0800 118 2500 Wastewater Recycling Centre Reduces Operating Costs with Toro PC Pump
Lower running costs. Fewer interventions. Fast payback.
Project Overview
This wastewater recycling centre (WRC) switched from a rotary lobe pump to a high efficiency Toro progressive cavity pump, with a notable energy consumption and maintenance reductions
By replacing a costly rotary lobe pump with a highly efficient progressive cavity pump, this WRC significantly reduced their energy consumption and maintenance demands.
The upgrade delivered around £35k in annual savings and achieved a return on investment in just over six months.
Challenge
An existing rotary lobe pump was costly to operate and maintain, putting pressure on AMP8 financial and carbon targets. Recorded running current was approximately 50 A, and the pump required around six maintenance interventions each year. With each intervention averaging at £5,000, maintenance alone represented a substantial recurring cost, alongside the excessive electricity consumption of the pump.
The objective was not simply to replace equipment like-for-like but to reduce whole-life operating cost while increasing reliability across the required pumping duty.
They sought a partner who could help them assess the true cost of ownership, operational risk and resilience gains, rather than just the initial Capex.
Solution
To deliver long-term reliability and do what was best for the customer, Atlantic Pumps assessed the actual measured current, operating hours, energy cost and maintenance frequency.
The comparison highlighted that a Toro T-series progressive cavity pump would run at just 19A on a 415 V, three-phase supply, compared to the 50A drawn by the rotary lobe. Operating 10 hours a day, this translates to a reduction in electrical input from 30.6 kW down to 11.6 kW.
Crucially, the recommended pump’s design is inherently suited to demanding applications like those found at this, and many other, wastewater and sludge treatment works.
Based on an expected intervention rate of one scheduled maintenance a year, the case for replacing the rotary lobe pump with the Toro progressive cavity pump was clear.
Estimated annual operating cost*
| Cost measure | Rotary lobe pump | PC pump |
| Running current (reported) | 50 A | 19 A |
| Estimated electrical input | 30.6 kW | 11.6 kW |
| Annual electricity cost | £16,725 | £6,356 |
| Annual maintenance cost | £30,000 | £5,000 |
| Total annual operating cost | £46,725 | £11,356 |
*Based on a power efficiency factor of 0.85, 10 hours per day, electricity priced at £0.15/kWh.
Return on investment
| Annual electricity saving | Approximately £10,370 |
| Annual maintenance saving | £25,000 |
| Total estimated annual saving | Approximately £35,370 |
| PC pump capital cost | £18,000 |
| Simple payback | 0.51 years — approximately 6.1 months |
Results
Downtime reduction, longer wear-life, timesaving simplicity and a 60% energy saving
In the first six months of operation, the site has seen the reduction of maintenance and zero unplanned downtime.
Furthermore, the new pump’s energy efficiency is remaining stable, showing a low wear rate and smooth operation.
Coupled together, the investment looks to have nearly paid for itself already. Subject to verification of the final trial results, this type of pump could support carbon reduction, treatment outcomes, and TOTEX wins in similar applications on other wastewater treatment and water recycling sites.
Found this article useful?
To discuss solutions for your wastewater treatment pumps, contact Martin Gillman at [email protected], or your ccount manager at Atlantic Pumps.
