assembly, disc modules, spray bar, sludge inlet, filtrate and cake outlets Applications Industrial and municipal biosolids Food and beverage processing sludge Chemical and pharmaceutical waste streams DAF float thickening and dewatering Facilities with variable sludge flow or loading m³/hr m² Why choose a screw press? FRC’s screw press provides reliable, low-footprint sludge dewatering with minimal water, energy, and labor requirements. Its clog-free, automated operation ensures consistent cake dryness—making it a smart investment for sustainable and cost-effective sludge management. Screw Press FAQ Q: What’s the main benefit over a belt press? A: The screw press consumes less water and energy, and its clog-free, self-cleaning design minimizes maintenance. Q: Is the screw press noisy or odorous? A: No. It operates quietly in an enclosed frame with minimal odor release. Q: What sludge cake dryness can be achieved? A: It consistently produces ≥20% solids in the dewatered sludge cake. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

The PCCS-Series is a space-saving DAF system that can ship in a 20-ft ISO container—ideal for remote, temporary, or small-scale wastewater applications. , FRC Systems » Products PCCS-Series Compact DAF System Compact DAF System for Mobile Wastewater Treatment Features & Specs FAQ Photos All Products The PCCS-Series is a space-saving DAF system that can ship in a 20-ft ISO container—ideal for remote, temporary, or small-scale wastewater applications. The PCCS-Series Compact DAF from FRC Systems is a high-efficiency, solution for suspended solids and FOG removal. Designed to ship in a standard 20-foot ISO shipping container, it’s the go-to option for remote, mobile, or space-constrained industrial wastewater treatment needs. The PCCS-Series DAF uses a non-proprietary pump and angled dissolving tube to generate whitewater microbubbles, introduced into the main wastewater stream inside a compact tank. By blending high free area for flow with high effective surface area for bubble-particle contact, the system optimizes solids and FOG separation. A motorized skimmer removes surface sludge into a hopper, while clarified water exits from the tank bottom. Its compact form allows for rapid deployment and high treatment efficiency in small or mobile applications. Product Sheet (PDF) Request More Info Key Features Compact design fits inside a 20’ ISO shipping container Easy to transport and quick to install Angled air dissolving tube enables fast whitewater generation Non-proprietary pumps Stainless-steel construction resists corrosion in harsh environments Fully customizable system configuration including skids, catwalks, and controls Specifications Flow Rate: Up to 150+ GPM (34.1 m ³ /hr) Free Separation Area: 8 – 45 sq ft (0.7 - 4.2 m²) Effective Separation Area : 35 – 252 sq ft (3.3 - 23.4 m²) Construction: Stainless steel (304, 316, duplex, or custom alloys) Applications Remote and temporary wastewater treatment Packaged or export systems Industrial TSS and FOG removal Pilot-scale installations Why choose the PCCS DAF? Mobility, ease of setup, and reliable treatment performance make the PCCS-Series the compact DAF system of choice for industrial users facing space or location constraints. PCCS FAQ Q: What makes the PCCS-Series ideal for mobile applications? A: It can be fully containerized in a 20-foot ISO container, allowing easy transport and deployment in remote or temporary operations. Q: Can the PCCS-Series be integrated with flocculators? A: Yes, it’s fully compatible with FRC’s F-Series flocculators for enhanced pretreatment and solids removal. Q: How quickly can the system be commissioned? A: It’s skid-mounted, prewired, and pre-plumbed, enabling plug-and-play installation typically within hours. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC biological wastewater treatment systems use MBBR and MBR technology to remove BOD, COD, and nutrients. Compact, efficient, and scalable solutions for industrial and municipal wastewater treatment. , FRC Systems » Products Biological Removal Systems Overview Advanced Biological Wastewater Treatment with Scalable FRC System Designs Features & Specs FAQ Photos All Products FRC biological wastewater treatment systems use MBBR and MBR technology to remove BOD, COD, and nutrients. Compact, efficient, and scalable solutions for industrial and municipal wastewater treatment. FRC biological treatment systems use Membrane Bioreactor (MBR) and Moving Bed Biofilm Reactor (MBBR) technologies to deliver high-performance treatment in compact, reliable designs. They reduce BOD, COD, and nutrients while minimizing footprint and operator involvement. With flexible configurations and durable construction, FRC systems provide cost-effective solutions for industrial and municipal wastewater. Moving Bed BioReactor (MBBR) Specialized plastic carrier media circulate freely in an aerated tank, providing a large, protected surface area for biofilm growth. The biofilm consumes organic matter and nutrients, naturally shedding excess biomass for removal via clarification or DAF. Membrane BioReactor (MBR) Submerged ultra-filtration or micro-filtration membranes replace traditional clarifiers, filtering out biomass and suspended solids. This process produces exceptionally high-quality effluent suitable for reuse, discharge, or advanced polishing. Product Sheet (PDF) Request More Info Key Features High-efficiency removal of BOD, COD, nutrients, and suspended solids Compact footprint compared to conventional activated sludge systems Resilient performance under variable flows and shock loads Low operator involvement with automated controls and monitoring Durable stainless-steel or concrete tank construction Scalable and upgradeable for future capacity needs Specifications Flow Rates: Up to 10,000+ GPM (2,271+ m³/h) depending on configuration MBBR Media Fill: 30 – 70% tank volume MBR Membrane Pore Size: 0.04 – 0.4 μm Construction: Stainless steel, coated steel, or reinforced concrete Applications Industrial wastewater with high organic load Municipal wastewater treatment and reuse projects Mining, landfill leachate, and renewable fuels Facilities requiring nutrient removal (nitrogen, phosphorus) Treatment plants needing compact or retrofit solutions Why choose biological system from FRC? FRC provides biological treatment with proven MBR and MBBR technologies. Our systems deliver high-quality effluent in a compact footprint while reducing energy, sludge, and operator needs—helping with compliance today and scalability for tomorrow. Biological Treatment FAQ Q: What is the difference between MBR and MBBR wastewater treatment? A: MBBR systems use moving carrier media for biofilm growth and organic removal, while MBR systems use submerged membranes for advanced solids separation and high-quality effluent. Both are effective biological treatment methods, but MBR produces effluent suitable for reuse or discharge without further clarification. Q: What are the advantages of MBBR wastewater treatment? A: MBBR offers compact footprint, resilience to shock loads, low operator involvement, and scalability by simply adding more carrier media. It is ideal for industrial plants or municipal facilities with variable influent conditions. Q: Why choose an MBR system over conventional activated sludge? A: MBR systems replace large clarifiers with compact membrane tanks, producing very low suspended solids effluent . This allows direct reuse of treated water, reduces space requirements, and eliminates the need for return activated sludge handling. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC’s MBR system integrates biological treatment with membrane filtration, producing ultra-clear effluent in a space-saving configuration. , FRC, Biological, MBR, FRC Systems » Products Membrane BioReactor MBR System Membrane Bioreactor System for Advanced Wastewater Reuse and Filtration Features & Specs FAQ Photos All Products FRC’s MBR system integrates biological treatment with membrane filtration, producing ultra-clear effluent in a space-saving configuration. FRC’s Membrane Bioreactor (MBR) system integrates biological treatment with advanced membrane separation for ultra-clear effluent. Ideal for reuse or discharge into sensitive environments, MBRs provide high-performance treatment in a compact design. Wastewater is biologically treated in a reactor where microorganisms break down organic matter and nutrients. Instead of using a clarifier, the MBR system uses submerged ultra-filtration membranes to separate treated water from biomass. Membranes retain solids and pathogens, allowing only clean water to pass through. Sludge is wasted directly from the MBR tank. Aeration supplies oxygen and mixes the biomass, while membrane cleaning systems prevent fouling, producing high-quality effluent suitable for reuse or discharge. Product Sheet (PDF) Request More Info Key Features Submerged membrane modules eliminate clarifiers Ultra-low TSS and turbidity and contaminants for reuse or discharge Compact footprint vs. conventional systems Sludge wasting directly from MBR tank Durable stainless-steel or concrete tank construction Excellent BOD, COD, nitrogen, and phosphorus removal Specifications Treatment Targets: BOD, TSS, TN, TP, COD Effluent Quality: TSS < 5 mg/L (typical) Reuse Potential: Service water, irrigation, cooling tower Membrane Type: Submerged ultra-filtration Options Air blowers and scour systems Clean-in-place (CIP) membrane cleaning SCADA control and automation panels Stainless or concrete tank configurations Applications Industrial wastewater reuse High-quality municipal effluent Decentralized or mobile treatment systems Facilities with space or discharge constraints Why choose an MBR system? FRC’s MBR delivers top-tier effluent quality, small footprint, and streamlined operation—making it ideal for advanced wastewater reuse and treatment compliance. MBR FAQ Q: What effluent quality does an MBR produce? A: FRC’s MBR systems produce ultra-clear water with <5 mg/L TSS, suitable for reuse or sensitive discharge. Q: Is a clarifier still needed? A: No. MBR systems replace secondary clarifiers with ultrafiltration membranes for solid-liquid separation. Q: Can MBRs be retrofitted into existing tanks? A: Yes. They can be installed in stainless-steel or retrofit into concrete basins. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC Dissolved Air Flotation (DAF) systems remove TSS, FOG, BOD & COD from industrial and municipal wastewater. Durable stainless-steel designs with high-rate, compact, and open-tank options deliver reliable separation and compliance. , FRC Systems » Products Dissolved Air Flotation (DAF) Systems Overview DAF Solutions for Industrial and Municipal Wastewater Features & Specs FAQ Photos All Products FRC Dissolved Air Flotation (DAF) systems remove TSS, FOG, BOD & COD from industrial and municipal wastewater. Durable stainless-steel designs with high-rate, compact, and open-tank options deliver reliable separation and compliance. FRC Dissolved Air Flotation (DAF) systems remove Total Suspended Solids (TSS), Fats, Oils & Grease (FOG), Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD), and other contaminants. Available in high-rate, compact, and open-tank designs, FRC units deliver dependable separation for industrial and municipal wastewater. With stainless-steel construction, plug-and-play setup, and automated controls, our DAF systems ensure compliance while reducing costs. DAF works by dissolving air into a pressurized recycle stream of clarified effluent. When released into the tank, microbubbles attach to solids, oils, and grease, lifting them to the surface for skimming. Clarified effluent exits for reuse or discharge. FRC high rate designs use plate packs, to boost separation efficiency, cut energy use, and shrink system footprint. PCL-Series / High Rate FRC’s PCL-Series DAF removes solids, oils, and FOG using high-rate flotation, crossflow plate packs, and in-tank sludge thickening for high-capacity wastewater applications. PCCS-Series / Compact The PCCS-Series is a space-saving DAF system that can ship in a 20-ft ISO container—ideal for remote, temporary, or small-scale wastewater applications. PWL-Series / High Solids FRC’s PWL-Series DAF handles heavy solids with a counter-current skimmer, large flotation surface, and sludge dewatering grid for efficient solids removal. Product Sheet (PDF) Request More Info Key Features High-efficiency removal of TSS, FOG, BOD, and COD Multiple configurations: high-rate, compact, and open-tank designs Non-proprietary pumps with angled air dissolving tubes Sludge dewatering grid option for drier, denser sludge Corrosion-resistant stainless-steel construction with alloy options Fully customizable system configuration including skids, catwalks, and controls Specifications Flow Rates: Up to 2,000+ GPM (454.2 m ³ /hr) Free Area : 5 – 500+ sq ft (0.5 - 46.5 m²) Effective Area: 35 – 3,100+ sq ft (3.3 - 288+ m ² ) Construction: Stainless steel (304, 316, duplex, or custom alloys) Applications Food & Beverage wastewater treatment (meat, poultry, dairy, breweries) Oil & Gas, petrochemical, and refinery effluent treatment Pulp & Paper and chemical manufacturing facilities Municipal wastewater pretreatment and sludge thickening Mining, landfill leachate, and renewable fuels industries Any application requiring solids, FOG, or BOD/COD reduction Why choose an FRC DAF System? With hundreds of installations worldwide, FRC is a leader in Dissolved Air Flotation technology. Our stainless-steel DAF systems combine efficiency, low maintenance, and reliability with non-proprietary components and engineering support—delivering complete solutions that ensure compliance and reduce costs. Dissolved Air Flotation (DAF) FAQ Q: What does a Dissolved Air Flotation (DAF) system remove from wastewater? A: DAF systems effectively remove Total Suspended Solids (TSS), Fats, Oils & Grease (FOG), Biological Oxygen Demand (BOD), and Chemical Oxygen Demand (COD) . This makes them ideal for food processing, oil & gas, pulp & paper, and municipal wastewater treatment applications. Q: How does a DAF system work? A: A DAF unit generates microbubbles that attach to suspended solids and FOG. These bubbles lift contaminants to the water’s surface, where they are skimmed off as sludge. Clarified effluent exits the bottom of the tank for discharge or reuse. Q: What industries use DAF wastewater treatment systems? A: DAF systems are widely used in food & beverage, oil & gas, petrochemical, pulp & paper, chemical manufacturing, mining, municipal wastewater, and renewable fuels . They provide cost-effective compliance with strict discharge regulations. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC’s internally fed rotary drum screens remove coarse solids and reduce TSS/FOG to protect downstream processes like DAF or MBR. , FRC, DAF, Screens, Screening, FRC Systems » Products Rotary Drum Screens Coarse Solids Removal Coarse Solids Removal in Industrial Wastewater Pretreatment Features & Specs FAQ Photos All Products FRC’s internally fed rotary drum screens remove coarse solids and reduce TSS/FOG to protect downstream processes like DAF or MBR. FRC’s Rotary Drum Screen Systems provide the first line of defense in wastewater treatment by removing solids and protecting downstream equipment. Engineered for industrial and municipal use, these internally fed screens offer high capture efficiency, durable stainless-steel construction, and automated low-maintenance operation across a wide range of flow rates and applications. Wastewater flows into a headbox and spreads across the internal surface of a rotating drum screen. Solids are trapped on the screen’s surface while liquid passes through the openings. As the drum rotates slowly, solids tumble, dewater, and are discharged from the bottom. An automatic spray bar periodically cleans the screen without continuous water flow. This slow-speed, internally fed process improves capture rates and protects downstream systems like DAFs and membranes from overload. Product Sheet (PDF) Request More Info Key Features Internally fed drum design for high solids retention Slow drum rotation for enhanced solids dewatering Stainless-steel construction resists corrosion in harsh environments Flat-welded wedge wire or perforated plate screen media Automatic cleaning via low-pressure spray system Fully enclosed design with headbox, splash guards, and base frame Trunnion-mounted for long-term mechanical stability Specifications Flow Capacity: Up to 6,500 GPM (application-dependent) Screen Openings: 250 – 2,540 microns (0.010” – 0.1”) Drum Sizes: Up to 80” diameter and 180” length Screen Media: Wedge wire or perforated plate Construction: Stainless steel (304, 316, duplex, or duplex) Standard Features: Enclosed headbox, splash guards, chain drive, trunnion wheels, spray bar Applications Food and beverage processing (meat, dairy, produce) Industrial manufacturing wastewater Primary screening for municipal systems Pretreatment before DAF, MBR, or clarifiers Cooling water and intake protection Why choose a Rotary Drum Screen? FRC screens deliver consistent solids removal with reduced water use and lower maintenance. Designed for durability and performance, they extend the life of downstream equipment and improve overall plant reliability—making them a critical component of any high-performance treatment system. Screens FAQ Q: What’s the difference between wedge wire and perforated plate screens? A: Wedge wire offers finer openings and better cleaning for high solids; perforated plate is more robust for coarse screenings. Q: How are FRC screens cleaned? A: An automated spray bar removes debris at set intervals, minimizing water use and manual labor. Q: Can I use these screens before a DAF system? A: Yes, they are typically installed upstream of DAF units to reduce TSS and FOG loading. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC provides fast-delivery OEM parts to keep your wastewater systems running—available for both FRC and compatible third-party equipment. , FRC, Spare Parts, Parts, Aftermarket, FRC Systems » Products Spare Parts Components for Wastewater Systems Spare Parts for DAF, CPI, Belt Press & Screening Systems Features & Specs FAQ Photos All Products FRC provides fast-delivery OEM parts to keep your wastewater systems running—available for both FRC and compatible third-party equipment. FRC Systems offers a comprehensive inventory of genuine OEM spare parts for all our wastewater treatment equipment—including DAF systems, rotary drum screens, belt presses, screw presses, and more. Stocking the right parts reduces downtime, extends system life, and ensures continuous, compliant operation. FRC knows the typical components in your treatment system—such as pumps, bearings, skimmer chain, belts, and valves—and maintains a ready stock of OEM replacements. When a part is needed, it’s matched to your system specs and shipped rapidly. Parts are available for FRC systems and various competitor’s equipment. This support ensures minimal downtime, reliable operation, and continued compliance with permit requirements, especially during scheduled maintenance or emergency repair situations. NEED PARTS? Contact our Parts Department: Ken Parker | 1-470-695-4464 | kenneth.parker@sulzer.com Product Sheet (PDF) Request More Info Key Features OEM-grade parts for all FRC systems Fast shipping and emergency order support Support for legacy equipment and competitor brands Dedicated parts specialists for selection and troubleshooting Improves system uptime, performance, and regulatory reliability Parts DAF Systems Recycle pumps, plate packs, skimmer drives, augers, valves, flow meters, pneumatic panels, bearings, chains and more Belt Filter Press Filter belts, scraper blades, cog wheels, gaskets, steering valves and more Rotary Drum Screens Drive sprockets, chains, trunnion wheels, pillow block bearings, spray nozzles and more CPI Oil-Water Separators Corrugated plate packs, auger drives, skimmer assemblies, drain valves and more Flocculators Pumps, meters, fittings, tubing, control panels, sensors and more Our in-house team can assist with: Component Identification : Match parts to your exact system specifications Performance Upgrades : Recommend improved materials or designs for longer life Preventive Maintenance Kits : Bundled parts for scheduled service intervals Emergency Repair Support : Rapid response for critical failures Compatibility Checks : Verify fit for legacy FRC systems and competitor equipment Technical Guidance : Troubleshooting assistance for installation and operation Why choose FRC spare parts? Using genuine FRC parts protects your system investment, reduces risk of failure, and ensures long-term performance. Backed by fast delivery and expert support, FRC’s spare parts program is your front-line defense against costly downtime. Spare Parts FAQ Q: What types of spare parts does FRC provide? A: FRC supplies OEM spare parts for all its equipment lines, including DAF systems, CPI separators, rotary drum screens, belt presses, and screw presses. Common parts include pumps, skimmer chains, sprockets, bearings, belts, valves, and spray nozzles. Q: Can I get parts for non-FRC systems? A: Yes. FRC stocks and sources compatible parts for many third-party systems. Our team can match specifications and assist with part identification, even for competitor equipment. Q: How fast can spare parts be delivered? A: Many parts are in stock and available for immediate shipment. Emergency orders are supported to reduce downtime and maintain permit compliance. Q: How do I know which parts I need? A: Contact FRC’s Spare Parts Specialist with your system serial number or part description. We’ll verify component specs and recommend replacements. Q: Can FRC help with part installation? A: Yes. FRC offers technical support and can coordinate installation assistance through our service and field engineering teams. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC offers North America’s largest fleet of rental and pilot wastewater treatment systems—including DAFs, screens, presses, and CPI units. Skid-mounted, plug-and-play, and backed by expert support. , FRC, Rentals, Rental, Pilot, Pilots FRC Systems » Products Rental Systems & Pilot Testing Modular Wastewater Treatment Solutions Temporary Treatment for Emergency Use or Testing Features & Specs FAQ Photos All Products FRC offers North America’s largest fleet of rental and pilot wastewater treatment systems—including DAFs, screens, presses, and CPI units. Skid-mounted, plug-and-play, and backed by expert support. FRC Systems provides the most comprehensive fleet of rental and pilot wastewater treatment systems in North America. From emergency bypass to pilot testing for new plant designs, our modular, skid-mounted units are engineered for fast setup, reliable performance, and proven results. Whether you need temporary treatment capacity, permit compliance, or data to validate full-scale design, FRC delivers tailored solutions with full engineering support. FRC rental and pilot systems arrive pre-wired, pre-plumbed, and fully outfitted with chemical dosing, pumps, instrumentation, and controls. After connection to site utilities, units are brought online within hours. For temporary treatment, rentals provide immediate capacity during plant shutdowns, emergencies, or compliance events. For validation, pilot systems replicate full-scale treatment in a controlled environment, measuring key performance metrics such as TSS, BOD, FOG, and sludge behavior. FRC engineers oversee setup, training, and ongoing support to ensure optimal operation. Product Sheet (PDF) Request More Info Key Features Modular, skid-mounted units up to 3,000+ GPM (681 m³/h) DAF, CPI, screens, sludge dewatering, and biological options SCADA-ready with integrated HMI controls Rapid deployment with plug-and-play installation Full field support from FRC engineers Available Systems Emergency bypass and permit compliance Coverage during maintenance or construction delays Pilot testing to validate full-scale design Process optimization and scale-up trials Seasonal or remote wastewater treatment needs Applications Emergency bypass and permit compliance Coverage during maintenance or construction delays Pilot testing to validate full-scale design Process optimization and scale-up trials Seasonal or remote wastewater treatment needs Why choose FRC rentals? FRC combines the industry’s largest rental fleet with proven pilot testing expertise, giving you flexible access to treatment capacity and data-driven system design. Our plug-and-play equipment, rapid deployment, and expert engineering support reduce downtime, lower risk, and ensure compliance—backed by the trusted name in wastewater solutions. Rentals & Pilots FAQ Q: What equipment is available for rent? A: DAF units, CPI separators, belt/screw presses, screens, flocculators, and full chemical dosing skids. Q: How quickly can a rental unit be deployed? A: Most units are plug-and-play and operational within hours of delivery. Q: Is technical support included? A: Yes. FRC provides onsite setup, training, and remote support for all rental deployments. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

Thank you for submitting a request with FRC Systems. Thanks! Your message has been sent! A member of our team will review your submission and get back to you as soon as possible. In the meantime, explore more of FRC Systems... Project References Knowledge Center News LinkedIn Feed Industries Jar Testing Pilot Testing Team Directory About FRC How Acidulation Transformed Wastewater Treatment for a Major Ice Cream Producer 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. 3 min read How a Mining Equipment Manufacturer Transformed Wastewater Treatment This case study highlights how FRC’s dual‑stage clarification process, advanced separation technologies, and rugged equipment design helped the facility reduce pollutant loadings, meet requirements for discharge to the local POTW, and even reuse treated water inside the plant. 3 min read How Dual-Stage DAF Treatment Revolutionizes Wastewater Management in Bakeries A leading industrial bakery—producer of popular cookies and crackers found in homes across the country 2 min read Wastewater Solutions: FRC Systems brings DAF, Sludge Dewatering & Screening Tech to IPPE 2026 CUMMING, GA – November 25, 2025 – FRC Systems, a recognized leader in industrial water and wastewater treatment, announced today its plans to attend and exhibit at the International Production & Processing Expo (IPPE) 2026. The event will take place from January 27-29, 2026, at the Georgia World Congress Center in Atlanta, Georgia. 2 min read

Explore FRC Systems’ range of products designed for efficient water and wastewater treatment. Our solutions are tailored for sustainability and cost-effectiveness, ensuring optimal performance for your specific needs. FRC Systems » Products Products & Services Solutions for Wastewater Treatment & Management Filter by Category Biological Pretreatment Service Sludge Management PCL-Series High-Rate DAF FRC’s PCL-Series DAF removes solids, oils, and FOG using high-rate flotation, crossflow plate packs, and in-tank sludge thickening for high-capacity wastewater applications. Button PCCS-Series Compact DAF The PCCS-Series is a space-saving DAF system that can ship in a 20-ft ISO container—ideal for remote, temporary, or small-scale wastewater applications. Button PWL-Series Open-Style DAF FRC’s PWL-Series DAF handles heavy solids with a counter-current skimmer, large flotation surface, and sludge dewatering grid for efficient solids removal. Button Flocculators FRC Flocculators enhance solids separation with static mixing, air injection, and zero energy input—optimizing chemical use before DAF systems. Button Oil & Water Separators FRC’s CPI Separator uses corrugated plates for gravity-driven oil and solids separation—ideal for refineries, terminals, and food processors. Button Dewatering Belt Press FRC’s stainless-steel belt press reduces sludge volume with stacked dewatering zones and continuous belt cleaning for low-maintenance operation. Button Dewatering Screw Press The FRC Multi-Disc Screw Press provides efficient, continuous dewatering with ultra-low water usage and self-cleaning discs for reliable sludge management. Button Rentals & Pilots FRC offers North America’s largest fleet of rental and pilot wastewater treatment systems—including DAFs, screens, presses, and CPI units. Skid-mounted, plug-and-play, and backed by expert support. Button Biological MBBR 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. Button Biologicial MBR FRC’s MBR system integrates biological treatment with membrane filtration, producing ultra-clear effluent in a space-saving configuration. Button Rotary Drum Screens FRC’s internally fed rotary drum screens remove coarse solids and reduce TSS/FOG to protect downstream processes like DAF or MBR. Button Jar Testing FRC performs jar tests to determine optimal coagulant/polymer dosing, simulate DAF performance, and reduce chemical costs. Button System Upgrades FRC upgrades aging systems with modern recycle pumps, air dissolving tubes, SCADA-enabled panels, and brand-agnostic integration. Button Spare Parts FRC provides fast-delivery OEM parts to keep your wastewater systems running—available for both FRC and compatible third-party equipment. Button

FRC’s PWL-Series DAF handles heavy solids with a counter-current skimmer, large flotation surface, and sludge dewatering grid for efficient solids removal. , PWL Series, Open-Style DAF, Dissolved Air Floatation, FRC Systems » Products PWL-Series High-Solids DAF System Open-Tank DAF System for High-Solids Wastewater and Heavy Load Processing Features & Specs FAQ Photos All Products FRC’s PWL-Series DAF handles heavy solids with a counter-current skimmer, large flotation surface, and sludge dewatering grid for efficient solids removal. The PWL-Series DAF system from FRC is purpose-built for high-solids wastewater streams. Its low-built, rectangular design provides a large surface area for effective flotation, while the counter-current skimmer and dewatering grid maximize sludge dryness and simplify maintenance. Wastewater flows horizontally through the open-tank PWL system while whitewater, created in an angled dissolving tube, introduces microbubbles that bind to suspended solids. These solids rise to the surface and are removed using a skimmer that moves in the opposite direction of flow, minimizing sludge carryover. The system’s built-in dewatering grid thickens sludge in place. This open configuration handles heavy solids efficiently and allows for easy inspection and maintenance. Product Sheet (PDF) Request More Info Key Features Low-profile rectangular tank ideal for high solids Counter-current skimmer minimizes sludge carryover Integrated sludge dewatering grid promotes thicker, drier sludge output Angled air dissolving tube enables fast whitewater generation Non-proprietary pumps Stainless-steel construction resists corrosion in harsh environments Fully customizable system configuration including skids, catwalks, and controls Specifications Flow Rate: Up to 1,020+ GPM (231.7 m³/hr ) Free Separation Area: 14 – 510 sq ft (1.3 - 47.4 m²) Construction: Stainless steel (304, 316, duplex, or custom alloys) Applications Meat and poultry processing Rendering and slaughterhouses High-solids food and beverage facilities Mining and industrial wastewater Municipal waste activated sludge thickening Why choose the PWL DAF? Built for tough, solids-heavy wastewater, the PWL-Series excels in performance, service life, and operator convenience—making it the preferred solution for demanding industries. PWL FAQ Q: Why choose an open-tankDAF system? A: PWL systems are better suited for high-solids wastewater due to their large surface area and low-profile design. Q: What is counter-current skimming? A: It means the sludge skimmer moves opposite the water flow, reducing carryover and maximizing float recovery efficiency. Q: Is the PWL-Series easy to maintain? A: Yes. Its open configuration and integrated sludge grid simplify inspection, cleaning, and sludge handling. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC’s PCL-Series DAF removes solids, oils, and FOG using high-rate flotation, crossflow plate packs, and in-tank sludge thickening for high-capacity wastewater applications. , High Rate DAF, DAF, PCL, PCCS, compact, Dissolved Air Floatation, FRC Systems » Products PCL-Series High-Rate DAF System High-Rate DAF System for Large-Scale Industrial Wastewater Treatment Features & Specs FAQ Photos All Products FRC’s PCL-Series DAF removes solids, oils, and FOG using high-rate flotation, crossflow plate packs, and in-tank sludge thickening for high-capacity wastewater applications. The PCL-Series High-Rate Dissolved Air Flotation (DAF) system from FRC Systems is engineered for maximum performance in high-flow industrial wastewater environments. With a vertical, space-saving design and integrated crossflow plate packs, the PCL-Series efficiently removes Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), and other contaminants, delivering drier sludge and clearer effluent with a reduced footprint. In the PCL-Series DAF system, clarified effluent is recirculated and saturated with air using an angled air dissolving tube and non-proprietary recycle pump. This creates a whitewater stream filled with microbubbles. When mixed with influent wastewater, the bubbles attach to suspended solids, causing them to rise. A crossflow plate pack improves separation by increasing effective surface area. At the top, floated solids are skimmed off while a dewatering grid thickens sludge, and clarified water exits below. Product Sheet (PDF) Request More Info Key Features Vertical, high-built design for compact installation Crossflow plate pack increases separation area and solids capture Integrated sludge dewatering grid promotes thicker, drier sludge output Angled air dissolving tube for rapid whitewater generation Non-proprietary pumps Stainless-steel construction resists corrosion in harsh environments Fully customizable system configuration including skids, catwalks, and controls Specifications Flow Rate: Up to 2,000+ GPM (454.2+ m³/hr) Free Separation Area: 5.5 – 151 sq ft (0.5 - 14.0 m²) Effective Separation Area: 32 – 3,101 sq ft (3.0 - 288 m²) Applications Food and beverage processing Petrochemical and oil refining Pulp and paper industries High-load industrial wastewater Municipal pretreatment Why choose the PCL? The PCL-Series delivers reliable, high-rate separation with excellent sludge handling and energy efficiency, making it the ideal choice for demanding industrial and municipal wastewater applications. PCL FAQ Q: What industries benefit most from the PCL-Series DAF? A: The PCL-Series is ideal for industrial sectors with high flow and solids content, including food processing, petrochemical refining, and pulp & paper. Q: How does the crossflow plate pack improve performance? A: The plate pack increases the effective separation area, allowing higher hydraulic loading and improved solids capture within a smaller footprint. Q: Does the PCL-Series use proprietary parts? A: No. It uses ANSI-standard recycle pumps and readily available components, minimizing maintenance costs and downtime. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC upgrades aging systems with modern recycle pumps, air dissolving tubes, SCADA-enabled panels, and brand-agnostic integration. , FRC, System Upgrades, Upgrades, FRC Systems » Products System Upgrades Aeration, Automation & Retrofit Solutions Important Upgrades for Wastewater Systems Features & Specs FAQ Photos All Products FRC upgrades aging systems with modern recycle pumps, air dissolving tubes, SCADA-enabled panels, and brand-agnostic integration. FRC Systems provides upgrade services to modernize existing wastewater treatment equipment, enhancing performance, reliability, and control. Whether upgrading outdated panels or retrofitting aeration systems, FRC brings new life to both FRC and third-party systems. FRC assesses your current system to identify improvement opportunities in aeration, control, or automation. Upgrades may include replacing inefficient whitewater systems with angled air dissolving tubes, retrofitting proprietary recycle pumps with standard units or modernizing control panels with SCADA integration. Components are selected for compatibility and performance, and installations are completed with minimal disruption. These upgrades increase energy efficiency, reduce labor, and extend the service life of both FRC and third-party systems. Product Sheet (PDF) Request More Info Key Features Retrofit aeration systems with angled air dissolving tubes Upgrade to non-proprietary recycle pumps Electrical panel modernization with SCADA/DCS integration Pneumatic panels with process safeguards Custom-engineered solutions with minimal downtime Options Aeration: Angled dissolving tubes for faster saturation and less energy use ANSI-standard recycle pumps with solids tolerance Controls: PLC/HMI panels with SCADA, DCS, and remote access Alarming, trending, and historical data logging Safety & Integration: Pneumatic panels with interlocks and process protection Integration into centralized plant systems Applications Under performing or aging wastewater systems Energy-inefficient aeration or whitewater generation Manual systems needing automated control SCADA integration and digital monitoring rollouts Competitor system retrofits Why do system upgrades? FRC’s upgrades extend the life and value of your wastewater equipment. Whether improving aeration, automation, or control, our brand-agnostic solutions deliver high ROI without the cost of complete replacement. Upgrades FAQ Q: What types of system upgrades does FRC offer? A: FRC upgrades include aeration retrofits (angled air dissolving tubes), non-proprietary ANSI recycle pump replacements, SCADA-ready control panels, pneumatic safety panels, and brand-agnostic integrations. Q: Can I upgrade a non-FRC wastewater system? A: Yes. FRC’s solutions are compatible with many third-party designs. We frequently retrofit existing systems with improved components for better performance and automation. Q: What’s the benefit of upgrading my recycle pump? A: Replacing a specialty whitewater pump with a standard ANSI centrifugal pump reduces maintenance, lowers energy costs, and improves solids handling in recycle flow. Q: Why replace my air dissolving system with FRC’s angled tube? A: The angled air dissolving tube provides near-instant saturation of air into recycled water, improving whitewater generation and flotation efficiency while cutting energy use. Q: What features are included in a SCADA control panel upgrade? A: FRC’s upgraded panels support remote access, data trending, alarm notifications, historian integration, and seamless communication with DCS/plant systems. Q: How long does a typical system upgrade take? A: Most upgrades are engineered for minimal downtime. With prebuilt components and field-ready panels, many upgrades can be completed within a few days. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC Flocculators enhance solids separation with static mixing, air injection, and zero energy input—optimizing chemical use before DAF systems. , Flocculator, FRC, Wastewater, Solution FRC Systems » Products F-Series Flocculators Inline Flocculators for Coagulation and Chemical Pretreatment Before DAF Features & Specs FAQ Photos All Products FRC Flocculators enhance solids separation with static mixing, air injection, and zero energy input—optimizing chemical use before DAF systems. FRC’s Flocculators are energy-free, inline mixing systems that promote effective coagulation and flocculation before dissolved air flotation. With no moving parts and minimal maintenance, they enhance solids removal while reducing chemical usage. FRC’s F-Series flocculators operate as inline static mixers. As wastewater passes through, coagulants and flocculants are introduced at designated injection ports. The internal pipe layout includes wide-radius bends and inline mixing zones, promoting gentle chemical mixing and optimal particle collision without mechanical shear. Air injection ports can also be used to introduce microbubbles. This setup prepares wastewater for DAF by creating large, stable flocs that separate efficiently during flotation. Product Sheet (PDF) Request More Info Key Features Non-mechanical static mixing design Air injection ports for microbubble introduction Wide-radius bends protect floc integrity Chemical dosing and sampling ports allows for easy testing & optimization Built from corrosion-resistant HDPE, PVC, or stainless-steel Specifications Flow Capacity: Up to 4,000+ GPM (908+ m³/hr) Construction: PVC, HDPE, stainless-steel (304, 316) Options Custom diameters and flanged ends Sampling and monitoring ports Skid-mounted assemblies SCADA-ready control panels Why choose an FRC Flocculator? Reliable, low-maintenance, and energy-efficient, F-Series flocculators improve treatment effectiveness and lower chemical costs—making them essential for any chemical pretreatment train. Flocculator FAQ Q: How do F-Series flocculators work without moving parts? A: They use static inline mixing zones, air injection ports, and wide-radius bends to promote chemical reactions and floc growth without mechanical shear. Q: Can I inject both coagulant and polymer? A: Yes, the system includes separate injection zones for staged chemical addition and optimal floc formation. Q: Are F-Series flocculators customizable? A: Absolutely. They’re available in PVC, HDPE, SS304/316, and tailored for your specific flow and process requirements. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC performs jar tests to determine optimal coagulant/polymer dosing, simulate DAF performance, and reduce chemical costs. , FRC Systems » Products Jar Sample Testing Lab-Based Service Water Testing to Optimize DAF Chemistry and Sludge Dewatering Features & Specs FAQ Photos All Products FRC performs jar tests to determine optimal coagulant/polymer dosing, simulate DAF performance, and reduce chemical costs. FRC’s in-house jar testing identifies the optimal pretreatment chemical strategy for dissolved air flotation and sludge dewatering. These controlled tests simulate full-scale performance to inform chemical dosing, equipment selection, and system design. FRC performs jar testing by introducing various chemical treatments—coagulants, flocculants, pH adjustments—into small volumes of your actual wastewater. The process simulates coagulation, flocculation, whitewater interaction, and DAF flotation in a controlled lab environment. Sludge compressibility may also be tested for dewatering suitability. These tests help determine optimal chemical types, doses, and performance expectations before full-scale implementation, allowing you to fine-tune treatment and reduce chemical and operational costs. Product Sheet (PDF) Request More Info Key Features Tests for coagulants, flocculants, pH adjustment Simulates coagulation, flocculation, DAF, and dewatering Analytical testing (TSS, FOG, BOD, COD) available Sludge compressibility analysis for equipment selection Final report includes polymer recommendations and dose ranges Tests Include Water Quality Analysis Sludge Characterization Polymer Screening DAF Simulation pH Adjustment Studies Performance Benchmarking Applications DAF system design and optimization Sludge thickening and conditioning Chemical program development Pilot system validation Why choose FRC jar testing? With proven lab protocols and deep application expertise, FRC’s jar testing provides the clearest path to effective pretreatment, ensuring success from startup to long-term operation. Jar Testing FAQ Q: What is the purpose of jar testing? A: To identify the optimal coagulant/polymer combo, simulate DAF performance, and recommend dosing rates. Q: What parameters can FRC test? A: TSS, FOG, BOD, COD, sludge compressibility, and floc formation behavior. Q: Is jar testing required for every project? A: While optional, it's highly recommended for precise system design, chemical savings, and performance reliability. Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

Explore the FRC Project Archive to dive into our extensive archive of past projects. Whether you’re interested in comprehensive system solutions or specific site upgrades, you’ll find a wealth of real-world applications and innovative solutions that FRC Systems has successfully delivered. Discover how we’ve tackled challenges similar to yours and brought effective results. FRC Systems » Projects Project References Filter by Industry Filter by Application Filter by Products Filter by Solution 1 2 3 4 5 1 ... 1 2 3 4 5 ... 5 Food & Beverage Dairy System Solution Food & Beverage Dairy Turnkey Solution General Manufacturing Automotive Parts Turnkey Solution General Manufacturing Chemical System Solution Meat & Seafood Processing Poultry Turnkey Solution Municipal Wastewater Algae & Phosphorus Removal System Solution Oil & Gas Produced & Flowback Water System Solution Food & Beverage Beverage Product Solution Food & Beverage Beverage System Solution Food & Beverage Fruits & Vegetables System Solution 1 2 3 4 5 1 ... 1 2 3 4 5 ... 5

Case Study - Food & Beverage Yogurt Production The dairy processing plant in upstate New York produces a variety of yogurt products for distribution in grocery stores around the country. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

Product Sheet - General Flocculators Static inline mixer enhances coagulation and flocculation before DAF; energy-free design with air injection and chemical dosing ports. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

Case Study - Oil & Gas Renewable Diesel Refinery The wastewater treatment equipment needed on-site removes solids and recovers oils from site runoff and raw material containment areas. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

Case Study - Food & Beverage Pet Food Production The wastewater treatment equipment needed on-site removes solids and recovers oils from site runoff and raw material containment areas. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

An award winning Canadian-based global pet food producer was combatting major wastewater problems consisting of high levels of Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), Biological Oxygen Demand (BOD) and Chemical Oxygen Demand (COD). All Projects FRC Systems » Projects Pet Food Turnkey Solution Meat & Seafood Processing Previous Project Next Project FRC Components Screen, Flocculator, High-Rate DAF, Equalization Project Description An award winning Canadian-based global pet food producer was combatting major wastewater problems consisting of high levels of Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), Biological Oxygen Demand (BOD) and Chemical Oxygen Demand (COD). FRC engineers designed a turnkey solution complete with mechanical and electrical installation of the FRC supplied equipment to give the client a fully integrated solution and service through a single point of contact. The implementation successfully removed the requisite wastewater constituents to meet permit limits. The FRC Solution Rotary Drum Screen – Removes coarse and fine solids prior to downstream equipment Equalization – Homogenize wastewater for consistent wastewater characteristics. Aeration mixing is provided to prevent anoxic conditions and formation of ammonia Flocculator – Chemicals dosed to precipitate the colloidal solids High-Rate DAF – Float the precipitated solids thereby removing TSS, FOG, O&G, and insoluble BOD Parameter Design Data Flow (gpm) 70 Flow (m3/h) 16 TSS (mg/L) 4500 FOG (mg/L) 1610 BOD (mg/L) 3140 COD (mg/L) 6970 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC systems are custom designed to combat the harsh environments often found in industrial manufacturing environments. These DAF systems can be found in vertical markets such as automotive parts, chemical, health and beauty, pharmaceuticals and wood applications. FRC Systems » Industries General Manufacturing Browse Case Studies Quick Links APPLICATIONS Automotive Parts Chemical Health & Beauty Pharmaceuticals Wood General manufacturing has a wide range of challenges in their wastewater treatment needs. Our experienced engineering team has designed systems for companies across the manufacturing 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. Manufacturing applications each have their own qualities that present unique wastewater treatment challenges. Whether you want to recover oil for reuse or remove wastewater constituents like heavy metals, sand, or clay to bring you into compliance, FRC can deliver the best solution. Automotive Parts Industry Automotive applications include stamping mills, parts manufacturing, transmission manufacturers, assembly lines, and die casting, all of which require a well thought out design approach. FRC’s complete wastewater treatment systems are engineered to remove oils, grease, cleaning chemicals, and heavy metals that are commonly found in automotive wastewater. Our systems are designed to minimize chemical usage and reduce sludge volume resulting in increased cost-savings. Turnkey Solution Skidded Solution Turnkey Solution Chemical Industry The Chemical industry is very diverse and complex. Wastewater application needs range from oil-water separation, solid-liquid separation, and biological treatment. FRC has been designing systems for the chemical industry for decades and will put our experience to work to design the best wastewater treatment system for your application. System Solution Health & Beauty Industry FRC designs highly sustainable wastewater treatment systems using a batch process consisting of multiple equalization tanks with mixing to combat the diversity of wastewater produced in health and beauty plants. Our approach can help you recover valuable leftover product and oils from washdown water while removing wastewater contaminants before discharge. Turnkey Solution Skidded Solution System Solution Pharmaceuticals Industry At FRC, we know that the best wastewater treatment system is designed to protect the expensive biological treatment systems needed in pharmaceutical applications. FRC has the experience to develop the correct solution for your wastewater treatment demands, which may include a Dissolved Air Flotation (DAF) system before and/or after the biological system. Turnkey Solution System Solution Wood Industry FRC wastewater has the complete line of wastewater treatment equipment to design a full-scale system for the manufactured wood industry. This may include a rotary drum screen, equalization, Dissolved Air Flotation (DAF), biological treatment, and sludge dewatering via belt press to meet discharge limits and reduce sludge hauling costs. Debarking is a critical process in the manufactured wood industry. With a rotary drum screen, bark can be recovered and sold as a byproduct or used as fuel for process energy. Our highly durable rotary drum screen is a great addition to processing in this industry. Turnkey Solution System Solution

Field Engineer Back to Team Oleksandr Dyatlov Field Engineer +1 770-534-3681 FRC Products Project References Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

Application Engineer Back to Team Zachary Mailliard Application Engineer +1 770-534-3681 FRC Products Project References Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

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Product Sheet - General Belt Press Automated belt press with stacked zones and continuous cleaning for high-throughput sludge dewatering in industrial and municipal plants. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

Case Study - Oil & Gas Renewable Diesel The diesel plant needed to remove FOG produced mainly from free and emulsified oils. FRC provided a full solution to meet their needs. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

One of the world’s leading manufacturers in the construction and resources, and energy & transportation industry has an automotive axle assembly plant that produces wastewater volumes of over 500,000 gpd with extremely high levels of Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG) and Chemical Oxygen Demand (COD). All Projects FRC Systems » Projects Automotive Parts Turnkey Solution General Manufacturing Previous Project Next Project FRC Components Oil & Water Separation, Flocculator, High-Rate DAF, Sludge Dewatering, Equalization Project Description One of the world’s leading manufacturers in the construction and resources, and energy & transportation industry has an automotive axle assembly plant that produces wastewater volumes of over 500,000 gpd with extremely high levels of Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG) and Chemical Oxygen Demand (COD). FRC designed a solution that allowed them to meet discharge requirements for FOG of less than 100 mg/L and TSS of less than 300 mg/L. Using dual-stage treatment, oil was recovered using a FRC CPI oil-water separator prior to a DAF system to bring the client to compliance. FRC has implemented this solution at multiple sites for this client. The FRC Solution OWS – Removed a significant portion of the non-polar material Equalization – Homogenize wastewater for consistent for consistent wastewater characteristics. Aeration mixing is provided to prevent anoxic conditions and formation of ammonia. Flocculator – Chemicals (coagulant, caustic, acid, and polymer) are dosed to precipitate the colloidal solids. High-Rate DAF – Float the precipitated solids, yielding clean effluent water that is in compliance with the TSS and O&G limits Sludge Dewatering – Dewater the DAF sludge to reduce sludge hauling costs Parameter Design Data Discharge Req. Flow (gpm) 350 - Flow (m3/h) 79.5 - O&G (mg/L) 125000 < 100 TSS (mg/L) 10820 < 300 COD (mg/L) 146000 - Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC designed and supplied a full turnkey mechanical and electrical installation solution for this greenfield bakery manufacturer of rebranded muffins and gourmet iced cakes. All Projects FRC Systems » Projects Convenience & Prepared Foods Turnkey Solution Food & Beverage Previous Project Next Project FRC Components Screen, Flocculator, High-Rate DAF, Biological Treatment, Equalization Project Description FRC designed and supplied a full turnkey mechanical and electrical installation solution for this greenfield bakery manufacturer of rebranded muffins and gourmet iced cakes. The facility had to reduce the high levels of Total Suspended Solids (TSS) and Biochemical Oxygen Demand (BOD) in their wastewater to be able to discharge to a local water source. FRC provided a complete solution to meet their compliance requirements. The FRC Solution Rotary Drum Screen – Remove coarse solids such as small pieces of muffins and cakes, as well as any floating hairnets and other “garbage”. Equalization – Homogenize wastewater for consistent wastewater characteristics. Aeration mixing is provided to prevent anoxic conditions and formation of ammonia. Primary Flocculator – Chemicals dosed to precipitate the colloidal solids. Primary DAF – Float the precipitated solids thereby removing TSS and insoluble BOD. Biological Treatment – Remove soluble BOD and as a result it creates biosolids. Secondary Flocculator – Short flocculator to precondition biosolids with flocculant. Secondary DAF – Float the biosolids, yielding clean effluent water fit for discharging to the local watering source. Parameter Design Data Flow (gpm) 125 Flow (m3/h) 28.4 TSS (mg/L) < 300 BOD (mg/L) < 300 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC Systems' FAQ section addresses common inquiries about their wastewater treatment solutions, including system capabilities, maintenance, and industry applications. Frequently asked questions What industries does FRC Systems serve? FRC Systems provides wastewater treatment solutions across multiple industries, including: • Oil & Gas – Handling produced water, frac flowback, and oily wastewater. • Poultry Processing – Managing high-fat and protein-laden wastewater. • Meat & Seafood Processing – Treating organic-rich effluents with high BOD and TSS. • Municipal Water Treatment – Supporting wastewater clarification and sludge removal. • General Manufacturing – Custom solutions for diverse industrial wastewater challenges. What technologies does FRC Systems offer? Our solutions include: • Dissolved Air Flotation (DAF) Systems – For efficient solids and oil removal. • Chemical Treatment Systems – Coagulation, flocculation, and pH adjustment. • Sludge Dewatering Solutions – Reducing waste volume and disposal costs. • Filtration & Screening – For pre-treatment and solid separation. What is Dissolved Air Flotation (DAF)? Dissolved Air Flotation (DAF) is a wastewater treatment process that is highly effective in the removal of suspended solids (TSS), fats/oils & grease (FOG), biological oxygen demand (BOD) and other contaminants from water. It is particularly effective in situations where conventional sedimentation methods are less efficient. Here’s a breakdown of what DAF is and its primary uses: 1. Air Dissolution: In DAF, air is dissolved into water under pressure in a specialized tank, saturation tube or pump. 2. Pressure Release: When this pressurized water is injected into the flotation vessel, the pressure drops which releases the dissolved air as tiny microbubbles. 3. Flotation Mechanism: These microbubbles attach to suspended particles and contaminants, causing them to rise to the surface. 4. Skimming: The accumulated material (sludge or float) at the surface is skimmed off, while the clarified water is collected from below. What Are Some Uses of DAF? Dissolved Air Flotation, or DAF, is used in a variety of applications, including: 1. Industrial Water Treatment: In industries such as food and beverage, oil and gas, and pulp and paper, to treat process water and wastewater. 2. Municipal Wastewater Treatment: To remove solids, algae, phosphorus and other contaminants before further treatment or discharge. 3. Sludge Thickening: DAF is used thicken biological sludge, reducing the overall sludge volume reducing transportation, handling and disposal costs. 4. Drinking Water Purification: To remove algae, particulates, and other contaminants from source water. 5. Pre-treatment: As a pre-treatment step for more advanced treatment processes, enhancing overall efficiency. 6. Stormwater Management: To treat runoff and reduce pollutants before discharge. Does FRC Provide Rentals or Pilots? With the largest Dissolved Air Flotation (DAF) rental fleet in the US and equipment ranging from 10–3,000 gpm, we can tailor a solution to your needs. All FRC rental equipment is available for short-term and long-term rental agreements as well as pilot testing and long-term lease agreements. FRC rental systems and stand-alone equipment are installed in a “plug-and-play” configuration for ease of installation and start-up. Once in place on-site, the unit can be operational within a matter of hours. What is a Flocculator? A Flocculator from FRC Systems is designed to provide the necessary mixing action and retention time to chemically treat wastewater. Here’s how it works: 1. Coagulation: Coagulants are added to the wastewater to break emulsions and form micro-flocs. 2. Flocculation: Flocculants are then added to agglomerate these micro-flocs into larger, more robust macro-flocs. 3. Mixing: Mixing: The flocculator ensures proper mixing energy required by the chemicals and maintains the integrity of the flocs, which is crucial for effective separation in the subsequent Dissolved Air Flotation (DAF) process. FRC Systems offers both Plug-Flow Reactors (PFR) and Continuous-Stirred Tank Reactors (CSTR) as flocculators, each designed to optimize the chemical treatment process. What is the difference between the PCL, PCCS and PWL? The main differences between PWL, PCL, and PCCS Dissolved Air Flotation (DAF) systems from FRC Systems lie in their design and application: 1. PWL (Open-Tank DAF System): (https://www.frcsystems.com/products/daf-open-style) 1. Design: Open tank, low-built separators with side walls typically 8 to 10.5 feet tall. 2. Application: Better suited for high solids loading rates. The skimmer assembly rotates against the hydraulic flow, shortening sludge skimming distance and eliminating solids carry-over. 2. PCL (High-Rate DAF System): (https://www.frcsystems.com/products/daf-high-rate) 1. Design: Features corrugated plate packs that increase the effective separation area, allowing for a smaller footprint. 2. Application: Ideal for high hydraulic loads with lower solids loading rates. The plate packs help maintain laminar flow and increase effective separation area which increases overall system performance. 3. PCCS (High-Rate DAF System): (https://www.frcsystems.com/products/daf-high-rate) 1. Design: Similar to PCL, the PCCS features a high-rate design and corrugated plate packs. However, the PCCS is specifically designed to fit within a shipping container, making it easily transportable. Ideal for temporary or mobile wastewater treatment needs, such as remote locations or construction sites. 2. Application: Efficient for removing Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), and other pollutants from wastewater. Each system is tailored to specific wastewater treatment needs, with PWL being more suitable for higher solids content and PCL/PCCS for higher hydraulic loads. If you have a specific application in mind, I can help you determine which system might be the best fit! Is FRC a part of Sulzer? In 2018, FRC Systems joined the Chemtech division of Sulzer, where our clients receive our expert team’s dedicated attention backed by Sulzer’s global resources.

Product Sheet - General PWL-Series Open Tank DAF System DAF system with counter-current skimmer and sludge grid for heavy solids in food, mining, and industrial wastewater. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

Product Sheet - General Jar Testing Jar tests can determine optimal coagulant/polymer dosing, simulate DAF performance, and reduce chemical costs. To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

FRC provided a solution for one of the longest continuously running refineries in the United States at a facility producing 11,000 bbl/d. All Projects FRC Systems » Projects Oil Refineries Product Solution Oil & Gas Previous Project Next Project FRC Components High-Rate DAF Project Description FRC provided a solution for one of the longest continuously running refineries in the United States at a facility producing 11,000 bbl/d. The existing wastewater treatment system included a trickling filter upstream of a sand filter before sending the effluent to the local river. The sand filter was becoming overloaded with solids coming out of the trickling filter. FRC installed a DAF in front of the sand filter to remove the biosolids, allowing the sand filter to operate at a higher efficiency and the client to stay in compliance. The FRC Solution High-Rate DAF – Float the agglomerated biosolids, yielding effluent water with very low solid concentration that the sand filter is better able to handle. Parameter Effluent Req. Flow (gpm) 660 MLSS (mg/L) < 50 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC supplies wastewater solutions for one of the country’s largest family-owned and -operated prepared foods companies at their plants all across the United States.   All Projects FRC Systems » Projects Convenience & Prepared Foods System Solution Food & Beverage Previous Project Next Project FRC Components Screen, Flocculator, High-Rate DAF, Sludge Dewatering, Equalization Project Description FRC supplies wastewater solutions for one of the country’s largest family-owned and -operated prepared foods companies at their plants all across the United States. Their production process creates wastewater with high levels of Total Suspended Solids (TSS) that must be brought below the required permit level. FRC provides solutions that not only handle the existing wastewater but are also designed to accommodate future expansion. The FRC Solution Rotary Drum Screen – Remove coarse and fine solids prior to Equalization. This includes small pieces of vegetables, sandwiches, and other small pieces of food. Equalization – Homogenize wastewater for consistent wastewater characteristics. Aeration mixing is provided to prevent anoxic conditions and formation of ammonia. Flocculator – Chemicals are dosed to precipitate colloidal solids. High-Rate DAF – Float the precipitated solids, yielding clean effluent water. Belt Filter Press – Increase dry solids content of the DAF sludge, thereby lowering sludge disposal costs. Parameter Design Data Flow (gpm) 500 Flow (m3/h) 43.5 TSS (mg/L) 2000 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

One of the largest beef producers in North America was expanding their facility which increased their wastewater volume to 425,000 gpd at the site. All Projects FRC Systems » Projects Beef System Solution Meat & Seafood Processing Previous Project Next Project FRC Components Reactor Tanks, High-Rate DAF, Biological Treatment, Flocculator, Open-Style DAF Project Description One of the largest beef producers in North America was expanding their facility which increased their wastewater volume to 425,000 gpd at the site. FRC engineers designed a solution to upsize the entire wastewater treatment system including the existing primary DAF system and secondary DAF system to efficiently and cost effectively handle the added demand. The FRC Solution Reactor Tanks – Chemicals dosed to precipitate the colloidal solids and oil emulsifications Primary High Rate DAF – Float the precipitated solids thereby removing Total Suspended Solids (TSS), Fats, Oils, and Grease (FOG), and insoluble Biological Oxygen Demand (BOD) Biological Treatment – Remove soluble BOD and as a result it creates biosolids Secondary Flocculator – Short flocculator to precondition biosolids with flocculant Secondary Open-Style DAF – Float the biosolids, yielding clean effluent water Parameter Avg Max Effluent Req. Flow (gpm) 300 600 - Flow (m3/h) 68 136 - TSS (mg/L) 600 2000 < 100 FOG (mg/L) 400 600 < 50 Insoluble BOD (mg/L) 500 1000 < 50 MLSS (mg/L) 2000 5000 Avg < 100 Peak < 200 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

A family-owned producer of award-winning bourbon and fine liquors was generating wastewater of more than 600,000 gpd coming off the existing aerobic biological treatment system. All Projects FRC Systems » Projects Beverage System Solution Food & Beverage Previous Project Next Project FRC Components Flocculator, Open-Style DAF Project Description A family-owned producer of award-winning bourbon and fine liquors was generating wastewater of more than 600,000 gpd coming off the existing aerobic biological treatment system. FRC was able to quickly deliver a ”plug and play” DAF System from our rental fleet for an immediate solution. The results from the rental system were so successful that a second system was ordered and installed as a assist DAF system to the original rental DAF system. The FRC Solution Chemical Dosing Skid + Flocculator Skid – Polymer is dosed to agglomerate the biosolids. Chemical dosing pumps are installed on a separate skid with a local E-Panel that communicates to the DAF skid via ethernet cable. Open-Style DAF Skid – Float the preconditioned biosolids thereby removing the Mixed Liquor Suspended Solids (MLSS). An E-Panel, including PCL and HMI, duty/standby DAF recycle pumps, and AOD sludge pump are installed on the DAF skid. Parameter Design Data Flow (gpm) 500 Flow (m3/h) 113.6 MLSS (mg/L) 10000 - 20000 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

One of the largest family-owned pork processers was building a new plant with the goal of having a completely modern facility from start to finish. All Projects FRC Systems » Projects Pork System Solution Meat & Seafood Processing Previous Project Next Project FRC Components Screen, High-Rate DAF, Flocculator, Equalization Project Description One of the largest family-owned pork processers was building a new plant with the goal of having a completely modern facility from start to finish. FRC was called in to design a wastewater treatment system to meet discharge goals for a large volume of wastewater (1.3 MGD) containing high levels of Fats, Oils, and Grease (FOG) and Total Suspended Solids (TSS). FRC engineers designed a multi-stage approach that would minimize solid waste, generate clean effluent, and recover re-usable oils as a separate product. The wastewater treatment system was integrated with the overall plant automation system to allow for data collection and remote monitoring. The FRC Solution Rotary Drum Screen – Removes coarse solids prior to further treatment such as hog hair and small pieces of meat High Rate DAF #1 – Uses dissolved air without chemicals to recover oils Equalization – Homogenize wastewater for consistent wastewater characteristics. Aeration mixing is provided to prevent anoxic conditions and formation of ammonia Flocculator (Duty/Standby) – Chemicals dosed to precipitate the colloidal solids High Rate DAF #2 & DAF #3 (Duty/Standby) – Floats the precipitated solids, yielding clarified wastewater Parameter Design Data Flow (gpm) Avg 900 Max 2400 Flow (m3/h) Avg 205 Max 545 TSS (mg/L) 4200 FOG (mg/L) 1300 BOD (mg/L) 4900 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

An international energy company that is also one of the biggest Oil & Gas producers in the US, has a site in the Middle East where water is scarce. All Projects FRC Systems » Projects Produced & Flowback Water System Solution Oil & Gas Previous Project Next Project FRC Components Flocculator, High-Rate DAF Project Description An international energy company that is also one of the biggest Oil & Gas producers in the US, has a site in the Middle East where water is scarce. The FRC solution of a Dissolved Nitrogen Flotation (DNF) and flocculator was designed which allows the client to re-use the treated effluent. Nitrogen was chosen instead of air to keep the oxygen limit below 1 ppb due to the long pipelines. The DNF and flocculator were constructed of stainless steel 316 wetted materials, and the system including the auxiliary support equipment were rated for a class 1, div 2 area classification. The FRC Solution Flocculator – Chemicals (coagulant and flocculant) were dosed to precipitate the oily solids High-Rate DAF – Float any free oils, precipitated oil emulsifications and colloidal solids yielding clean effluent water for water re-injection Parameter Effluent Req. Flow (gpm) 440 Flow (m3/h) 100 TSS (mg/L) < 10 Oil In Water (mg/L) < 20 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

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A jar test provides a simple and effective qualitative test to determine a combination that results in effective solids removal with DAF treatment. FRC Systems » Services Jar Testing Shipping a Sample? Learn more about our Sample Packaging & Shipping Procedure Shipping A Sample? FRC can suggest the right pretreatment chemicals. A FRC Systems jar test provides a simple and effective qualitative test in which we add various coagulant and/or flocculant chemicals to your wastewater samples in order to determine a combination that results in effective solids removal with dissolved air flotation (DAF) treatment. We also offer optional analytic testing for both treated and untreated samples, including Total Suspended Solids (TSS), Fats, Oils & Grease (FOG), Biochemical Oxygen Demand (BOD), Chemical Oxygen Demand (COD), and many others. Based on the jar test results, FRC can recommend the proper pretreatment chemicals to discuss with your chemical supplier. The coagulants will be selected based on the application, wastewater characteristics, and sludge disposal options. Coagulation This is a purely chemical process which involves the destabilization of colloidal particles forming micro-flocs with a positive charge. We are determining how quickly micro-flocs can be formed to select the proper FRC product selection. During this step, we can determine a preliminary dosing recommendation. Flocculation The flocculant is a polymer that attracts the opposite charged micro flocs, and agglomerates the micro flocs into larger “macro flocs”. This is done in order to achieve a size suitable for separation in the flotation cell. Polymers can be an anionic, cationic, or nonionic. DAF Simulation In this step we generate whitewater by pressurizing water in a dedicated vessel. We inject the generated whitewater into the waste water sample to observe how the dissolved air interacts with the previously formed macro-flocs. Sludge Testing We also offer sludge testing which involves applying pressure to evaluate the behavior of the sludge. This allows FRC to recommend the proper dewatering technology.

This client is one of the largest global petroleum refiners, processing 366,000 barrels of crude oil per day at one of the largest refineries in the US. All Projects FRC Systems » Projects Stormwater Runoff Product Solution Oil & Gas Previous Project Next Project FRC Components Oil & Water Separation Project Description This client is one of the largest global petroleum refiners, processing 366,000 barrels of crude oil per day at one of the largest refineries in the US. They needed a system that could handle high volumes of storm water runoff in a small footprint while still allowing them to stay in compliance. FRC provided a Shell-DEP CPI that met their treatment requirements. The FRC Solution CPI (Shell-DEP) – Separate the free oils and a portion of the TSS from the wastewater Parameter Effluent Req. Average Flow (gpm) 40000 Peak Flow (gpm) 300000 TSS (mg/L) < 100 Oils (mg/L) < 50 Design Data Previous Project Next Project Submit a Project Profile Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

Application Engineer Back to Team Josh Schuyler Application Engineer Southeast US +1 770-534-3681 Josh is a chemical engineer at FRC who uses his hands-on skills to identify and develop solutions for our clients' wastewater processes. He focuses on providing viable options, from system adjustments to recommended operational changes, to help clients achieve optimal process performance. FRC Products Project References Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

White Paper - General The Ultimate DAF Buyers Guide Explore the key mechanical and process design aspects of DAF systems in this guide and gain the expertise needed to evaluate them effectively. With this knowled... To learn more, fill out the form to have access to the entire library for free! < Back To have access to our entire library for free, please provide the following: First name* Last name* Email* Company name* Yes, subscribe me to your newsletter. Access & Download

Warehouse Technician Back to Team Nick Beatty Warehouse Technician +1 770-534-3681 FRC Products Project References Have a Question? Need help customizing your wastewater solution? We're here to help! Send us a message!

FRC was founded in 1979 as a provider of wastewater treatment equipment to the food processing industry. FRC Systems » About FRC Systems Team Directory Project Archive Products For almost 50 years, FRC Systems has delivered thousands of system installations worldwide. FRC was founded in 1979 as a provider of wastewater treatment equipment to the food processing industry. Over the following two decades, FRC emerged as the eminent dissolved air flotation (DAF) systems provider to many of the food processing industry’s largest companies. From there, FRC began expanding its services to general manufacturing, oil and gas and municipal applications. In 2008, FRC Environmental was renamed FRC Systems International to better reflect the growing global reach of FRC. Our focus expanded to include screens, sludge dewatering, biological treatment systems, Moving Bed Bio Reactor (MBBR), Membrane Bioreactor (MBR), and Continuous Waste Activated Sludge (CWAS). Today, FRC is part of the Chemtech division of Sulzer, where our clients receive our expert team’s dedicated attention backed by Sulzer’s global resources. Why Choose FRC Systems? Application Experience & Know-How Our design and engineering teams are led by highly regarded specialists in the industrial wastewater treatment field with an average of 25+ years of experience in the industry. Client Focused All of our systems are engineered for the specific challenge at hand. We focus on client objectives from the beginning of the design process through installation and start-up. Our goal is not just to make a system that works, but one that works for you. Personal Attention Each wastewater project receives one-on-one attention throughout the entire process from a dedicated project manager and a team of our experienced engineers. Quality You Can Trust The FRC design process includes professional submittals with detailed 3D drawings for approval before manufacturing. Our wastewater treatment products are constructed using laser-cut, stainless-steel manufacturing and assembly to ensure quality control.