Technidrive delivers bespoke aerator drive upgrade for wastewater treatment plant

A major wastewater treatment operator has modernised ageing aeration equipment with a bespoke drive system engineered by Technidrive - helping to maintain operational reliability while minimising installation downtime and environmental risk.
The project involved replacing 12 aerator drive assemblies that had been in continuous service for more than 25 years and were approaching the end of their operational life. Because the original drive units were obsolete and could no longer be sourced, a tailored replacement solution was required that would integrate with existing tanks, aerator paddles and mounting arrangements without extensive modifications.
Aeration is a critical process in wastewater treatment, introducing oxygen into treatment tanks and supporting the biological processes needed to treat sewage effectively. As a result, equipment reliability is essential, with aerators often operating around the clock in challenging outdoor environments.
Following a series of detailed site surveys, Technidrive developed a complete drive package combining WEG motors with Bonfiglioli heavy-duty parallel helical gearboxes. The gearboxes were selected to withstand the significant axial and radial loads generated by the aerators while providing the long service life demanded by the water industry. Additional environmental safeguards included a dry-well gearbox arrangement, integrated oil pumps and food-grade lubricants to reduce the risk and impact of any potential leakage.
A key objective was ensuring the new assemblies matched the footprint of the original equipment. Technidrive reverse-engineered the existing installations and supplied fully assembled replacement units that could be lifted into position and connected within hours, significantly reducing disruption to treatment operations. The upgrade programme was completed in three phases, replacing four aerators at a time and avoiding the need for a full site shutdown.
Designed for a service life of at least 20 years, the project demonstrates how careful systems engineering can help water utilities modernise critical infrastructure, improve reliability and extend asset life while maintaining continuous wastewater treatment operation.