KWS Manufacturing

Biosolids Truck Loading System for Cedar Falls, IA WWTP

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Plant Name and Location

Cedar Falls WWTP
Cedar Falls, IA

Consulting Engineer

Black & Veatch Corporation
Kansas City, MO 64114


Woodruff Construction, LLC
Fort Dodge, IA 50501

General Description

The City of Cedar Falls, IA required upgrades to their existing Environmental plant that included two new belt filter presses and a dewatered biosolids truck loading system. The project involved modifications and additions to the existing Waste Reclamation Facility’s Disinfection and Solids Handling Facilities including biosolids processing improvements. The transfer of dewatered biosolids from one or two belt filter presses to the truck loading system was accomplished by using a shafted screw conveyor with electrically actuated slide gates to evenly distribute the biosolids in trucks.

Design Parameters

  1. Product Type: Dewatered Biosolids or Sludge
  2. Material Density: 53 to 65 Lbs. per Cubic Foot
  3. Solids by Weight: 20% Total Solids
  4. Conveyor System Capacity: 170 Cubic feet per Hour
  5. Duty: 24 Hours per Day, 7 Days per Week

KWS Advantages

KWS designed and manufactured a shafted screw conveyor and five electrically operated slide gates that met the dimensional requirements of the building and interfacing equipment. The expertise that KWS has with 3D modeling using Inventor ensured that the equipment fit exactly to the Customer’s requirements. Installation was accomplished quickly and efficiently which allowed the Contractor to deliver on time and within budget.

KWS supported the installation, commissioning and training by providing a qualified and registered Professional Engineer familiar with the project, design requirements and equipment delivered.

Special Features

The conveyor installation is such that there is limited access to the equipment for maintenance. Since one conveyor spans both Belt Filter Presses, it was essential that the equipment be reliable so that any maintenance downtime was minimal and that access to maintainable components would not require major disassembly of the equipment. KWS satisfied the Customer’s requirements by supplying an intermediate bearing assembly that required little or no maintenance and located the bearing between the Belt Filter Presses where it was readily accessible. Each screw section was mounted on large diameter heavy-duty pipe to allow for 16-foot long spans so that only one intermediate bearing was required. Routine bearing lubrication is achieved automatically using spring-actuated lubrication pots which can be replaced without tools. Should major maintenance be required, the intermediate bearing assembly can be removed without interrupting the adjacent screw sections.


"The equipment was easy to install and there were no installation issues. The equipment quality is excellent. Working with KWS has been a pleasure."

Tamsen Kirby, Project Manager – Woodruff Construction

Biosolids / Sludge

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