High-Efficiency Aeration and Mixing for Wastewater Treatment
Now part of the EDI product portfolio, AiroFlo™ Floating Brush Rotors deliver a proven, energy-efficient solution for aeration and mixing in municipal and industrial wastewater applications. Backed by more than 35 years of field performance, AiroFlo rotors combine innovative engineering with EDI’s global support, process expertise, and service network to help facilities improve treatment performance while reducing operating costs.
Designed for oxidation ditches, lagoons, equalization basins, digesters, sludge holding tanks, and retrofit projects, AiroFlo rotors provide both powerful mixing and high oxygen transfer in a single package.
The proprietary curved-tip C-Cup™ blade design creates exceptional subsurface oxygen transfer while minimizing spray, mist, and power consumption. Facilities routinely achieve equivalent or improved treatment performance with 30% to 60% less installed horsepower compared to conventional fixed-position rotors and vertical aerators.
Unlike the “Fixed-Brush-Rotors”, the AiroFlo rotors operate on a floating platform that automatically adjusts to changing water levels, maintaining optimal rotor submergence and performance. This “floating sweet spot” design ensures consistent oxygen transfer and mixing efficiency across a wide range of operating conditions.
Available in sizes from 5 to 30 horsepower, AiroFlo Floating Brush Rotors are engineered for long-term reliability with features such as a proprietary Flex Drive™ gearbox assembly, wastewater-lubricated bearing technology, and maintenance-friendly access systems. The result is a robust, low-maintenance aeration solution that simplifies operation while lowering lifecycle costs.
Whether upgrading aging aeration equipment, increasing oxygen capacity, or designing a new treatment process, AiroFlo Floating Brush Rotors provide wastewater professionals with a flexible and proven solution for reliable aeration and mixing performance.
The AiroFlo™ 1600 Series Floating Brush Rotor (FBR) is engineered for municipal and industrial wastewater treatment applications, the 1600 Series delivers both high oxygen transfer and powerful basin mixing while requiring significantly less installed horsepower than conventional aeration technologies. Facilities have reported energy savings of 30% to 60%, helping reduce total operating costs without sacrificing treatment performance.
Key Benefits
- Proven energy savings of 30% to 60%
- Higher oxygen transfer and mixing efficiency with less horsepower
- Consistent performance across varying water levels
- Predictable, low-maintenance operation
- Rugged construction for long service life
- Fast, straightforward installation and startup
- Supported by EDI’s global wastewater expertise and service network
Innovative In-Line Flex Drive™ Technology
At the heart of the 1600 Series is the proprietary In-Line Flex Drive™ system, engineered to improve reliability and reduce maintenance requirements.
Key features include:
- A unique swing-plate gear mount that allows tri-axial movement and minimizes critical alignment issues
- Elastomeric coupling technology that absorbs shock and vibration
- A floating shaft seal design that helps prevent wastewater migration along the shaft and into the gear reducer
- Simplified drive train maintenance and improved equipment longevity
The result is a more forgiving and reliable drivetrain that performs in demanding wastewater environments while reducing wear on key components.
Designed for Maintenance Predictability
The 1600 Series was engineered with a focus on simplifying operation and minimizing maintenance.
Protective Shield System
A comprehensive shield design helps protect the motor and gearbox from splash and surge conditions generated by the rotor while providing easy access for routine inspections and maintenance activities.
Maintenance-Free Bearing Technology
The 1600 Series utilizes AiroFlo’s proven bearing design to eliminate routine greasing requirements and reduce maintenance labor.
Benefits include:
- Years of dependable operation
- No grease points to maintain
- Reduced maintenance costs
- Improved operational reliability
An advanced floating brush rotor platform designed for facilities facing challenging operating conditions, higher solids accumulation, cold-weather operation, or applications requiring enhanced splash and debris management.
Key Benefits
- Proven energy savings of 30% to 60%
- High oxygen transfer efficiency with lower installed horsepower
- Enhanced mixing performance for improved process stability
- Floating design automatically adapts to changing water levels
- Predictable maintenance requirements and reduced downtime
- Corrosion-resistant construction for long service life
- Backed by EDI’s wastewater treatment expertise and service network
In-Line Flex Drive™ System
The 2200 Series features AiroFlo’s proprietary In-Line Flex Drive™ technology, developed to improve drive train reliability and reduce maintenance requirements.
This innovative drive configuration helps facilities achieve consistent performance while reducing wear on critical mechanical components.
Key features include:
- Swing-plate gear mounting system that accommodates tri-axial movement and minimizes alignment-related stresses
- Elastomeric coupling that absorbs shock loads and vibration
- Floating shaft seal technology designed to prevent wastewater migration along the shaft to the gear reducer
- Improved equipment protection and longer drive component life
Advanced Shielding Solutions
The 2200 Series adds enhanced protection features for more challenging applications.
The 2200 Series incorporates multiple shielding configurations designed to protect equipment, reduce maintenance requirements, and improve long-term performance in challenging wastewater environments.
Extended Vertical Shield (EVS): Helps reduce the accumulation of solids around the drive end of the rotor assembly, improving operational reliability and reducing maintenance demands.
Double Extended Vertical Shields (DEVS): Extends protection to both the drive end and tail end of the rotor, helping minimize solids buildup throughout the system.
Splash Containment Shield (SCS): For facilities operating in colder climates or applications prone to excessive splash, the Splash Containment Shield (SCS) helps prevent winter freeze-up conditions while reducing solids accumulation around the aerator.
Together, these shielding options provide outstanding protection for the motor and gearbox while enhancing operational efficiency and maintenance predictability.
Maintenance-Free Bearing Technology
The AiroFlo 2200 Series utilizes proven UHMW bearing technology designed to eliminate many of the maintenance challenges associated with conventional bearing systems.
Benefits include:
- Years of maintenance-free operation
- No routine greasing requirements
- Visual wear indicators for simplified inspections
- Reduced risk of catastrophic bearing failure
- Lower maintenance costs and greater operational reliability
Built for Tough Wastewater Treatment Environments
Whether installed in oxidation ditches, aeration basins, lagoons, industrial treatment processes, or rehabilitation projects, the AiroFlo 2200 Series provides reliable aeration and mixing performance while helping operators reduce energy consumption and maintenance costs.
Its floating platform maintains optimal operating submergence across varying water levels, ensuring consistent oxygen transfer and process performance without the limitations of fixed-position aerators.
Optimize Aeration Performance with EDI
Contact EDI to discuss your application requirements, request equipment sizing assistance, or learn how the AiroFlo 2200 Series Floating Brush Rotor can improve treatment efficiency, increase process reliability, and reduce lifecycle costs at your facility.