Transform your wastewater treatment operations with advanced hydraulic sludge mixing systems engineered for maximum efficiency. Our custom-designed solutions deliver superior solids suspension, thorough blending, and reduced energy consumption, helping industrial facilities optimize sludge management while minimizing operational costs. With proven performance across hundreds of global installations, we provide reliable mixing technology that keeps your treatment processes running smoothly.
Our Hydraulic Sludge Tank Mixing Solutions
Comprehensive mixing technologies engineered to optimize your sludge management processes with energy-efficient, reliable performance.
Hydraulic Sludge Mixing Systems
Custom-designed hydraulic mixing systems specifically engineered for demanding sludge applications in wastewater treatment facilities. Our solutions provide thorough mixing, excellent solids suspension, and long-term reliability with minimal maintenance requirements.
Advanced jet mixing technology creating optimal bidirectional flow patterns for applications without air requirements. Ideal for tanks requiring comprehensive circulation and mixing performance in sludge management operations.
High-performance jet mixers featuring 24-jet configurations for enhanced mixing efficiency. Available in corrosion-resistant stainless steel, perfect for specialty sludge applications and demanding industrial environments requiring superior blending capabilities.
Versatile jet mixing systems engineered to create flow patterns for effective solids suspension and blending. Suitable for various tank configurations including round and rectangular designs in sludge treatment applications.
Complete turnkey aeration systems including FRP tanks, pumps, blowers, aerators, and all necessary components. Designed for refinery and chemical applications requiring integrated sludge treatment and management solutions.
Tailored mixing and aeration solutions designed to meet your unique operational requirements. Available in various materials and configurations, including mini jet mixers for smaller applications and self-contained units for specialized installations.
Engineering Excellence in Every Sludge Mixing Solution
At Mixing Systems, Inc., we understand that effective sludge management requires more than off-the-shelf equipment. Our hydraulic mixing solutions combine over four decades of engineering expertise with proven jet technology to deliver systems that precisely match your facility's requirements. From small-scale operations to the world's largest wastewater installations, our custom-designed mixers provide thorough solids suspension, energy-efficient operation, and virtually maintenance-free performance. With computer-aided design capabilities and hundreds of successful installations worldwide, we engineer solutions that optimize your processes while reducing operational costs.
Proven Global Performance
Trusted by Industry Leaders
Hundreds of successful installations serving major corporations worldwide, from pharmaceutical giants to petrochemical refineries.
"We can't really tell how well it is mixing but it must be doing its job. Bugs are growing and we're making gas!"
Food & Beverage client with Covered Anaerobic Digester lagoon
"There is no doubt that the system is doing exactly what it was intended to do, thank you for working with us to make this project successful."
Industrial processing client
"Your system was really simple and straightforward to install. Thanks so much!"
Municipal Industry General Contractor
"The thermal imaging is telling us that your mixing system is working as designed and our solids accumulating should no longer be a concern. This is great news, thank you for working with us Amit and I hope we can do more work with you in the future."
Petrochemical industry client
"Just to let you know, the tank mixer we installed is still operating and working extremely well… we haven't had to enter the tank to clean it since it was installed and is scheduled for its routine inspection next year!"
Chemical industry client
"Your jet mixers are working better than anticipated! We have not had to enter tank 7 since your jet mixer was installed… 5 years ago, we went from annual cleanings to potentially having it on 5-year intervals or more! The eddy mixers we installed on tanks 11 & 12 are..."
Industrial manufacturing client
"I am very pleased with the results I see. For the most part the EQ tank is self-neutralizing. That is the main goal of the EQ tank's mixing system. There are few instances when the tank gets to >70% full and hasn't neutralized and chemicals must be added."
Food & Beverage client
"I just spoke to our Manager who has been intimate with the project operation, he stated confidently that all is running really well with the Tunnel Dewatering Pump Station (TDPS) mixing equipment / flushing nozzles."
Municipal client
"We can't really tell how well it is mixing but it must be doing its job. Bugs are growing and we're making gas!"
Food & Beverage client with Covered Anaerobic Digester lagoon
"There is no doubt that the system is doing exactly what it was intended to do, thank you for working with us to make this project successful."
Industrial processing client
"Your system was really simple and straightforward to install. Thanks so much!"
Municipal Industry General Contractor
"The thermal imaging is telling us that your mixing system is working as designed and our solids accumulating should no longer be a concern. This is great news, thank you for working with us Amit and I hope we can do more work with you in the future."
Petrochemical industry client
"Just to let you know, the tank mixer we installed is still operating and working extremely well… we haven't had to enter the tank to clean it since it was installed and is scheduled for its routine inspection next year!"
Chemical industry client
"Your jet mixers are working better than anticipated! We have not had to enter tank 7 since your jet mixer was installed… 5 years ago, we went from annual cleanings to potentially having it on 5-year intervals or more! The eddy mixers we installed on tanks 11 & 12 are..."
Industrial manufacturing client
"I am very pleased with the results I see. For the most part the EQ tank is self-neutralizing. That is the main goal of the EQ tank's mixing system. There are few instances when the tank gets to >70% full and hasn't neutralized and chemicals must be added."
Food & Beverage client
"I just spoke to our Manager who has been intimate with the project operation, he stated confidently that all is running really well with the Tunnel Dewatering Pump Station (TDPS) mixing equipment / flushing nozzles."
Municipal client
"We can't really tell how well it is mixing but it must be doing its job. Bugs are growing and we're making gas!"
Food & Beverage client with Covered Anaerobic Digester lagoon
"There is no doubt that the system is doing exactly what it was intended to do, thank you for working with us to make this project successful."
Industrial processing client
"Your system was really simple and straightforward to install. Thanks so much!"
Municipal Industry General Contractor
"The thermal imaging is telling us that your mixing system is working as designed and our solids accumulating should no longer be a concern. This is great news, thank you for working with us Amit and I hope we can do more work with you in the future."
Petrochemical industry client
"Just to let you know, the tank mixer we installed is still operating and working extremely well… we haven't had to enter the tank to clean it since it was installed and is scheduled for its routine inspection next year!"
Chemical industry client
"Your jet mixers are working better than anticipated! We have not had to enter tank 7 since your jet mixer was installed… 5 years ago, we went from annual cleanings to potentially having it on 5-year intervals or more! The eddy mixers we installed on tanks 11 & 12 are..."
Industrial manufacturing client
"I am very pleased with the results I see. For the most part the EQ tank is self-neutralizing. That is the main goal of the EQ tank's mixing system. There are few instances when the tank gets to >70% full and hasn't neutralized and chemicals must be added."
Food & Beverage client
"I just spoke to our Manager who has been intimate with the project operation, he stated confidently that all is running really well with the Tunnel Dewatering Pump Station (TDPS) mixing equipment / flushing nozzles."
Municipal client
The Mixing Systems Difference
Why Choose Mixing Systems, Inc.?
Four decades of engineering excellence delivering superior mixing solutions worldwide.
Proven Experience
Over 40 years of specialized expertise in jet aeration and mixing system design, with hundreds of installations operating globally.
Energy Efficiency
Our systems deliver significant energy reductions compared to conventional methods, substantially lowering your operational costs over time.
Custom Engineering
Computer-aided design capabilities ensure every system is precisely engineered to match your specific tank configurations and process requirements.
Low Maintenance
All mechanical assemblies positioned outside tanks for easy access, with no in-basin moving parts ensuring virtually maintenance-free operation.
Dedicated professionals with deep expertise in mixing technology.
Founded in 1985 by an engineer with now over 45 years of experience in jet aeration and mixing systems, Mixing Systems, Inc. has grown to become a preferred provider of submerged jet systems. Since our beginnings in Dayton, Ohio, we've supplied hundreds of wastewater treatment systems globally, serving industry leaders across food & beverage, bulk chemical, petrochemical, pharmaceutical, agriculture, poultry, dairy, and pulp & paper in addition to our extensive work with municipalities . A trusted resource to clients and engineers across water and wastewater, our success stems from an unwavering commitment to product excellence and customer satisfaction, continually striving to deliver aeration and mixing systems that offer superior durability, quality, and precision at competitive prices.
HundredsSuccessful installations worldwide
40+ YearsEngineering mixing solutions since 1985
6 ContinentsGlobal service reach and experience
Frequently Asked Questions
What is a sludge mixer?
A sludge mixer is specialized equipment designed to maintain homogeneous suspension of solids in sludge tanks, preventing settling and ensuring consistent material properties. Hydraulic jet mixers use high-velocity fluid streams to create circulation patterns that keep solids suspended while blending the contents throughout the tank.
What is the purpose of a sludge tank?
A sludge tank stores and processes semi-solid waste materials from wastewater treatment, allowing for settling, thickening, digestion, or temporary holding before further treatment or disposal. Proper mixing in these tanks is essential for maintaining process efficiency, preventing stratification, and ensuring consistent sludge characteristics for downstream processing.
How do hydraulic jet mixers differ from mechanical agitators?
Hydraulic jet mixers have no in-basin moving parts, eliminating the need for expensive underwater bearings and seals. They use centrifugal pumps outside the tank to force liquid through nozzles, creating high-velocity jets that provide superior mixing with lower maintenance requirements and easier servicing than traditional mechanical agitators.
What tank sizes can your mixing systems accommodate?
Our hydraulic mixing systems are especially cost-effective for large volume tanks over 1,000 gallons and can handle tanks up to 65 feet in diameter with single units. For larger installations, multiple mixers can be configured to serve tanks of virtually any size, with proven installations in some of the world's largest treatment facilities.
How much energy savings can I expect?
Our jet mixing and aeration systems typically deliver energy reductions of up to 40% compared to other aeration methods. The exact savings depend on your specific application, tank configuration, and operating conditions, but reduced operational power costs are a consistent benefit across installations.
What maintenance is required for hydraulic mixing systems?
Maintenance requirements are minimal since all mechanical assemblies are located outside the tank for easy access. There are no in-basin moving parts to service, and optional pneumatic backflush systems prevent nozzle clogging. Routine maintenance typically involves standard pump servicing and periodic system inspections.
Can your systems handle high-solids sludge applications?
Yes, our hydraulic mixing systems excel in sludge applications and can handle solid particles up to 2.2 inches in diameter. The systems are specifically designed for solids suspension and can maintain homogeneous mixing even in challenging high-solids environments, provided particles are smaller than the primary nozzle diameter.
What is the typical installation timeline?
Installation timelines vary based on system complexity and tank configuration, but our systems are designed with prefabricated sections for easier and faster assembly than comparable diffused aeration systems. We work closely with your team to minimize downtime and ensure efficient installation with comprehensive support throughout the process.
Have More Questions About Our Mixing Solutions?
Our experienced engineers are ready to discuss your specific sludge mixing challenges and requirements.
Trusted Excellence
Awards and Recognition
40+ Years in Business
Four decades of engineering excellence since 1985
Fortune 500 Clients
Trusted by global industry leaders worldwide
Global Installations
Hundreds of systems operating across six continents
Ready to Optimize Your Sludge Mixing Operations?
Contact our engineering team to discuss your specific requirements and receive a custom-designed solution proposal tailored to your facility's needs.
For immediate assistance, feel free to give us a direct call at +1 937-435-7227 You can also send us a quick email at amit@mixing.com
For immediate assistance, feel free to give us a direct call at +1 937-435-7227 You can also send us a quick email at amit@mixing.com