Dry Polymer Make-Down Systems

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Dry polymer systems need smart simplicity to meet limited operator requirements and support efficient polymer preparation. We achieve this with a few standard features on our M-Series line. First, our dry polymer feed systems automatically introduce the polymer granules to maintain a programmed solution strength. The granules are dispersed into a water cyclone in the wetting bowl, providing efficient initial activation. Next, the solution experiences high-energy hydraulic mixing to reduce agglomeration. From there, a second low-energy mechanical mixing stage continues to unravel the polymer without breaking the chains throughout the maturation process. Finally, the solution overflows a weir into the “drawdown chamber,” where it is pumped to process. The M-Series dry polymer make-down system offers precise control of dosing rate, dilution level, mixing time, and energy.

Dry polymers are typically the most cost-effective way to use flocculants. They contain 90+% active chemistry, while liquid polymers are closer to 30%. The active chemistry makes dry polymers ideal for liquid-solid separation, sludge dewatering, and potential cost savings.

We offer free jar testing to determine the best polymer, dosing rate, and equipment package for your application. In our lab, we’ll compare dry and liquid polymers to confirm flocculation efficiency, minimize consumption, and reduce cost. Contact us today for sample shipping instructions and to learn how we tailor a solution to your operation.

What size dry polymer system do I need?

Choose a dry polymer system model based on the consumption requirements for the application. Consumption can be defined as ppm or mg/L, pounds/hr, or the solution flow you need to deliver.

Our standard models are turnkey and provide the following flows: M100SS 0–4 GPM, the M500SS 0–8 GPM, the M800SS 0–12 GPM, and the M3000SS 0–25 GPM.

Custom designs handle anything from a few pounds per day to hundreds of pounds per hour. By incorporating an additional age tank, we can accommodate high-consumption applications of hundreds of gallons per minute.

Our team can confirm the right model for your application.

What is the pounds-per-hour capacity of a dry polymer system?

Clearwater’s standard M-Series systems have a maximum capacity of 50 lbs/hr of dry polymer. This maximum capacity is limited by the dilution water flow rate to ensure efficient activation and mixing without clumping.

Custom systems can provide 30 to 300 lbs/hr of dry polymer.

How does a dry polymer make-down system work?

A dry polymer make-down system turns powdered polymer into a usable liquid solution. It meters the powder, wets the particles, mixes the solution to uncoil the polymer chains, lets it age and fully activate, then doses it to the process. Designs differ in how they wet, activate, and mix the polymer and how much aging time they provide.

In Clearwater’s M-Series, a variable-speed feeder meters dry polymer into a stainless steel wetting bowl, where a water cyclone wets each particle. High-energy hydraulic mixing in the first chamber limits clumping and fish eyes. In the second chamber, a low-energy agitator continues to unravel the polymer for a set amount of time without breaking the chains. The aged solution overflows a weir into the drawdown chamber and is pumped to the process. The entire system is automated, with high/low batching setpoints and solution strength control.

How long does dry polymer need to age?

Clearwater’s M-Series dosing rates are based on a recommended 90-minute aging time. Aging gives the polymer time to fully activate, which helps minimize polymer consumption.

Is dry or liquid polymer more cost-effective?

Dry polymer is typically the most cost-effective flocculant option. It contains more than 90% active chemistry, lowering operational costs compared to liquid polymers, which have about 30% active chemistry.

Consider the capital costs of dry and liquid polymer systems along with estimated consumption. Dry polymer systems generally have a higher capital cost than liquid polymer systems.

Jar testing is the best way to compare dry and liquid polymers and estimate annual cost alongside capital equipment cost.

What else can a make-down system prepare besides polymer?

Although typically used for polymer flocculants, Clearwater has customized units to prepare and dose aluminum sulfate, bentonite clay, lime slaker, powdered activated charcoal, and starch.

Can I use big bags?

Yes, big bag options include 1,650–2,000 lb supports, a pan and hopper, a tower, or a hoist. Standard hoppers hold 110 lbs, with a 220 lb option.

Can I get a containerized dry polymer system?

Yes, containerized systems come in 10′, 15′, 20′, and 40′ high cube units, and double-stacked containers fit big bags for high-consumption applications. They include a single-point electrical hookup, HVAC, spray-foam insulation, and LED lighting.

How much operator attention does the system need?

Very little. The feeder automatically maintains a programmed solution strength, a flowmeter prevents low-flow batching, and a progressive cavity pump with VFD doses at a set flow or paces from a 4–20 mA signal. Hand/Off/Auto switches allow manual control.

PLC controls and the AutoFloc dosing system are optional. We also offer sensors with alarm outputs, such as low-level alarms in the polymer hopper and conductivity sensors to ensure solution strength.

What power and floor space does an M-Series system require?

Standard models run on 480V/3Ph/30A. Footprints range from 154″ × 61″ (M100SS) to 214″ × 89″ (M3000SS), and dry/wet weights are listed in the spec table above.

Is there a warranty?

Clearwater’s dry polymer make-down systems include a lifetime warranty, provided you use Clearwater chemistry exclusively. Systems that don’t use Clearwater chemistry have a standard 1-year warranty.

How do I find the right polymer and system for my application?

The best way to find the right polymer is to perform jar testing and determine the dosing rate. We test polymers in our lab to find the best product, dosing rate, and equipment package, and to confirm flocculation efficiency and minimize consumption.

What does a dry polymer system cost?

Cost depends on capacity, hopper or big bag setup, controls (standard or PLC), additional age tanks, number of dosing points, and whether the system is containerized. Contact us with your flow rate and polymer consumption, and we’ll provide a quote.

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