Insight Air – Smart aeration optimization

The Carbon Factor shows when aeration is truly effective—data-driven, patented, and reliable.

Insight Air

Smart aeration optimization.

The Carbon Factor reveals when air is actually effective and lays the groundwork for safe, data-driven ventilation optimization.
10 %
aeration energy use
Real-time
process signal
Patented
Carbon Factor

The most powerful way to save energy often goes unnoticed

Aeration is the largest source of energy consumption at wastewater treatment plants and is usually controlled based on dissolved oxygen levels. However, DO only indicates what is in the water, not what the biological process consumes.

Security surcharges

Aeration is driven by safety margins, not actual demand.

Energy with no benefit

More air does not mean better cleaning performance.

Process hidden

The true state of biology remains unclear.

A New Language for Biology

The Carbon Factor converts exhaust gas data into clear process information: the ratio of carbon degradation to nitrification, calculated from the O₂ and CO₂ in the exhaust air.

Carbon removal or nitrification

You can see in real time which reaction is currently taking place in the air.

Oxygen utilization

How effectively the oxygen supplied is actually utilized.

Effect of additional air

Whether increased aeration actually makes a difference right now or just wastes electricity.

From the sensor to a safe ventilation decision

Four steps to integrate the Carbon Factor as a control variable into your existing control system.

01 Trade Shows
EmiCo lite
Real-time exhaust gas analysis with 30 measurements per hour through the installation of EmiCo lite.
02 Calculate
Carbon Factor
Patented calculation based on the IPC of the measuring unit: the ratio of carbon degradation to nitrification. The results are displayed in EmiCo Insight.
03 Understanding
Stability window
System-specific - where nitrification and carbon degradation are in balance.
04 Optimize
aeration
Air factor (0.7–1.0) as a multiplier applied to the existing air requirement, in increments of ±5% every 10 minutes.
It’s not just about measuring; it’s about understanding whether the air has an effect.

Insight Air is a monitoring tool, not a replacement

Insight Air modifies the existing control system solely by applying a multiplier (air_factor 0.70–1.00). The DO control, minimum air flow, and safety logic of the PLC remain unchanged. A reduction occurs only if all four conditions are met simultaneously.

CF in the stability window

Biology in balance, an intervention is certain.

O₂ exhaust air > Threshold value

Over-aeration in the exhaust air can be clearly measured.

NH₄ below the limit value

Nitrification under control. Effluent limits values secured.

Measurement data 
valid

Watchdog OK, no critical device alarm.

If there is a loss of communication, a sensor failure, an increase in NH₄, or the dissolved oxygen level falls below the minimum threshold, the Air Factor immediately drops to 1.0. No exceptions.

Measurement, analysis, and implementation without disrupting the system

Variolytics delivers the tools. Control remains with you.

What Variolytics offers

  • EmiCo lite Measurement Technology (O₂, CO₂)
    EmiCo Insight (Software)
  • Patented calculation of the carbon factor
  • Handover of the Air-Factor and the automation concept

What remains with the operator

  • Plug-and-play installation on the system
  • On-premises integration with the existing control system
  • Full control – open, compatible, transparent

We will only intervene when the data from your system allows us to do so

Phase 0: 1–2 weeks
Preparation
Install the measurement equipment, establish the Modbus connection, and test the watchdog and all fail-safe logic.
Phase 1: 4 weeks
Observation without intervention
The logic continuously evaluates the process without interfering. CF stability windows and thresholds are based on real operational plant data.
Phase 2: 6–8 weeks
Closed-loop control
A conservative start with a threshold value at a relatively high oxygen concentration in the exhaust air, followed by a reduction.

Reference Project: Municipal Wastewater Treatment Plant, Southern Germany, 2025

2.47–7.02

CF Stability Window

17.5% ABV

O₂ threshold for exhaust air

0.3 mg/L

NH₄ Limit Procedure

€47,000–€129,000

Estimated savings per year

Get to know Insight Air

Please feel free to schedule a personal consultation.

Consultation appointment
Discuss your investment in detail
Schedule an initial consultation, and we’ll work together to determine whether and how Insight Air fits into your process and control system.
Discuss the pilot project