Keeping the Motor Running: Inside Wastewater’s Hidden Powertrain

Wastewater treatment plants rely on nonstop mechanical power to keep water moving, oxygen flowing, and critical equipment turning—and the systems behind that power are the focus of this episode.

Dave Zimmerman of Dodge Industrial breaks down how gearboxes, bearings, motors, and couplings form the “powertrain” that drives nearly every major process in a treatment plant.

Zimmerman explains how these components support pumps, aeration basins, clarifiers, bar screens, screw conveyors, and oxidation ditches—operating 24/7 under punishing conditions of moisture, grit, vibration, and load. He highlights how smart mechanical design can cut energy consumption by 7–10 percent, a major opportunity for utilities facing some of the highest electricity bills in municipal government.

As the water workforce shrinks, Zimmerman outlines how pre-engineered, easy-to-install components reduce maintenance complexity and keep equipment online longer. Lessons from heavy industries like mining and aggregates—where shock loads and extreme stress are the norm—are shaping tougher, more durable systems for wastewater plants.

The conversation also explores emerging technologies such as sensors, real-time monitoring, and predictive maintenance tools that help operators understand equipment health and prevent catastrophic failures before they happen.

Learn more about Dodge Industrial.

waterloop is a nonprofit news outlet exploring solutions for water sustainability.