Integrated Engineers Inc.

The Vision
Integrated Engineers, Inc was established in 1994 by David Wensloff, P. E. based on his vision that environmental compliance should be effective, simple and affordable for industries.

To achieve his vision David invented the Floccin line of wastewater flocculants for superior liquid solid separation. Combine that with custom designed, engineered and built wastewater equipment along with his unique holistic wastewater optimization process and his vision was complete.

The rest is history as they say. Integrated Engineers has established a reputation for wastewater solutions that work, millions of dollars saved for industry, millions of gallons of increased wastewater processing capacity for a long list of satisfied customers.

The Approach
Integrated Engineers' approach to water & wastewater systems is unique in that your entire wastewater process is evaluated. A comprehensive evaluation of your system is performed including engineering aspects, equipment and chemistry. You can even pilot test your system before committing to full scale implementation.
The Process

You get the expertise of a broad network of experienced wastewater professionals, equipment manufacturers, and chemical suppliers, which we utilize to provide you with state of the art, cost effective wastewater treatment solutions that work.

The wastewater optimization process involves exhaustively studying your current wastewater system or proposed system in a series of stpes, including looking at processes occurring before your wastewater system is utilized. In this way weak steps or links are identified and optimized. This process is called wastewater optimization.

Wastewater Engineering, Wastewater Design, Wastewater Equipment & Wastewater Chemicals

Integrated Engineers, Inc was established by David Wensloff, P.E., in 1994 based upon his vision, that environmental compliance should be effective, simple and affordable for industries.

We are proud to offer you our staff of experienced professionals in engineering consulting, wastewater system training, system design, equipment manufacturing, turn key systems, installation, permitting, and wastewater treatment chemicals, which we provide with competitive rates that work best with your budgetary needs.

Wastewater Treatment Expertise That Sets Us Apart From The Competition

Integrated Engineers' approach to your wastewater system is unique in that your entire wastewater process is evaluated. Your comprehensive wastewater treatment system evaluation  includes engineering aspects, equipment and chemistry providing you with a complete system solution.

Your wastewater problems are solved by understanding your budgetary needs, evaluating your system, and providing you with a solution that has the best long term environmental advantages at a reasonable price.

Integrated Engineers applies a comprehensive analysis to your complete system, its operation and costs. Our evaluations include: existing equipment analysis, chemical usage and costs, maintenance, compliance, and ease of plant operations. We consider every aspect of your system from your operator's viewpoint all the way through your management considerations and legal compliance.

It is crucial to take the time to fully understand your needs for the short and long term including growth and changes in your internal processes. By keeping up to date with the ever-changing environmental regulations, we offer wide spectrum solutions knowing that any change internal to a facility can potentially impact the future environmental liability to you. Knowing this, we evaluate solutions for you based on capital and operating costs in conjunction with your expected growth, future plans and pending environmental regulations.

Our Areas of Wastewater Expertise

• Flocculating Agents
• Process Optimization
• Design and Build Turn Key Wastewater Systems
• Reduction in Effluent BOD/FOG/TDS/EC levels
• Environmental Regulatory Compliance
• Permitting with local Regulatory Agencies
• Engineering Consulting
• Equipment
• pH Controls Systems
• Installations
• Training on Wastewater Operations

 Industrial Wastewater Treatment

From Oil Refineries to Paper & Pulp Mills Integrated Engineers can significantly cut your industrial wastewater treatment operating costs, improve environmental compliance and increase throughput of your treatment system.

Enjoy reduced overhead and higher efficiencies

You can save big in flocculation and coagulation with our factory direct custom flocculating agents (Floccin™) and custom wastewater treatment equipment for your industrial wastewater treatment.

Your savings start after Integrated Engineers' evaluates your current wastewater treatment plant and/or wastewater treatment goals.

Floccin™ The Ultimate Flocculation Product

The flagship of our wastewater treatment chemicals, with a large inventory and extensive blends to find the best match for treating your water.  If one of our blends does not perform to your satisfaction we can custom blend a Floccin product to meet your treatment requirements. We also carry a long line of polymers, metal grabbers and deorderizers in addition to our superior flocculation products. Our Floccin™ line can provide you with greater efficiencies in treatment, faster throughput and thus money savings on your industrial wastewater treatment.

Floccin™ has proven to REDUCE OVERHEAD COSTS by reducing several processes and wastewater chemicals for our customers by reducing the chemical usage down to one easy chemical addition. Our Floccin™ is non-hazardous which eliminates hazardous chemical handling and hazmat storage/ containment fees.

Another cost saving feature about our Floccin™ is that once it has encapsulated the solids and is dewatered most waters can be collected for re-use and recycled back into the processing stage of the factory. The sludge from using Floccin™ can typically be disposed of in a regular landfill passing the TCP/LP paint test cutting costs further. Precious and other metals can also be reclaimed from the flocculant.

These features of our Floccin™ are helpful to achieve wastewater optimization.

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Floccin vs. Conventional Chemistry

1.       Reduced Surcharges:  The Floccin removes BOD, TSS and FOG (Biochemical Oxygen Demand, Total Suspended Solids, Fats/Oils/Greases) to lower levels, thereby reducing the surcharges paid to the POTW.  This is usually sufficient to explian the chemical costs of the Floccin compared to its competitors, but consider all of the value added savings outlined herein.

2.       Less Quantities of Chemicals used onsite:  Usually the Floccin alone is all that is needed versus 3-4 different products (acid/caustic/coagulant/polymer/Diatomaceous earth).  Wastewater chemical companies need to sell chemicals and we often find that you are using more chemicals or volumes than you need to be for their profit margins.

3.       No Diatomaceous Earth: Most of the time DE (Diatomaceous Earth) is not needed as a Filter press pre-coat when you use the Floccin Products.  Usually a Filter press will require 1-2 (50) lb. bags of DE as a pre-coat to decrease the sticking of the sludge to the plates.  Note, for every pound of DE used, it generates 3 pounds of sludge.  DE costs about $18/bag and account for the cost of DE sludge disposal as about 10-20% by volume is DE which is eliminated if you use the Floccin.  Some facilities have filter cloths that are tighter weave and need the DE even with the Floccin.  You will still be able to reduce the DE by 50%, so there is still a quantifiable savings here.  What is your sludge disposal costs and what part is from the DE as this can be reduced?

4.      No Drum Disposal:  Every drum has a $45 deposit that is not returned to you and is used as the fee for drum disposal (either disposed by recycling or washed and reused by the chemical supplier).  Account for this!  Example, your facility uses 5-6 drums/month of chemical = 6X$45=$270/month in drum disposal costs.

5.       No Drum/Tote Storage:  Full and empty drums must be stored in a secondary contained area.  This means that these chemicals must be stored inside a bermed storage area in case of leakage or spills as they are hazardous.  Empty drums and totes need to be stored until they are picked up by the chemical supply company.  Does our facility have storage issues or limitations?  What does secondary storage and handling cost you?

6.       Hazardous Chemicals:  The Floccin is nonhazardous, alum, ferric, acid (pH lower than 5.0), and caustic (pH over 10) are all hazardous to the employees.  Your facility must pay extra for workman’s Compensation and accident/injury insurances for having hazardous chemical handling onsite.  What is this costing your facility?

7.       Sludge Production:  The Floccin generates less sludge and dewaters to a drier dewatered cake.  This means there is less sludge disposal cost.  So your facility generates less tons/month.  Sludge cost is based on weight and volume.  If the sludge is drier, you are paying less for disposing of water that is in the sludge and more for % solids in the sludge.  The cost for sludge disposal is in the tipping fee (cost of dumping) and freight costs.  Typical tipping fee for a 20 yard roll off box is $900 and freight to a landfill 100 miles away is $300. What is this value?

8.       Sludge Reclassification:  The Floccin sludge will pass the STLC/TCLP EPA tests thereby not releasing toxins in a landfill.  Your facility can reclassify your sludge disposal from hazardous to nonhazardous but regulated.  This must be verified with analytical tests and fully documented at each facility.  Result:  Reduced cost and elimination of long term environmental liability for landfill leachate and future environmental cleanup as every disposer of sludges into landfills are documented in their manifests (paperwork designating the facility as the hazardous sludge generator).  What does this save the you?  Typically around $3,000-$5,000/20 yard  roll-off box.

9.       Labor Savings:  The Floccin saves labor.  How?  Less chemicals and feed equipment to maintain, no drum handling, no pre-coat of the Filter Press (the DE precoat procedure is to pour 1-2 bags into a hopper, add and mix water, run Filter press pump for 45 minutes to pre-coat the press) then switch to load the Filter Press.  The Floccin releases easily from a Filter Press therefore, reduction in filter press plate pressure washing which takes about 4 hours/wash. Employees can be freed up to perform others tasks in the facility.

10.       Water Reuse:  Many times, a facility can reuse their wastewater.  Why, because the Floccin does not contribute to the Total Dissolved Solids (TDS) and Conductivity as compared to conventional chemistry.  Some facilities can become zero discharge, what does this mean?  You can eliminate any wastewater sewer charges, sampling and environmental compliance with the local POTW.  In essence become a 'closed loop' system.

11.       Increase System Capacity: The Floccin makes a larger floc that settles faster or floats quicker than conventional chemistry.  Many facilities limit their production as they cannot exceed their environmental discharge limits without paying significant surcharges or fines.  Is the wastewater system limiting the facilities capacity to increase production?  Using the Floccin increases the system hydraulic capacity at no capital cost.  What is this worth?  Look at labor and electrical savings.

12.       Electrical Savings:  If the system can increase hydraulic or biological capacity, what is the savings in electricity?  For example, if a plant can run the same daily water in 25% less operating hours, what power savings are recognized?  What are your electrical cost in $/kw-hr?

13.     Shear Strength:  The Floccin sludge has a higher shear strength that allows sludge pumping and dewatering without the addition of polymers to rebuild the floc.  The Filtrate from dewatering has lower suspended solids (solids carry thru) thereby reducing the load to the wastewater system by having to retreat these solids for removal before discharge.  This means that the filtrate from a Filter Press, Belt Press or Centrifuge can be discharged directly or if the system is designed to return the filtrate to retreat, it will require less chemistry to separate in your process.  What is this value?

14.       Recover Oil:  The Floccin has a high affinity for removing oil (FOG, TOG, TPH) from wastewater.  Once removed, it is adsorbed into the Floc sludge.  The oil can be recovered if it is heated to 150 degrees and dewatered in a 3 phase centrifuge (water, oil, solids).  Recovered oil can be sold as it has value for refiners, biodiesel and other commodity applications.

15.       Recover Precious Metals:  The Floccin removes metals from wastewater, all metals.  If the industry has precious metals (Gold, platinum, silver, etc.) these can be removed and the sludge generated that holds these metals, smeltered and full recovery of these metals.  What can this save you?

16.      Metals Removal:  The Floccin can reduce the metals to below levels that conventional chemistry cannot achieve.  What is this worth?  It allows the plant to run its system at a higher flow and increase facility production with no capital costs.  Follow the Metals Removal Jar testing Procedure.

In conclusion, the Floccin products have a high performance in all phases of wastewater treatment and is beneficial to environmental safety and economic standards.

Call us today! (877) 965-1577

Integrated Engineers provides you with wastewater treatment systems that includes the capability to design and manufacture specialized custom equipment to meet your specific needs.

Each step of your wastewater treatment system process is evaluated to find the weak links and correct them.

The treatment of all wastewater follows the basic steps shown below.

The initial step is pH adjustment (if needed) to the desired set point. The wastewater is then mixed with our FloccinAgents™ prior to the liquid solids separation process (clarifier, DAF, Screen, or other).

If the water is high in soluble organics then usually a Biological process is used with or without prior liquid/solid separation. Final treatment is sludge dewatering with a dewatering table, Plate and Frame Press, Belt Press or Centrifuge.

Each of these steps has the potential for improvement, and that potential is different for all different industries.

Having a wastewater design, engineering, manufacturing and install company on your team is a critical component of your wastewater treatment success.

Current Conditions:

A food processing facility has a DAF with a daily flow of 200,000 gal/day or 208 gpm for 16 hours.  They use (8) 275 gallon totes  of alum, 4 drums of caustic,  3 totes of polymer and generate (8) 20 yard roll off boxes of dewatered sludge.  They use 8 pallets of (50) 40 lb. bags of DE/month.  The operators work 3 shifts and spend all day mixing polymer, changing drums, running the filter press, blowing down settled solids, etc.  Surcharges are $0.30/lb. for BOD and TSS.  The effluent has a BOD of 2,500 ppm and a TSS of 700 ppm.  The sludge is dewatered with a plate and frame press and conveyed to the roll off boxes.  Tipping Fees at the landfill for the sludge are $900/20 yard roll off box plus $400 in freight.  The system requires a total of 100 hp to run and the utility rate is $0.16/kw-hr.

 Current Considerations:

After a thorough site evaluation and jar tests and before running the trial, a sales person using the above listed value added steps makes an educated estimation of the current costs:

 Consider:  reduced surcharges, sludge volume, # chemicals, hazardous chemicals, less chemicals = less labor, system hydraulic capacity, electricity, dewatering, sludge dryness, drum disposal costs

Do Not Consider:  Since it is a food plant - Water Reuse, Metals removal, Sludge reclassification

Floccin Trial Results:

Using the Floccin 1105, the usage rate was determined to be 500 lbs/day.  During the trail, it was tested and confirmed that the DAF could run at 275 gpm due to good floc formation and the resulting effluent BOD was 900 ppm and the TSS was 60 ppm.  It was noticed that the sludge generated was reduced to an estimated 5 20 yard roll off boxes/month and it was drier and no DE was used.  Since the operator did not have to attend to the DE pre-coat, chemical tote/drum changes, they were able to unload and load trucks with the forklift as well as other tasks.

Whether your wastewater treatment solution requires pH adjustment, ozonation, ozonators, dissolved air flotation, aerators, clarifiers, rotary screens, plate and frame presses, sludge dewatering, sludge drying, specialized wastewater chemicals or a complete packaged plant we can provide you with the wastewater treatment chemicals and equipment you need for your industrial and municipal wastewater treatment success.

Though we focus primarily on industrial waste water treatment we have the capability and experience to provide you with biological municipal type wastewater treatment expertise and problem solving as well.

Integrated Engineers Inc manufactures much of your equipment right in our own plant giving you the further advantage of true design, build, install and save solutions to your wastewater treatment and/or compliance problems.

Wastewater Flocculants & Chemicals

• FloccinAgents™ Flocculating Agents
• Flocculation and Coagulation
• Metal Precipitates
• Microbes
• Enzymes
• Anti-foaming Agents
• De-foaming Agents

Wastewater Equipment

• Customized Equipment
• Packaged Biological Systems (BioReactors)
• Clarifiers
• Screens
• Plate Presses
• Aerators
• Custom Control Panels
• Chemical Feed Systems
• Tanks/Pump/Controls
• Flow Meters/pH Controllers

Wastewater Engineering

• Licensed Engineers
• Licensed Contractors
• System Evaluation
• Process Engineering
• Plant Construction
• Control Specialists