News & Updates

Turning high-strength wastewater into energy

In 2026, industrial wastewater treatment is shifting from pure pollutant removal toward energy and resource recovery. This is especially true in the food and beverage industry – the largest field of application: the higher the COD, the more valuable the wastewater. Anaerobic processes are growing faster than average because they generate biogas and produce significantly less sludge than aerobic aeration. At the same time, the pressure toward water reuse – right up to zero-liquid discharge – is increasing.

A guideline for planners: from around 2,000 mg/l COD, anaerobic pre-treatment becomes worthwhile in energy terms – roughly 0.35 m³ of methane (about 3.5 kWh) is produced per kilogram of COD. In the core industries the values are far higher: slaughterhouse wastewater around 6,000 mg/l, whey 50,000–70,000 mg/l, and wastewater from wine and sparkling-wine production at around 12,000 mg/l COD – a strong energy potential. Each of these figures is less a disposal problem than an energy opportunity. Other sectors – such as delicatessen producers, confectionery and baked goods manufacturers, agriculture and biowaste – offer enormous potential too.

The economic leverage is twofold: disposal and wastewater costs fall, while electricity and heat from the CHP unit are used directly on site. The project calculator shows in just a few minutes how much potential lies in your own wastewater stream.

With the mobile FlexBio demonstration unit, we bring state-of-the-art wastewater technology directly to the customer. Anaerobic pretreatment combined with aerobic post-treatment and a membrane bioreactor (MBR) – fully integrated into a passenger car trailer, including complete measurement, control, and data acquisition technology.

Unknown or challenging wastewaters can be tested directly on site. Customers experience the treatment performance of FlexBio technology live: reduction of COD, nitrogen and phosphorus, pH stabilization, and process stability, all measurable in real time. The system is operational within one day and requires no special infrastructure. All process data are automatically recorded, transmitted, and analyzed. The result is a well-founded report with clear recommendations for the optimal treatment solution.

Put Us to the Test

• Fully mobile pilot plant integrated in a passenger car trailer
• No special infrastructure required
• Connected and fully operational within one day
• On-site testing directly with the customer’s original wastewater
• High treatment performance (COD, nitrogen, phosphorus, pH control)
• Live monitoring of treatment efficiency and energy production (biomethane/biogas)
• Automatic data acquisition, transmission, and evaluation
• Flexible test duration depending on wastewater characteristics and objectives (recommended 2–4 months)
• Professional final report with results and concrete recommendations for action
• Minimized investment risk prior to full-scale plant implementation
• Early identification of potentials and technical limitations
• Sound decision-making basis instead of laboratory or theoretical data

How much energy is hidden in your wastewater or organic residues?
With the new FlexBio Project Calculator, you can find out in just a few seconds!

Our interactive online tool gives you an instant overview of:

• the energy potential in your wastewater, substrates, or organic waste,
• the cost savings you can achieve in disposal and energy expenses, and
• the return on investment (ROI) you could reach with a FlexBio system.

Using it is simple: just enter a few key parameters about your operation, and you’ll receive an initial, personalized assessment of how your residual materials can be turned into sustainable energy sources.

Whether you’re in food production, the beverage industry, agriculture, or another sector – the Project Calculator shows how FlexBio’s innovative wastewater and biogas technologies can help you protect the environment and climate while significantly reducing operating costs.

FlexBio Project Calculator – your first step toward greater efficiency, energy, and sustainability.

At FlexBio, we are continuously committed to meeting the needs of our customers in the best possible way. We are therefore pleased to introduce a new area within our portfolio: contract manufacturing of plastic tanks and systems.

As experts in plastic, steel, and plant engineering, we offer a wide range of customized applications for various industries. From order processing and production to assembly and commissioning, we accompany our customers every step of the way.

With innovative ideas at fair prices, we deliver everything from simple tanks to complex system solutions – always with the proven FlexBio quality and precision.

Experience our innovative anaerobic wastewater treatment plant in motion! Our new animation film vividly illustrates the entire process – from inflow to purified effluent, including biogas generation, treatment, and conversion into electricity and heat. The film showcases all key components and modules of the system and highlights the expandability and modularity of our container-based design. In an engaging and visually clear way, it demonstrates how FlexBio turns wastewater into valuable energy. A fascinating journey through the world of sustainable wastewater treatment – made by FlexBio.