During biomass analysis, Maji detected a high presence of inorganic particles inside the activated sludge. The particles appeared in a wide size range, from small fine material to larger particles above 700 microns.
This finding was important because it changed the way the plant teams looked at the problem. When settling performance, floc structure, or sludge behavior changes, the first explanation is often biological: filamentous bacteria, weak flocs, toxicity, sludge age, or nutrient imbalance. In these cases, Maji showed that the issue was also physical. Non-biological material was entering or accumulating in the process and becoming part of the mixed liquor.
The inorganic particles affected the biomass in a very practical way. Instead of a clean biological floc structure, the sludge contained hard, non-biodegradable material that changed how the flocs formed, moved, and settled. This can disturb normal biomass structure, create heavier or irregular flocs, affect sludge settleability, and in some cases contribute to hydraulic or sludge-handling limitations.
For the operations teams, the value was that Maji helped separate a physical sludge-quality issue from a purely biological one. This prevented broad, unfocused troubleshooting. Instead of only adjusting aeration, sludge age, or wasting rates, the teams could start looking for the actual source of the inorganic load.
Inorganic particles
In several cases, this led to direct operational actions. One plant temporarily stopped a suspected incoming stream to check whether the inorganic load decreased. Another team cleaned accumulated material from wasting lines and sludge-handling areas. In other cases, the plant reviewed grit and grease removal performance, inspected upstream process areas, and traced the issue back to a specific discharge source.
This made the biomass analysis practical. Maji did not only show that inorganic particles were present. It helped the plant understand where to look, what to check, and how to reduce the impact on the biological process.
The finding also explained why standard biological adjustments alone were not always enough. If the activated sludge contains a significant load of inorganic material, the biology cannot simply “fix” the problem. The plant needs to understand how the material is entering the system, whether it is accumulating, and how it is affecting settling, wasting, and sludge handling.
By following the biomass over time, the teams could also see whether the situation improved after operational changes. When the suspected stream was paused, when accumulated material was removed, or when upstream sources were addressed, Maji helped track whether the inorganic particle load decreased and whether the biomass structure returned toward a healthier condition.
his case shows why biomass analysis should not focus only on microorganisms. Activated sludge is a living biological system, but it is also affected by the physical material entering the plant. Inorganic particles can change how the sludge behaves, even when the biological population itself is not the main problem.
For these plants, Maji helped turn a hidden physical issue into a clear process insight: the activated sludge was being influenced by inorganic material, and the solution required looking beyond the biology.