Set clear objectives
Decide what the pilot must prove: sustainable flux at a given temperature, effluent quality against a permit or reuse standard, cleaning frequency and chemistry, or behavior under shock loads. Each objective needs a measurement plan and a decision rule agreed at the start.
Duration and data
Most pilots run long enough to see at least one seasonal temperature change or several production cycles. Log flux, TMP, temperature, MLSS, DO and cleaning events continuously, and sample effluent on a schedule. Capture upsets too; they show how the full plant will behave.
Zyramic pilot support
We rent modules for US pilots, including Swing, Palisade and ceramic options, and help interpret the data. For temporary full-scale capacity rather than testing, see MBR rental.
Worked sizing example
Take a 2,642 gpd (10 m³/day) industrial pilot:
| Item | US | Metric | Note |
|---|---|---|---|
| Average flow | 2,642 gpd | 10 m³/day | about 2 gpm (417 L/h) |
| Design flux (gross) | 8.8 gfd | 15 LMH | Zyramic design guidance |
| Derate for relaxation and cleaning | ~20% | ~20% | |
| Net flux | ~7.1 gfd | ~12 LMH | |
| Membrane area needed | ~374 ft² | ~35 m² | average flow ÷ net flux |
| Swing-8 cartridges | ~3 | ~3 | 135 ft² (12.5 m²) each |
| Peak factor | ~1.2 | ~1.2 | |
| Peak flow | ~3,170 gpd | ~12 m³/day | extra area, short-term higher flux, or equalization |
This is an illustration only; a real design also checks temperature, MLSS, redundancy and the cleaning schedule.
Tips for a smooth project
- Compare modules on lifecycle, not area alone
- Plan how replacement parts will be sourced later
- Allow room for handling and inspection
- Check cassette dimensions before ordering replacements
Next step
A good way to see which design choices matter most for your plant is to look at your own maintenance history. Tell us what has needed attention in the past, and we will explain which of our options fits it best.
Sizing considerations
To give a useful recommendation we usually need:
- Pilot objectives and success criteria
- Feed characteristics and variability
- Site utilities and space
- Duration
- Who will operate and sample
Most relevant product: Rentals. See also replacement membranes, rentals and how to choose.
Why engineers look at Zyramic flat-sheet modules
| Item | Details |
|---|---|
| Smaller sheets, less wear and tear | each sheet flexes less in service, and a damaged unit affects less area. |
| Strong wide membrane welds | designed to resist delamination over the membrane's life. |
| Thick, robust membrane | about 250 microns including support. |
| Assembled in Poughkeepsie, NY | of domestic and imported components. In our Poughkeepsie shop we cut and weld membrane sheets to plates, build module frames and assemble complete modules. For funded projects, tell us your domestic-content requirements and we'll review what we can document. |
| Buy, rent or replace | new modules, rentals and pilots for US projects, and replacement membranes that fit many existing cassettes. |
Performance and life depend on pretreatment, design flux and operation; flux figures are Zyramic design guidance, sized to each project.
Frequently asked questions
How big is a pilot?
Big enough for representative results; often a single module or a few cartridges.
Can I pilot ceramic and polymeric side by side?
Yes, ask us about configurations.
Who owns the data?
You do.
Is a pilot required for municipal sewage?
Usually not, but it can still help for unusual permits.
What does a pilot cost?
Pilot costs depend on scale, duration and support, so we quote each one.
Can pilot results be used for design?
Yes, a well-run pilot provides the flux, cleaning and quality data engineers need for full-scale design.