FlexBio is a system provider of compact and modular wastewater and biogas plants. Our technologies efficiently treat wastewater while simultaneously generating energy in the form of biogas, offering flexible and sustainable solutions for industry, commerce, and agriculture.

FlexBio is innovative because we combine wastewater treatment with energy generation. Our compact container-based systems are modularly expandable, ready for immediate use (Plug & Play), and sustainably reduce both operating costs and CO₂ emissions.

FlexBio was founded in 2014.

FlexBio is attractive to customers because we combine efficient wastewater treatment with added value. Our systems reduce operating costs, generate energy from wastewater, are flexibly expandable, and provide everything from a single source – from planning to service.

FlexBio processes are suitable for municipal, commercial, and industrial wastewater. They have proven particularly effective in the food and beverage industry, slaughterhouses, dairy operations, and agriculture – wherever wastewater contains high organic loads.

Yes, municipal wastewater can also be treated using FlexBio technology. We offer compact container systems with SBR and MBR processes that achieve outstanding purification performance and even enable water reuse.

No, preliminary tests are not always necessary. In many cases, a standardized analysis is sufficient to design the right solution. However, for more complex wastewater, laboratory or pilot tests can be useful to determine the optimal plant size and operating parameters.

The energy yield depends on the organic load of your wastewater. On average, 1 kg of COD produces about 0.35 m³ of methane, equivalent to roughly 3.5 kWh of primary energy. This allows you to significantly reduce wastewater treatment costs while generating valuable on-site energy.

No, purchasing is not the only option. FlexBio also offers flexible financing and leasing models as well as operator models. This allows you to use the system without major upfront investment and pay only for the treated wastewater or the achieved performance.

Yes, FlexBio systems are also suitable for isolated or stand-alone applications. Thanks to their compact container design, they operate autonomously, require minimal space, and provide both clean water and usable energy. The treated water can additionally be reused for landscape or green area irrigation.

In principle, it is more effective to digest wastewater and solid substrates separately, as each process can then be optimized for its specific material stream. However, biogas storage, purification, and utilization can be combined—allowing you to leverage synergies, reduce investment costs, and increase overall efficiency.

Our compact biogas plants efficiently process liquid substrates such as production wastewater and slurry, as well as solid residues like food waste, distillery slop, peel residues, or other organic by-products from industrial and commercial operations.

The systems are modular and available in various sizes – from smaller units for individual production lines to large-scale plant networks for industrial wastewater. This modular concept allows capacities to be flexibly expanded as needed.

Depending on the organic content of the wastewater or waste material, methane-rich biogas is produced, which can be used for on-site electricity and heat generation. Typical outputs reach several hundred thousand kWh per year—often exceeding the company’s own energy demand. For an initial assessment of your potential, feel free to use our Project Calculator!

They are quick to install (Plug & Play), transportable, modularly expandable, and require minimal space. In addition, they can be easily integrated into existing infrastructure.

Yes, the generated biogas can be integrated into CHP units, boiler systems, or used directly. When utilized in a CHP unit, the system can operate as a stand-alone solution, enabling complete energy self-sufficiency. Biogas can also be upgraded to biomethane, allowing injection into the natural gas grid.

The internal energy demand is very low, as the biological process operates efficiently. Typically, it amounts to only 5–10% of the energy produced, leaving the majority available for operational use.

No, the systems are fully enclosed and low in emissions. Additionally, exhaust air treatment with biofilters or adsorbers can be integrated, ensuring that no unpleasant odors are released.

No, the systems are largely automated and can be remotely monitored. Your staff will receive a brief training session, while regular maintenance is carried out by FlexBio.

Depending on the plant size, building and environmental permits may be required. FlexBio supports you in preparing all necessary documentation and regulatory approvals.

Thanks to savings on disposal costs and on-site energy utilization, the payback period is typically between 3 and 6 years—depending on substrate quantity and energy recovery. For an initial assessment of your project’s potential and expected payback time, feel free to use our Project Calculator!

In general, it is more effective to digest wastewater and solid substrates separately, as each process can be optimized for its specific material stream. However, biogas storage, purification, and utilization can be combined—allowing you to leverage synergies, reduce investment costs, and increase overall efficiency.

The power consumption is very low. While conventional aerobic systems require about 0.7–1.0 kWh per kg COD, FlexBio systems consume only 0.07–0.1 kWh per kg COD—approximately 90% less energy.

Yes, a connection to the plant’s existing piping system is required. However, the containerized systems are designed according to the Plug & Play principle, making the integration of inlet and outlet lines quick and straightforward. Supply lines for heating and electricity, as well as water inlet and discharge pipes—and, if applicable, a biogas line—need to be connected to the container.

FlexBio systems can handle a wide range of COD concentrations—from lightly loaded municipal wastewater to highly organic industrial effluents. Reductions of more than 90% COD are achievable.

In addition to COD, FlexBio systems reliably reduce nitrogen and phosphorus compounds, fats, suspended solids, and microorganisms—depending on the process, even achieving nearly germ-free water. The pH value is also consistently stabilized within the neutral range.

Yes, FlexBio systems ensure a consistently high effluent quality suitable for discharge. By combining anaerobic treatment with SBR or MBR technology, even the most stringent discharge limits are reliably met.

No problem – FlexBio systems are modular. Multiple containers can be easily combined, allowing the treatment capacity to grow flexibly with your wastewater volume.

Yes, FlexBio container systems also require maintenance—but the effort is minimal. Thanks to automated control, robust technology, and remote monitoring, maintenance is usually limited to routine inspections and a few service visits per year.

No, operating a FlexBio system does not require special training. The systems are highly automated, easy to operate, and do not require additional specialist staff—your existing employees can manage operation after a brief introduction.

No, the container cannot be placed directly on grass. For safe and stable operation, a solid, level, and load-bearing surface (e.g., a concrete slab) is required for installation and connection to the piping system. We recommend a strip foundation, concrete slab, or prefabricated foundation elements.

FlexBio systems are delivered in standardized ISO containers. Some modules are oversized but still built in container form and road-transportable. The containers are robust, easy to transport, and typically supplied in RAL 5010 (blue) – however, other colors can be provided upon request to match customer preferences.

We handle the permitting process together with you. FlexBio provides all required documentation and supports you in submitting the necessary applications. If a building permit is needed, we work closely with your authorized architect or engineer. All structural verifications and stability calculations for our modules are, of course, included in the delivery scope.

Yes, even large wastewater volumes can be treated with FlexBio systems. Thanks to the modular concept, multiple containers can be combined into a high-performance plant network—allowing treatment capacity to grow flexibly with your needs.

No, FlexBio systems are highly reliable and require very little maintenance. Thanks to robust engineering, automated control, and optional remote monitoring, they operate smoothly and without frequent interruptions—maintenance work is predictable and kept to a minimum.

Power consumption depends on the organic load of the wastewater. For example, in a food-processing plant with 3,500 mg/l COD and 90% reduction:

• Anaerobic treatment: approx. 0.22–0.32 kWh per m³ of wastewater
• Aerobic (conventional) treatment: approx. 2.2–3.2 kWh per m³ of wastewater

In other words, with FlexBio technology you need only about one-tenth of the energy required by conventional systems—while additionally recovering biogas as usable energy.

Yes, heat is required to maintain the microorganisms in the optimal temperature range (typically 30–38 °C) for anaerobic wastewater treatment. However, the heat demand is moderate and can usually be fully covered by the biogas generated in the process.

Fats in the wastewater do not directly clog the system, but problematic compounds such as palmitic acids can accumulate and affect the biological process. In practice, these substances are effectively managed through proper pre-treatment, temperature control, and optimized process management. FlexBio systems are specifically designed to reliably treat fat-containing wastewater—without the risk of clogging.

No, fats do not cause the biological process to wash out. The anaerobic biofilm adheres firmly to the carrier material inside the reactor, ensuring stable retention within the system. Even with higher fat content in the wastewater, the biological process remains protected and fully functional.

No, FlexBio systems are completely enclosed and operate under controlled conditions. There is no risk of odor or contamination. All process areas are sealed, and any contact with wastewater or gas is prevented—ensuring safe and hygienic operation at all times.

The investment costs of a FlexBio system are comparable to those of conventional treatment technologies. The key advantages become evident in the significantly lower operating costs—thanks to reduced energy consumption and biogas production. When the generated biogas is utilized, the payback period is often under five years, sometimes even shorter depending on wastewater volume and energy recovery. For potential and ROI evaluation, feel free to use our new Project Calculator!

No, alcohols do not interfere with the treatment process. On the contrary, they are easily degradable by microorganisms and are efficiently converted during the anaerobic process—without any negative impact on the biological system.

FlexBio systems are primarily designed for the removal of organic pollutants. Heavy metals are not biologically degraded but can be effectively removed using additional processes such as precipitation, filtration, or adsorption—these can be integrated into the system as optional modules if required.

Yes, FlexBio systems can remove various types of contaminants. In addition to organic compounds (COD/BOD), nitrogen, phosphorus, fats, suspended solids, microorganisms, and odors are reliably reduced. Depending on your requirements, additional modules can be integrated to treat specific pollutants.

Yes, FlexBio systems can also be adapted for wastewater with low or no organic load. In such cases, physical and chemical treatment stages—such as filtration, flotation, or membrane biological reactor (MBR) —are used instead of anaerobic digestion. These modules can be combined to achieve the required discharge or reuse quality.

In most cases, no additional pre-treatment is required. FlexBio systems already include suitable mechanical or biological pre-treatment depending on the application. However, for wastewater with high levels of solids, fats, or fibers, an upstream screening or separation unit may be recommended to ensure optimal system performance and stability.

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Yes, the FlexBio process can be flexibly integrated into existing infrastructure. There are three installation options:

• New installation: as a complete stand-alone solution.
• Retrofit: existing plant components are replaced and modernized with FlexBio technology.
• Expansion: existing systems are extended with additional FlexBio modules.

This ensures that every solution can be individually tailored to your operational requirements—from modernization to complete new installations.

Because the biological process in the system needs time to stabilize, and meaningful results can only be obtained over an extended period. This allows real load variations, process fluctuations, and the full performance potential to be reliably evaluated.

Yes, the results from the pilot or demonstration plant can be directly scaled up. FlexBio systems are modular and based on identical process technology, meaning the data collected during the test phase can be reliably applied to the design and operation of a full-scale installation.

The integrated buffer (holding) tank should be fed continuously and flow-proportionally (e.g., hourly dosing matching actual throughput) so that inflow fluctuations and load peaks are realistically reproduced. In addition, mechanical pre-treatment, an equalization tank, an adjustable bypass pump, automatic sampling and comprehensive process monitoring (pH, temperature, flow, and—if applicable—gas measurements) ensure practice-oriented and transferable test results.

Depending on wastewater quality and origin, the pilot unit typically treats about 500–4,000 litres per day (0.5–4 m³/day).

No. The pilot unit is set up, monitored and evaluated by FlexBio. It runs fully automated, so your staff do not need to perform any additional operation.

The effort is very low — a visual inspection at regular intervals is sufficient. Only in case of malfunctions or abnormalities is a short intervention necessary; FlexBio takes care of all remaining tasks.

You will receive brief weekly progress reports during the trial phase. After completion, FlexBio provides a comprehensive final report including all results, evaluations, and recommendations for the next steps.

The pilot plant is monitored automatically and via remote access. In addition, regular inspections by our specialists as well as laboratory and online analyses ensure safe and stable operation at all times.

Yes, the test costs apply in all cases. Even if the results are not as expected, expenses and operational costs are incurred on our side. At the same time, you gain valuable insights into the characteristics of your wastewater, which can be highly beneficial for future decisions and alternative treatment approaches.

Yes, the sampling interval can be adjusted flexibly. In the event of significant inflow variations, more frequent sampling is possible to create a more detailed database and achieve even more meaningful results.

In most cases, no building permits are necessary, as the pilot units are mobile and provided on a trailer. If a permit is required in specific cases, we will support you with all necessary coordination and documentation.

No, you do not need to take any special precautions. The pilot plant is fully enclosed and equipped with all relevant safety components, including gas monitoring, pressure protection, and a biogas biofilter (methane oxidation). This ensures that the generated biogas is safely captured and treated at all times.

According to the integrated measurement technology, the following parameters are continuously recorded online:

• Wastewater flow rate (flow meter, volume counter)
• Biogas volume (raw gas)
• Gas composition: CH₄, CO₂, H₂S, O₂
• Gas temperature (for calculation of normalized volume)
• Biogas absolute pressure (for calculation of normalized volume)
• Process temperature (in all treatment stages)
• Oxygen concentration in the aeration stage
• pH value (in all treatment stages)
• Redox potential (in all treatment stages)
• Conductivity (in the inflow)

Sampling is carried out by the operating personnel at clearly marked sampling points. To evaluate plant performance, both online and offline measurements are regularly recorded. Since some parameters cannot be reliably measured online, complementary laboratory analyses are performed. Typical parameters include:

• COD concentration in influent and effluent
• Nitrogen concentration in influent and effluent
• Phosphorus concentration in influent and effluent

Yes, the sample analyses can be performed by any recognized or accredited laboratory. It is important, however, that the laboratory reports are promptly forwarded to FlexBio so that the results can be included in the ongoing evaluation.

The collected samples are sent in prepared, pre-paid shipping envelopes—ideally by Wednesday to ensure they arrive at the laboratory before the weekend. The analysis is then carried out in our in-house laboratory, where the samples are professionally examined and evaluated.

The pilot plant is a multi-stage system combining anaerobic main treatment in a fixed-bed fermenter with a downstream aeration stage including an MBR (membrane bioreactor). This setup effectively reduces the organic load while simultaneously producing methane. The combination is unique, as it integrates all key treatment stages into one compact unit.

The plant can be installed outdoors or in a well-ventilated, partially open hall. The final installation site is determined together with FlexBio to ensure optimal operating conditions.

A solid, level, and load-bearing surface (e.g., concrete slab or asphalt area) is required to ensure safe and stable operation.

The mobile demonstration unit should be placed close to the wastewater source (max. 30 m) and have an outlet for the treated water (max. 20 m). A power supply of 400 V, 3-phase, 32 A CEE plug (without residual-current device, max. 20 m distance) is also required. In addition, a minimum area of 9 m × 4 m and sufficient maneuvering space for the trailer must be provided.

The inflow is usually connected via an on-site pressure line (max. 1 bar) with a 1-inch male thread and a ball or gate valve. The demonstration unit automatically fills its internal buffer tank through its own control valve.
Alternatively, the wastewater can be supplied from an external tank or pump pit using the provided hose. A submersible pump (included in the accessories) can also be integrated and directly controlled by the system.