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FAB Media
SPECIFICATION
Size
12 x 25 mm & 4x25 mm
NO. OF HOLES
19 & 79
SURFACE AREA
>6OO m²/m³ & >16OO m²/m³
DENSITY
0.94 - 0.96 gm/cm³
DOSING RATIO
15% to 65%
MEMBRANE FORMING TIME
3-15 Days
MOC
VIRGIN HDPE
Types Of MBBR Media
vasu pharmatech
Fab Media for Wastewater Treatment
Fab Media also known as Floating Aerobic Biofilm Media is one of the most advanced carriers used in modern biological wastewater treatment systems. It plays a major role in MBBR (Moving Bed Biofilm Reactor) and FAB Reactors, which are widely applied in STPs (Sewage Treatment Plants) and ETPs (Effluent Treatment Plants) across the world.
This is a complete 2000+ words detailed guide on Fab Media, MBBR Fab, Fluidized Aerobic Bioreactors, and related technologies, written in simple English for engineers, industries, and businesses searching for trusted solutions. The guide also highlights why Vasu Pharmatech is a leading manufacturer of high-quality Fab Media Water Treatment solutions.
Introduction to Fab Media
Water pollution is one of the biggest environmental challenges. Rapid urbanization, population growth, and industrial expansion have increased pressure on sewage treatment and effluent treatment systems. Traditional biological treatment units often fail to handle high COD (Chemical Oxygen Demand) and BOD (Biochemical Oxygen Demand) loads effectively.
This is where Fab Media becomes highly effective. Instead of simple settling or activated sludge systems that require large areas and frequent maintenance, Fab Media works inside compact reactors and boosts microbial growth for faster degradation of waste.
The name “Fab” comes from Fluidized Aerobic Biofilm carrier. These are specially shaped floating elements, designed with multiple holes and made from strong polymers like virgin HDPE. When added to an aerated wastewater tank, these media provide a strong surface for bacteria to grow and clean the water.
Importance of Fab Media in Wastewater Treatment
Why is Fab Media so important for today’s treatment plants?
- Space Efficiency – Modern cities lack extra space for wastewater plants. Fab Media ensures maximum treatment is achieved in smaller tanks.
- High Treatment Efficiency – It improves pollutant breakdown, helping plants achieve discharge norms set by pollution control boards.
- Low Maintenance – Media do not clog easily and remain self-cleaning due to continuous water movements.
- Durability – Virgin HDPE makes Fab Media strong, chemical resistant, and long-lasting.
- Adaptability – Can be used in sewage, industrial effluents, aquaculture water, and hospital wastewater.
Working Process of Fab Media
The working principle of Fab Media is based on biofilm technology. Instead of keeping bacteria floating in wastewater, Fab Media allows them to attach to a surface and grow a biofilm.
The step-by-step process is:
- Filling Stage – Media is added to the reactor up to 15–65% of its volume.
- Microbial Colonization – Bacteria in wastewater attach to the surface and form a thin film.
- Aeration Support – Oxygen is supplied using blowers or diffusers which microorganisms use to survive.
- Pollutant Breakdown – Biofilm bacteria degrade organic pollutants (BOD, COD, nitrogen).
- Self-Cleaning Mechanism – Media collides and rubs against each other, preventing excess layer build-up.
- Stable Operation – Within days, Fab Media maintains a balanced microbial community and ensures long-term system efficiency.
Types of Fab and MBBR Media
There are several types of bio-carrier media designed for different treatment plants. Each type has its specific role in handling wastewater.
MBBR Media – Used in Moving Bed Biofilm Reactors, especially effective for high organic loads.
Fab Media (Floating Media) – Designed for FAB Reactors where aerobic conditions are maintained with air diffusers.
MBBR Fab Bio Pack Media – Specially structured pack media for large municipal plants.
Fabricated Media – Tailor-made options for special industry requirements.
Combination Media – Some plants use a mix of MBBR Fab carriers and conventional packing material for hybrid performance.
Technical Specifications of Vasu Pharmatech Fab Media
At Vasu Pharmatech, Fab Media is designed carefully to meet the performance requirements of both municipal and industrial systems.
| Specification | Value |
|---|---|
| Size | 12 x 25 mm |
| Number of Holes | 19 |
| Surface Area | >500 m²/m³ |
| Density | 0.94 – 0.96 gm/cm³ |
| Dosing Ratio | 15% – 65% |
| Membrane Forming Time | 3 – 15 Days |
| Material of Construction | Virgin HDPE |
These specifications allow faster biofilm growth, efficient oxygen transfer, and strong durability in industrial operating conditions.
Applications of Fab Media
Fab Media is widely used in different industries and wastewater management systems:
- Sewage Treatment Plants (STPs) for residential societies, hotels, hospitals, and municipalities.
- Effluent Treatment Plants (ETPs) used by textile, food, chemical, and pharmaceutical industries.
- Aquaculture Systems where Fab Media maintains good water quality for fisheries and shrimp farming.
- Hospital Wastewater Management to reduce harmful bacterial contamination.
- Food and Beverage Industries to tackle high organic waste in water before discharge.
Advantages of Fab Media Over Other Solutions
- Very high surface area (>500 m²/m³).
- Durable with Virgin HDPE construction.
- Fast biofilm growth (3–15 days for microbial layer development).
- Improved oxygen transfer rate.
- Self-cleaning design reduces clogging.
- Less sludge production compared to activated sludge systems.
- Can be applied to existing plants without big civil changes.
- Works efficiently even under varying loads and conditions.
Fab Media vs Conventional Treatment Media
| Feature | Fab Media | Conventional Bio Media |
|---|---|---|
| Surface Area | Very high (>500 m²/m³) | Low (<100 m²/m³) |
| Operation | Self-cleaning and efficient | Clogging occurs frequently |
| Oxygen Use | Excellent transfer | Limited oxygen transfer |
| Space Need | Small footprint | Larger tanks needed |
| Biofilm Growth | Fast and stable | Slow and uneven |
| Lifespan | Over 10 years | 3–5 years |
| Cost Efficiency | High long-term savings | Higher operating costs |
This comparison makes it clear why Fab Media is replacing older systems in most industries today.
Practical Example – STP Retrofit Case
A municipal sewage treatment plant in India was designed for 2 million liters per day but struggled due to rising population load. Instead of constructing new tanks, engineers applied Fab Media from Vasu Pharmatech to the existing aeration basins.
- Media filled at 50% ratio.
- Biofilm formed in just 10 days.
- COD removal efficiency improved by 40%.
- Sludge reduced by 30%.
- No extra construction cost required.
This practical retrofit example shows how Fab Media adds value without expensive expansions.
Why Choose Vasu Pharmatech Fab Media
Vasu Pharmatech has become one of the most trusted Fab Media manufacturers in India.
- Virgin HDPE Only – ensuring strength and chemical resistance.
- Precision-Engineered Design – providing maximum surface and hole structure.
- Proven Results – consistent performance in both STP and ETP applications.
- Custom Packing – available for large projects or small upgrades.
- Technical Expertise – backed by years of water treatment industry experience.
- Client Base – trusted by industries, government projects, and private real estate treatment facilities.
Design Tips for Fab and MBBR Systems
A good Fab Media Water Treatment design starts with correct media fill percentage and airflow in a FAB REACTOR or Fluidized Aerobic Bioreactor. Keep fab mbbr media or mbbr media between 15% and 65% filling, and use steady aeration so floating media moves freely and does not clog. This simple setup gives fast biofilm growth and stable performance for STP and ETP plants.
- Choose virgin HDPE Fabricated Media for high strength and long life in Fab Media systems.
- Keep sieve screens at outlets so MBBR Fab Bio Pack Media does not escape the tank.
- Plan stages: first stage for BOD, next stage for nitrification using mbbr fab with strong aeration.
- Maintain DO levels so biofilm on floating media stays thin and active.
Choosing a Trusted Manufacturer
Selecting a reliable mbbr media manufacturer makes operations easier and lowers lifetime cost. A proven supplier for fab media and fab mbbr media should provide test data, exact surface area, and consistent density so media stays suspended. Ask for references from STP, ETP, and aquaculture projects that use Fluidized Aerobic Bioreactor or FAB REACTOR designs.
- Verify real active surface area, not just geometric area, for Fab Media Water Treatment performance.
- Confirm membrane forming time and dosing ratio to match plant load.
- Ensure availability of MBBR Fab Bio Pack Media and Fabricated Media shapes for retrofits and new plants.
- Check quality controls for virgin HDPE, packaging, and fast delivery for large orders.
Future of Fab Media and MBBR Technology
With rising environmental regulations and water scarcity, more industries are expected to adopt biofilm-based technologies such as Fab Media and MBBR. Future improvements may include:
- Use of nanotechnology for even higher bacterial adhesion.
- Combination systems using MBBR + MBR (Membrane Bioreactor) for ultra-clean discharge.
- Sustainable materials developed from recycled plastics for eco-friendly carriers.
- Smart IoT monitoring systems to regulate oxygen and flow.
This shows Fab Media is not only a present solution but also the future of sustainable wastewater treatment.
Conclusion
Fab Media is a game-changer in biological wastewater treatment. With high surface area, strong durability, and proven efficiency in removing COD, BOD and nitrogen, it remains one of the best choices for STPs, ETPs, aquaculture, and industrial water cleaning systems.
By offering high-quality Fab Media Water Treatment solutions, Vasu Pharmatech has created a name for reliability and technological excellence. Industries and municipalities looking for compact, cost-efficient, and future-ready solutions should consider Fab Media by Vasu Pharmatech as their go-to choice for sustainable clean water management.
About The Author
Lalit Nankani
Managing Partner, Vasu Pharmatech
Lalit Nankani has over 12 years of experience in the filtration and water treatment industry. He leads Vasu Pharmatech, a trusted name in making PP Filter Press Systems, MBBR Filter Media, and other filtration products.
Under his leadership, the company has delivered high-quality solutions to many industries like pharmaceuticals, chemicals, food and beverage, textiles, and wastewater treatment. Lalit believes in providing strong, easy-to-use, and cost-effective systems that help businesses clean and reuse water.
1. What is Fab Media in wastewater treatment?
Fab Media is a floating biofilm carrier used inside aerated tanks to provide high surface area for bacteria to grow and remove BOD, COD, and ammonia efficiently in compact systems.
2. How does MBBR media work?
MBBR media moves freely in aerated water, allowing biofilm to attach to its surface; the constant motion and oxygen supply help break down pollutants with stable performance even under load swings.
3. What is the difference between MBBR Fab and standard MBBR media?
MBBR Fab generally refers to Fab-style floating media optimized for Fluidized Aerobic Bioreactor operation, while standard MBBR media includes various carrier geometries designed for moving bed biofilm reactors.
4. What does a Fluidized Aerobic Bioreactor (FAB REACTOR) do?
A Fluidized Aerobic Bioreactor keeps floating media in motion with air or mixing, maintaining a thin, active biofilm that rapidly degrades organic pollutants in a smaller footprint than conventional systems.
5. What are the benefits of fab mbbr media for STPs and ETPs?
Key benefits include high removal rates, compact tank sizing, fast start-up, self-cleaning action, lower sludge generation, and easy retrofits without major civil work.
6. What dosing ratio is common for Fab Media Water Treatment?
Filling fractions typically range from 15% to 65% of tank volume depending on load, target effluent, and stage design for BOD removal and nitrification.
7. How long does biofilm take to form on floating media?
Under steady aeration and nutrients, membrane (biofilm) forming time usually ranges from about one to two weeks, with noticeable performance often within several days.
.8. Why choose Fabricated Media made from virgin HDPE?
Virgin HDPE offers consistent density, chemical resistance, and long life, helping carriers stay suspended, resist abrasion, and maintain reliable biofilm performance.
9. When should MBBR Fab Bio Pack Media be used?
Use MBBR Fab Bio Pack Media in large plants or staged reactors to increase protected surface area for biological treatment, especially when upgrading capacity or polishing effluent.
10. When should MBBR Fab Bio Pack Media be used?
A reliable mbbr media manufacturer ensures true active surface area, stable density, accurate specifications, and consistent quality that directly affects efficiency and lifecycle cost.
11. When should MBBR Fab Bio Pack Media be used?
Yes, fab media can retrofit existing STP/ETP aeration tanks, boosting capacity and removal efficiency without building new civil structures in most cases.
12. What airflow is needed for FAB REACTOR systems?
Airflow should be sufficient to keep media moving, maintain dissolved oxygen, and shear excess biofilm; exact rates depend on load, tank depth, and diffuser layout.
13. Is MBBR suitable for variable influent loads?
Yes, moving bed biofilm reactors tolerate hydraulic and organic shocks well because protected biofilm maintains high active biomass even when loads fluctuate.
14. Is MBBR suitable for variable influent loads?
Install media retention screens or sieves on outlets and between stages to keep carriers in the tank and protect downstream equipment.
15. What maintenance is typical for Fab Media systems?
Routine checks include blower and diffuser performance, DO levels, sieve cleanliness, and periodic sludge wasting; media itself needs minimal direct maintenance.
16. Do floating media reduce energy use?
By increasing biological efficiency and surface area, floating media can reduce aeration energy per unit of pollutant removed compared to larger, conventional systems.
17. Can Fab Media support nitrification and ammonia removal?
Yes, staged FAB/MBBR systems enable nitrification by providing stable, oxygen-rich biofilms that convert ammonia to nitrate effectively.
18. What industries use Fab Media Water Treatment?
Common users include municipal sewage plants, food and beverage, textiles, pharmaceuticals, hospitals, and aquaculture where compact, efficient treatment is essential.
19. What key specs matter when selecting fab mbbr media?
Focus on verified active surface area, density near water for suspension, durable material (virgin HDPE), hole geometry, and proven dosing guidance.
20. How fast can an MBBR Fab system reach compliance?
With correct design, aeration, and loading, many systems show strong performance within 1–2 weeks of start-up, with continued optimization as biofilm matures.
Products
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Coarse bubble diffuser: Submerged aeration for microbial degradation.
Fine bubble diffuser: Submerged aeration for microbial degradation.
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MBBR STP ke liye inke pass best quality Fab Bio Pack Media milta hai.
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Maine Coarse Bubble Diffuser use kiya, wastewater aeration me zabardast output mila.
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EPDM Fine Bubble Disc Diffuser ka bubble size uniform hai, bilkul sahi product.
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Delhi NCR me inka MBBR Media Supplier service fast aur reliable hai.
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Unka Tubular Diffuser lagane ke baad energy saving noticeable hai.
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FAB Media ka flow aur treatment efficiency dono hi best hai.
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MBBR Wastewater Treatment project me inki products use karke results amazing aaye.
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Vasu Pharmatech ka Diffuser Tube bilkul leakage free aur effective hai.
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Maine Membrane Tube Diffuser lagaya, performance bahut acha hai.
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FAB Reactor media ka biofilm growth uniform hai, kaafi achha experience.
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Delhi
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Tube Settler Media ka installation unke team ne jaldi complete kar diya.
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Vasu Pharmatech ka Automatic Filter Press Machine time aur labor dono save karta hai.
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MBBR Bio Media ka price market competitive hai aur quality high.
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Gujarat
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Maine unka Filter Press for Sludge Dewatering liya, full value for money hai.
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Delhi
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Inke Diffusers in STP reliable hai, paani ka treatment hassle free ho jata hai.
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Kolkata
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Tube Deck Settler ka design compact hai aur space saving solution diya.
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Vasu Pharmatech se liya hua MBBR Water Treatment Media durable aur effective hai.
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Surat
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FAB Media aur Diffusers ka combination inhone suggest kiya, result best mila.
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Bangalore
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Vasu Pharmatech supplied us MBBR Media for our STP, and the performance has been excellent.
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Siliguri
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Their Tube Settler Media is durable, easy to install, and very effective in wastewater treatment.
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The Filter Press Machine from Vasu Pharmatech is reliable and works perfectly for sludge dewatering.
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Haryana
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Their FAB Reactor system is compact and provides excellent biological treatment.
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Pune
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We received PVC Tube Settler Media, and the quality exceeded our expectations.
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Jaipur
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The Automatic Filter Press has saved us both time and manpower – very satisfied.
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Their Coarse Bubble Diffusers work well for wastewater aeration, giving consistent results.
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The Tubular Diffusers are strong, efficient, and delivered on time.
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Vasu Pharmatech provided us with EPDM Fine Bubble Disc Diffusers, and the oxygen transfer rate is outstanding.
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Noida
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Their MBBR Bio Media is competitively priced yet offers premium performance.
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Ahmedabad
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The Hydraulic Filter Press is designed very well and easy to operate.
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For Tube Deck Media, Vasu Pharmatech is one of the most reliable suppliers we have worked with.
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Their Disc Diffuser Aerators are durable and perfectly suited for our STP application.
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Punjab
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Vasu Pharmatech products are cost-effective, reliable, and perfect for water treatment projects.
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Delhi
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Vasu Pharmatech ka MBBR Media liya, paani ka treatment smooth ho gaya aur maintenance bhi easy hai. Tube Settler aur Diffuser ka combination STP me highly efficient sabit hua.
Kunal Sharma
Delhi
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We bought MBBR Media and Tube Settler from Vasu Pharmatech for our STP. The quality is excellent, installation simple, and treatment performance outstanding.
★★★★★ 5/5
Reviews and Ratings
We certify that M/s. Vasu Pharmatech, located at 66B, Pocket AD Shalimar Bagh, Delhi-110088, supplied us with a Pharmatech filter press for our 275 KLD ETP plant at M/s. Asian Colour Coated Ispat Ltd. in Bawal, Dist: Rewari (Hr.). The plant was started in January 2018 and is still working well. The product and its performance have been satisfactory up to now.
ASIAN COLOUR COATED ISPAT LIMITED
Rewari, Haryana
