In Part 1 of this series, we explored the hidden costs of sludge buildup in municipal and industrial lagoons and why traditional aeration systems often fall short in truly addressing the problem. Now in Part 2, we’ll look more closely at how harsh seasonal conditions, rising BOD loads, and ever-tightening budgets create even greater barriers to effective sludge reduction.
We’ll show how floating air-driven aerators, like the Titus FL system from Titus Wastewater Solutions, offer not just an innovative solution for sludge reduction, but a resilient, cost-effective option for year-round operation, even in the most extreme climates.
Cold Weather: The Silent Treatment Killer
If your lagoon is located north of the Mason-Dixon line or in a high-elevation region, you already know about the limitations of conventional aeration equipment. When winter hits, most mechanical systems must be shut down or risk catastrophic damage. And when your treatment process stalls in cold weather, sludge reduction stalls with it.
Why Does This Happen?
- Surface aerators throw water into the air, where it freezes instantly—creating hazardous ice buildup and risking structural failure.
- Fixed-position diffusers become clogged or buried in sludge and are nearly impossible to inspect or maintain when the lagoon is frozen.
- Electrical components break down quickly in cold, damp environments, leading to costly repairs and shortened equipment life spans.
These aren’t rare failures. They happen across the country every winter.
“We’ve seen brush aerators freeze solid and snap under the weight of ice,” says Lewis Titus, founder of Titus Wastewater Solutions. “And if you’re relying on surface agitation for oxygen transfer, freezing weather shuts you down completely.”
When systems fail in cold weather, sludge reduction becomes an uphill battle. Without consistent mixing and oxygen transfer, dissolved oxygen levels fall, biological treatment slows, and solids begin to accumulate. Over time, that buildup puts serious pressure on system capacity, permitting, and budgets.
Floating Aeration in the Real World: Built for the Freeze
Floating aerators like the Titus FL are designed to operate from the ground up, delivering continuous aeration, reliable mixing, and consistent sludge reduction without seasonal shutdowns or damage. Unlike traditional systems, the entire aeration and mixing process happens below the surface, so there’s no spray to freeze in the air and no exposed moving parts to seize in the cold.
The secret is in the system’s design:
- All air movement originates onshore where a blower system powers the aerator remotely, keeping electrical and mechanical components safely out of the lagoon.
- The airlift pump and membrane diffuser work inside a submerged column, naturally insulated from freezing temperatures at the surface.
- The floating units are neutrally buoyant, designed to stay just below the water’s surface, allowing for gentle motion and operation even when ice forms overhead.
This level of cold-weather reliability isn’t just theoretical. It’s been demonstrated in real-world conditions where other systems failed.
“We had a system running in Riverton, Wyoming, during a stretch of 44 below zero,” says Titus. “Everything else was frozen solid. Ours kept running under the ice, mixing the lagoon and maintaining dissolved oxygen levels.”
Even in extreme cold, the Titus FL system supports active biological treatment and steady sludge reduction, helping operators avoid the long-term costs of seasonal downtime and sludge accumulation.
Real-World Cost Savings: A Case Study in Smart Remediation
In a recent project, a small utility was facing a $200,000 bill to dredge two sludge-laden lagoons. On top of that, they expected to spend another $200,000 replacing a bottom-diffused aeration system that was no longer effective. The TITUS Twister was half the cost, and eliminated the dredging expense, resulting in more than $300,000 in savings.
✓ Sludge levels dropped 55% in 4 months without mechanical dredging.
✓ No extensive system of diffusers and piping, reducing installation costs significantly.
✓ Total capital savings: over $300,000.
✓ Odors were dramatically reduced, eliminating neighborhood complaints.
✓ Maintenance was reduced by about 90%.
✓ Direct drive “run slow blower” technology reduces noise and increases blower life.
✓ Low pressure (about 3.7 PSI) high volume air reduces the temperature rise of the blower to about 50 degrees F. Lower temperature increases the service life of blower combined with NO Belt maintenance gives significant maintenance cost reduction.
“We saved them from having to replace a flawed system of tube diffusers with basically the same old technology, and eliminated the need for an expensive dredging,” says Titus. “Plus, the smell disappeared, which was a big deal for that neighborhood.”
This real-life example shows just what’s possible when sludge reduction is built into the treatment process. By removing solids biologically instead of mechanically, the facility kept costs down, avoided disruptive construction, and improved conditions for the surrounding community.
Thinking Beyond Initial Efficiency Numbers
Oxygen transfer efficiency (OTE) may look great in a lab report, but it rarely tells the full story of how an aeration system will perform in the field. Many engineers still rely on OTE as the primary benchmark, even though real-world lagoon conditions require a broader view.
Here’s what truly matters when it comes to long-term lagoon performance and effective sludge reduction:
Mixing power: Can the system eliminate dead zones where solids settle?
Resilience: Will it continue operating in cold weather, or shut down during winter?
Mobility: Can the unit move to cover more area and attack sludge piles directly?
Maintenance needs: How often does the system require in-lagoon servicing?
Cost over 10–15 years: What will you spend over 10 to 15 years on energy, maintenance, and sludge removal?
The Titus FL aerator performs across all of these categories. It delivers not only strong oxygenation and consistent mixing, but also long-term sludge reduction with zero in-lagoon maintenance and lower total cost of ownership.
The True ROI: Reduce Sludge, Extend Life, Stay Compliant
Sludge reduction isn’t just a matter of managing volume—it directly affects system performance. As sludge accumulates, it reduces treatment capacity, shortens solids retention time, and raises the risk of noncompliance due to poor effluent quality. These issues aren’t just operational; they can lead to serious permitting challenges and expensive upgrades down the line.
Titus aeration systems offer a long-term remediation strategy that helps facilities regain lost lagoon capacity and improve overall biological performance. With better oxygen distribution and continuous mixing, operators can see meaningful reductions in BOD and COD. Over time, the system helps extend the lifespan of existing infrastructure and delay or even eliminate the need for costly dredging projects.
“In many cases, we can reduce sludge levels by 50–60% or more, depending on how much of it is volatile,” notes Titus. “It’s a slower process than dredging—but it’s steady, cost-effective, and doesn’t shut your plant down.”
This kind of steady biological sludge reduction allows facilities to stay operational while gradually reclaiming treatment volume. It’s a sustainable path forward for aging lagoons that need results without interruption or major capital expenses.
Coming Up in Part 3:
In the final installment of this series, we’ll dive into the science and strategy behind optimizing lagoon performance even further, including:
- Odor control through oxygenation and mixing
- The performance science behind volatile solids digestion
- What specifying engineers need to ask when evaluating lagoon upgrades
- A lagoon vs. mechanical plant cost comparison
Want to reduce sludge and avoid costly dredging at your facility?
Contact Titus Wastewater Solutions to schedule a performance review or request a quote for the Titus FL system. No boats. No dredges. No shutdowns. Just smarter, year-round sludge control.