Since the 1950s, wet wells and lift stations have been the traditional solution for handling wastewater in commercial and industrial applications. However, even time-tested systems have limitations, particularly when fats, oils, and grease (FOG) and solids repeatedly clog pumps, drive up maintenance costs, and risk contamination or downtime.
In food and beverage processing, where wastewater often contains a mix of fibrous materials, traditional submersible pumps weren’t designed to handle the challenge. Fortunately, a more innovative alternative now exists: the OverWatch® Direct In-Line Pump System equipped with the patented DIPCUT® impeller.
The Problem with Traditional Wet Wells
Wet wells are prone to solids buildup and clogging from:
- Fats, oils, and grease (FOG)
- Organic waste like skins, rinds, or animal by-products
- Inorganic debris like wipes, gloves, or packaging materials
Over time, these materials bind together, forming solid layers or choking pump inlets. Clearing them means sending in vacuum trucks, cranes, and maintenance crews, all while production slows or stops.
Additionally, stagnant wastewater can create septic conditions, releasing harmful gases, odors, and bacteria that threaten workers’ safety and regulatory compliance.
In short, wet wells work, but they’re messy, high-maintenance, and increasingly outdated.
The OverWatch® Solution: No Wet Well, No Clogs
The OverWatch Direct In-Line Pump System eliminates the need for a wet well. Instead of waiting for wastewater to accumulate, OverWatch lifts influent directly at the entry point, eliminating the need for a wet well. Influent is contained, eliminating odors and reducing maintenance.
The optional, patented DIPCUT® impeller for self-cleaning operations features a variable vane design that senses solids in the flow and activates only when needed. The DIPCUT impeller is available for select models up to 18.5 kW (25 HP). This impeller design improves pump efficiency and reduces energy consumption.
Paired with variable frequency drives (VFDs) and smart controls, the system automatically adjusts to changing flow rates, even starting a secondary pump when needed to maintain throughput.
Case Study: OverWatch® Powers Pet Food Plant Expansion
Challenge:
A leading pet food manufacturer in Tennessee expanded production by 100,000 square feet, adding new lines and washdown stations. The increased wastewater overwhelmed their existing system, but limited space and odor concerns made a traditional wet well impractical.
Solution:
The facility replaced its wet well with an OverWatch® Direct In-Line Pump System installed in a compact 48-inch basin beneath a pedestrian walkway. The system automatically adjusted to fluctuating wastewater flows, preventing FOG buildup and eliminating odor issues, all without requiring deep excavation or costly odor suppression systems.
Results:
- Reduced construction and installation costs
- Simplified maintenance with dry-access installation
- Improved worker health and safety
- Reliable, efficient wastewater management to support production growth
Read the full case study.
Engineered for Modern Food & Beverage Operations
Direct In-Line Pump technology is revolutionizing solids handling in wastewater systems, particularly for food and beverage facilities that deal with high solids content and limited space.
By removing the wet well and introducing intelligent, variable solids-handling capabilities, facilities can reduce energy use, minimize downtime, and eliminate the need for constant pump replacement.
Learn more at flowsolutions.com or contact Industrial Flow Solutions to explore how OverWatch® can transform your wastewater operations.
