The best alternative to activated sludge package plants?
Michael Clayton
Upgrading Ageing Activated Sludge Package Plants: Why Orenco AdvanTex® is the Ideal Solution
Across North America, many small communities, commercial facilities, and mobile home parks rely on traditional activated sludge package plants designed and installed decades ago. While these systems were once standard for decentralized wastewater treatment, ageing units are increasingly becoming operational nightmares aka rust buckets.
If you have ever seen an old package plant, you know what we are talking about. Corroding steel tanks, high electricity bills, noisy blowers, constant mechanical upkeep, frequent sludge hauling costs and dangerous working conditions put the owners and operators of these systems in a bad position.
At AQWA, we are wastewater treatment plant operators at our core and nothing makes us happier than seeing an old package plant upgraded with a new plant that is safe, reliable, efficient, and easy to operate. We use Orenco AdvanTex® Treatment Systems to offer a dramatically more efficient, reliable, and cost-effective path forward for these sites.
The Problem with Ageing Activated Sludge Package Plants
Activated sludge depends on suspended growth biology: continuous aeration blows massive amounts of air into wastewater tanks to keep bacteria suspended and alive. Activated sludge treatment can be great and is the foundation of most large municipal systems, but it really is not the best solution for small and variable flow systems for many reasons:
High Energy Consumption: Continuous motor blowers run non-stop, driving up monthly electric bills.
Heavy Maintenance & Operator Hours: Suspended growth systems are biologically sensitive. Shock loads, flow surges, or temperature drops require frequent operator intervention and chemical adjustments.
Rapid Sludge Accumulation: Activated sludge generates large volumes of waste activated sludge (WAS), requiring frequent, expensive sludge hauling.
Nuisance Factors: Loud blower motors, vibrating equipment, and bad odors make old package plants an eyesore and earache for surrounding residents.
Rust, Rust, and more Rust: If you want to generate massive amounts of corrosion, rust and weakened steel, painted steel package plants and the gases associated with wastewater are a match made in heaven.
Why Orenco AdvanTex® is the right choice for package Plant Upgrades
Orenco’s AdvanTex® technology utilizes a non-submerged, attached-growth textile media filter rather than suspended growth aeration. Wastewater is micro-dosed over engineered textile sheets where a rich ecosystem of microorganisms treats the effluent.
This fundamental shift in process offers significant operational and financial benefits:
1. Significantly Lower Electrical Costs
Instead of running high-horsepower air blowers 24/7, AdvanTex systems use small, high-efficiency fractional horsepower pumps that dose effluent intermittently based on programmable timers. Electricity consumption drops drastically—often by 50% to 80% compared to traditional activated sludge plants.
2. Reduced Operator Visit Requirements
AdvanTex systems are exceptionally stable. Because microorganisms live attached to the textile media rather than suspended in liquid, the system naturally withstands surge flows, organic shock loads, and periods of low usage (such as seasonal drops in flow). Operators spend far less time tweaking controls or troubleshooting biological upsets. AQWA has obtained reductions in operator grade and visitation frequency from NCDEQ and SCDES. Activated sludge plants typically required the operator to visit the plant 5 days per week. Our AdvanTex systems only require 1 operator visit per week.
3. Much Lower Sludge Removal Costs
In traditional activated sludge, high bacterial turnover yields huge amounts of excess sludge. AdvanTex systems incorporate multi-compartment primary/septic tanks that allow primary solids to settle and undergo long-term anaerobic digestion. Solids accumulate slowly, extending sludge pump-out intervals from weeks or months to years.
4. Quiet, Odorless, and Discreet Operation
With no heavy blowers or noisy surface aerators, AdvanTex systems operate silently. The biological process takes place under covered, insulated fiberglass filter pods, virtually eliminating nuisance odors. The low-profile pods blend seamlessly into landscaping without drawing negative attention from neighbors.
Real-World Success: The Countryside Mobile Home Park Upgrade
A prime example of this technology in action is the Countryside Mobile Home Park community in Sophia, North Carolina. Check out the case study.
The property owner faced a common challenge: an ageing activated sludge package plant that was deteriorating, costly to maintain, and situated right near residents. The new system needed to meet strict state discharge limits while lowering maintenance demands and eliminating local visual and noise complaints.
By replacing the failing package plant with an Orenco AdvanTex® System, the facility achieved:
Full compliance with existing discharge permits.
A dramatically reduced maintenance footprint and fewer required operator visits.
A quiet, low-impact footprint that eliminated odors and visual clutter in the neighborhood.
Upgrading Your Wastewater Facilities?
If you are managing an ageing package plant that is draining your operational budget, upgrading to a packed-bed textile filter like Orenco AdvanTex® can lower your life-cycle costs while restoring reliable, hassle-free treatment. Get in touch for a free review of your project and proposal including preliminary sizing, layout, and cost estimate.
projects@aqwa.net
252-243-7693