By Tommy Butler M.Pharm MBS
Choosing a package sewage treatment plant is an important decision. Whether you are developing a hotel, holiday park, housing estate, mining camp, military facility or remote community, the treatment system you select can affect your operating costs, maintenance requirements and peace of mind for decades.
Having worked in the sewage treatment industry for many years, my advice is straightforward: do not choose a sewage treatment plant based purely on its purchase price. Look at the whole life cost, the simplicity of the process, the track record of the manufacturer and the experience behind the product.
At Butler Manufacturing Services (BMS), we have been manufacturing and supplying sewage treatment systems internationally for decades. Our Blivet Package Sewage Treatment System has been exported to more than 60 countries, and we have Blivet systems that have been operating for over 30 years.
Here is what I believe you should consider when comparing different package sewage treatment brands, and why these factors matter so much in the long run.
1. Look Beyond the Purchase Price
One of the most common mistakes I see customers make is focusing too heavily on the initial purchase price.
It is understandable. When comparing quotations, the price is an obvious figure to look at. However, the cheapest system to purchase is not necessarily the cheapest system to install, operate or maintain.
There are several costs that are often overlooked when comparing package sewage treatment plants:
Installation costs: How much work is required to install the system? Does it need additional concrete tanks, settlement tanks or other equipment?
Transport costs: How much will it cost to transport the complete system to your site?
Electrical consumption: How much electricity will the plant use every year?
Maintenance: How frequently will the system need servicing, and who can carry out that work?
Spare parts: Are replacement parts readily available, or will you need to source specialist components from overseas?
Sludge removal: How frequently will the plant need to be desludged, and what will that cost?
Reliability: What happens if the plant breaks down? How quickly can it be repaired, and what expertise will be required?
Long-term support: Will the manufacturer still be around to provide advice and assistance in 10, 20 or 30 years?
These costs can make a substantial difference over the lifetime of a sewage treatment plant.
Calculate the 20-year cost of ownership
I would encourage anyone comparing different brands to ask for a realistic estimate of the total cost of ownership over 20 years.
This should include the initial purchase price, installation, transport, electricity, routine maintenance, spare parts, sludge removal and any anticipated major repairs or replacements.
Ask suppliers to explain the assumptions behind their figures. Electricity consumption, for example, should be based on the expected operating conditions and actual equipment requirements rather than an optimistic estimate.
The important point is that you should compare like with like. A system that appears cheaper on paper may require additional tanks, more installation work, higher electricity consumption or more frequent specialist maintenance.
A sensible purchasing decision considers the entire lifecycle of the plant, not just the first invoice.
2. Understand the Treatment Process and Its Complexity
Sewage treatment technology has developed considerably over the years. There are several different biological treatment processes available, including activated sludge, moving bed biofilm reactors (MBBR), sequencing batch reactors (SBR) and rotating biological contactors (RBC).
Each process has its own characteristics, advantages and limitations. The right choice depends on the application, discharge requirements, site conditions and operating arrangements.
However, one principle has guided my thinking throughout my career: complexity is not automatically innovation, and more complicated does not necessarily mean better.
I have seen a tendency in engineering for innovation to introduce additional components, controls and equipment. Sometimes that is justified. In other cases, it creates additional things that can wear out, require maintenance or go wrong.
My preference is for a process that achieves the required treatment standard with as few moving parts and as little unnecessary complication as possible.
Why fewer moving parts matter
Every mechanical or electrical component introduces a potential maintenance requirement. Air blowers, pumps, valves, controls and other equipment may all need inspection, servicing or replacement.
Where a treatment process depends on multiple items of equipment operating correctly, the operator needs to understand how those components work together and what to do when something goes wrong.
This becomes particularly important at remote sites, holiday parks, construction camps and other locations where a specialist wastewater technician may not be readily available.
A simpler process can make maintenance easier, reduce the number of spare parts required and make the plant more resilient in day-to-day operation.
That does not mean every simple system is automatically reliable or that every complex system is unsuitable. The question is whether the additional complexity delivers a worthwhile treatment or operational benefit.
3. Compare Electricity Consumption Carefully
Electricity is one of the ongoing costs that can be overlooked when purchasing a package sewage treatment plant.
Many conventional systems, including many activated sludge, MBBR and SBR installations, use powered air blowers for aeration. Depending on the particular design, they may also require pumps and other electrically driven equipment.
The power consumption of these systems varies according to their size, configuration, loading and operating conditions.
In our experience, the Blivet can use substantially less electricity than many conventional aeration-based alternatives. We have found that some comparable systems can consume five to ten times as much electricity, although the actual difference depends on the specific systems being compared.
How does the Blivet achieve this?
The Blivet uses the BMS Aerotor, our development of the rotating biological contactor concept.
The Aerotor combines fixed-film biological treatment with an integrated aeration and hydraulic lifting arrangement. Rather than relying on a conventional continuously operating air blower as the primary means of aeration, the process uses a rotating mechanism to support biological treatment.
The Blivet has just one continuously moving electrical component: a motor rated at no more than 0.75 kW.
This relatively simple mechanical arrangement is one of the features I believe deserves greater attention when customers compare treatment plants.
Fewer continuously moving electrical components can mean fewer items to service and replace, as well as lower electricity consumption.
If you are comparing brands, ask each manufacturer for the expected annual electricity consumption in kilowatt-hours under your anticipated operating conditions. Make sure the figures cover the complete treatment plant, including any ancillary equipment required for normal operation.
You can then calculate the expected annual electricity bill using your own electricity tariff.
That is a much more useful comparison than simply looking at the motor rating or taking a general statement about energy efficiency at face value.
4. Consider Maintenance and the Availability of Spare Parts
A sewage treatment plant does not operate in isolation. It needs to be maintained throughout its working life.
Before choosing a system, I would want to know exactly what routine maintenance is required, how frequently it must be performed and who is capable of doing it.
Some systems require regular attention from people with specialist technical knowledge. That may be perfectly manageable at a large facility with dedicated maintenance staff, but it can be a significant disadvantage at a smaller or remote installation.
Can a local caretaker maintain the system?
One of the practical advantages of the BMS Blivet is that routine servicing can be carried out by a local caretaker or maintenance person, provided they have received appropriate instruction and the work falls within their competence.
The system is designed to be straightforward to operate and maintain. Its parts are field-replaceable, and standard components can be sourced locally in many locations rather than relying on proprietary parts that may have to be shipped from the manufacturer.
This is particularly valuable for international projects, remote communities, mining camps and facilities where downtime can be expensive.
There is an important distinction, however, between routine maintenance and specialist commissioning. The Blivet requires appropriate technical expertise to commission the system and ensure it is correctly configured for the application. Specialist advice may also be required when optimising treatment performance or diagnosing more complex problems.
I believe that is the right way to approach any treatment plant: make routine operation as straightforward as possible while ensuring that the system is correctly designed, commissioned and supported.
Ask about sludge removal
Another important question is how frequently the system will need to be desludged.
Sludge removal has a direct cost, involving a contractor, transport and disposal. The frequency will depend on the treatment process, the quantity and characteristics of the incoming sewage, the loading and the design of the plant.
Do not assume that all package plants have the same desludging requirements.
Ask the manufacturer to provide a realistic estimate based on your application and include this cost in your long-term financial comparison.
5. Check Whether the System Is a Complete Package
Something that can easily be missed when comparing quotations is whether the quoted product represents a complete treatment system.
A supplier may offer an attractive price for the main treatment unit, but the installation may also require separate settlement tanks, additional treatment tanks, pumping equipment or other infrastructure.
These additional items can affect the total project cost, the installation programme and the space required on site.
The Blivet is designed as a complete, all-in-one package sewage treatment system. You do not need to add separate treatment tanks to complete the basic treatment process.
That can simplify the project considerably. There are fewer separate items to procure, transport, position and connect, and the overall installation can be more straightforward.
Of course, every site still needs to be assessed for its particular requirements. Inlet arrangements, foundations, discharge infrastructure, pumping requirements and other site-specific works may still be necessary. The important point is to establish exactly what is included in each supplier's quotation.
Consider transportation and installation time
Transport can be particularly important for international projects or locations that are difficult to access.
All Blivet models can be shipped in a standard 40-foot shipping container. This provides a practical advantage for projects where international freight, logistics and delivery planning are important considerations.
The system can also be brought into operation within a day of unpacking in suitable circumstances, once the necessary site connections, installation work and commissioning arrangements are in place.
For temporary installations and projects with tight schedules, this can be a valuable advantage.
When comparing brands, ask for a realistic installation programme, including any civil engineering works, additional tanks, electrical connections, commissioning and testing. The delivery date of the treatment unit is not necessarily the date when the complete plant will be ready to operate.
6. Look for a Proven Track Record, Not Just Promises
This is one of the most important points I would make to anyone purchasing a sewage treatment plant.
Many suppliers can make impressive promises about effluent quality, energy efficiency, maintenance and reliability. Those claims need to be supported by appropriate technical information and real-world experience.
The difficulty is that a treatment plant is a long-term investment. You may be buying a product that you expect to operate for 20 years or more.
What happens if the supplier disappears after five years?
What happens when you need a replacement part, advice about a process problem or assistance with an unusual operating condition?
An agent or distributor may provide a useful service, but businesses can change ownership, change product lines or cease trading. If the company behind the product has little experience or a limited history, the customer may be left trying to find support for equipment that was supposed to last decades.
Why I recommend dealing directly with an established manufacturer
Where possible, I recommend dealing directly with a manufacturer that has a long history in the market.
An established manufacturer is more likely to have accumulated practical knowledge of how its equipment performs under different conditions, what problems can arise and how those problems can be resolved.
That knowledge matters just as much as the physical product.
At Butler Manufacturing Services, we have been manufacturing wastewater treatment equipment since 1986. The Blivet has been exported to more than 60 countries over 40 years, and we have Blivet systems more than 30 years old that are still operating.
For me, this history is important because it represents decades of accumulated experience. It is not simply a matter of having manufactured a product for a long time. It is the knowledge gained from designing systems, seeing how they perform in the field, learning from operating experience and helping customers solve problems.
When evaluating another manufacturer, I would ask for references from installations that have been operating for many years, not just recently completed projects.
Ask how long the company has been trading, whether it manufactures the equipment itself, what technical support it provides and whether it can demonstrate a credible history of long-term installations.
A good product matters. A good manufacturer with the knowledge to design, support and maintain that product over its working life matters just as much.
7. Examine Real-World Case Studies
A manufacturer's website may contain impressive specifications, but I would also look for examples of how its systems perform in real applications.
Different sites present different challenges. A sewage treatment plant serving a small residential development has different requirements from one serving a remote mining camp, a large hotel or a temporary construction site.
Case studies can help you understand whether a manufacturer has experience with projects similar to yours.
For example, BMS has published case studies covering the use of the Blivet and other wastewater treatment systems in applications including:
A temporary sewage treatment plant for an Australian mining camp.
A large tourist accommodation and camping site.
A large housing estate.
Military camps.
Construction sites and other commercial applications.
These examples illustrate the range of settings in which package sewage treatment solutions may be required.
When reviewing case studies, I recommend looking beyond the project photographs. Try to establish what the original challenge was, why the system was selected, what treatment requirements had to be met and how the installation was delivered.
Where information is available, look for operating history, maintenance experience and measured treatment results.
You can explore the BMS examples in our sewage treatment case studies.
If a manufacturer cannot provide credible evidence of experience in applications like yours, I would want to understand why before making a decision.
8. Understand What Makes the BMS Aerotor Different
The biological treatment process is at the heart of any package sewage treatment plant. Understanding how it works can help you compare competing products more meaningfully.
The BMS Aerotor is a development of the rotating biological contactor, or RBC, concept. It incorporates a rotating structure with spiral fibreglass media and an integrated arrangement for aeration and hydraulic lifting.
The design is intended to provide a large biological surface area within the rotor, facilitate movement of the wastewater through the treatment process and reduce the need for external pumping and sludge-return arrangements.
According to the BMS technical description, approximately 97% of the Aerotor's surface area is inside the rotor drum. The integrated design also supports self-cleansing operation and gravity-driven recirculation.
These are engineering features intended to address some of the limitations associated with conventional RBC arrangements.
The result is a treatment process designed to achieve a high standard of effluent quality without relying on a large number of continuously moving electrical components.
The Aerotor can be configured for applications requiring more demanding treatment performance, including ammonia and nitrogen reduction where the relevant design and operating conditions support those requirements.
However, it is important to distinguish between the capabilities of a treatment technology and the performance guaranteed for an individual installation. Actual effluent quality depends on the plant design, incoming sewage characteristics, hydraulic and organic loading, temperature, operating conditions and applicable discharge requirements.
For a particular project, ask the manufacturer to confirm the required treatment performance in writing and explain how it will be achieved.
You can read more about the engineering behind our approach in What Is an Aerotor, and How Is It Different from a Normal RBC?.
9. Make Sure the System Is Properly Designed for Your Application
Even a well-engineered treatment plant will not perform as intended if it is incorrectly selected or designed for the site.
Before recommending a system, a manufacturer or suitably qualified wastewater specialist needs to understand the characteristics of the project.
Important considerations include:
The expected number of people or population equivalent served.
Average and peak daily flows.
Variations in flow throughout the day, week or season.
The organic strength of the incoming sewage.
The required effluent quality and discharge consent conditions.
The availability of electricity and maintenance personnel.
Site access, ground conditions and installation constraints.
The availability of suitable infrastructure for discharge or further treatment.
A hotel or holiday park, for example, may experience substantial seasonal variations in occupancy. A remote camp may have limited access to specialist maintenance. A housing development may have relatively predictable flows but stringent discharge requirements.
The most appropriate solution needs to account for these differences.
This is another reason I place so much value on a manufacturer's experience. A company that has worked across a wide range of applications develops practical knowledge of what works, what does not and how to avoid common design mistakes.
Do not simply ask a supplier to quote for a plant based on a population figure. Give them the information they need to select and design the right system and expect them to explain the reasoning behind their recommendation.
10. Use a Consistent Checklist When Comparing Brands
When I advise someone who is comparing package sewage treatment systems, I recommend asking every supplier the same questions.
This makes it easier to identify differences that may not be obvious from the headline price.
Purchase and installation
Is the quoted price for a complete treatment system?
Are additional tanks or major items of equipment required?
What civil engineering works and site connections are necessary?
What are the transport costs?
How long will installation and commissioning take?
Operating costs
What is the expected annual electricity consumption in kilowatt-hours?
What routine maintenance is required, and how often?
Which components are likely to need replacement?
How readily available are spare parts?
How frequently should the plant be desludged?
What specialist support will be required over the system's lifetime?
Treatment performance
What effluent quality is the system designed to achieve?
Is the proposed performance appropriate for the site's discharge requirements?
Can the manufacturer provide relevant test results or performance evidence?
How does the process respond to variations in flow and loading?
What monitoring, testing and operational procedures are required?
Manufacturer and support
How long has the manufacturer been operating?
Does it manufacture the product itself or act only as an agent?
Can it provide references for installations that have operated for many years?
Is technical support available after commissioning?
Can the company help with troubleshooting, upgrades and replacement parts in the future?
I would also ask each supplier to provide a projected 20-year cost of ownership, with the assumptions clearly stated.
You may find that one system has a lower initial price, while another offers a simpler installation, lower energy consumption or easier maintenance. Having the information in front of you allows you to make a more informed decision based on the requirements of your project.
Conclusion: Choose the Manufacturer as Carefully as the Treatment Plant
Choosing between package sewage treatment brands is about much more than comparing prices or looking at technical specifications.
You need a system that can achieve the required treatment standard, operate reliably under your site conditions, remain economical to run and be maintained throughout its working life.
My advice is to look at the total cost of ownership, pay attention to the simplicity of the treatment process, understand the maintenance requirements and investigate the manufacturer's track record.
Where possible, go directly to an established manufacturer rather than relying entirely on an intermediary. Look for decades of experience, evidence of long-term installations and the technical knowledge needed to select, design and support the right solution.
At BMS, we developed the Blivet around the principle that a sewage treatment plant should deliver high-quality treatment without unnecessary complexity. Its all-in-one design, low electrical power requirements, straightforward maintenance approach and long operating history reflect that philosophy.
The Blivet is not automatically the right answer for every application. The correct choice depends on your site's requirements, the discharge standard you must meet and the practical arrangements for installation and operation.
But if you are comparing systems, I would encourage you to look beyond the initial price and ask a more important question:
Which treatment plant offers the best combination of proven performance, whole-life cost, simplicity and long-term support for my particular application?
That is the question I believe every buyer should answer before committing to a sewage treatment system.
If you are planning a project and would like advice on selecting a suitable package sewage treatment plant, the team at Butler Manufacturing Services can help you assess your requirements and identify an appropriate solution.
You can learn more about the BMS Blivet Package Sewage Treatment System or contact our team to discuss your project.