ROTAMIX® SYSTEM
The Vaughan Rotamix® System is engineered for reliable, low-maintenance mixing of sludge, digesters, and high-volume tanks. By combining an advanced nozzle system with Vaughan’s proven Chopper Pump technology, Rotamix provides complete tank mixing with no moving parts inside the basin—reducing maintenance while improving overall process performance.
Rotamix® is a cost-effective alternative to traditional mechanical mixing systems. Using hydraulically optimized flow patterns, the system keeps solids in suspension, eliminates dead zones, and improves biological and chemical processes within the tank.
With fewer mechanical components and a robust design, Rotamix® reduces installation complexity, minimizes downtime, and lowers long-term operating costs.
Key Features:
- Trusted Vaughan Performance
- Lower installation and maintenance costs
- 10-year Vaughan nozzle warranty
- System improves volatile solids reduction
- Increases digester gas production
- Reduces sludge volume
- No moving parts inside the tank
- Prevents tangles and clogging with chopper pump technology
- Energy efficient operation (especially with Variable Frequency Drive)
- Continuous mixing, even during drawdown
How it Works
The Rotamix® system creates a powerful, multi-zone hydraulic mixing pattern that combines rotational and vortical flow by positioning the angle of the nozzles to ensurescomplete tank turnover.
Rotational Flow
The entire tank contents move in a uniform circular motion, preventing solids from settling.
Vortical Flow
A vertical-axis vortex introduces top-to-bottom circulation, ensuring complete blending throughout the tank.
Induced Flow
High-velocity nozzles generate additional flow, expanding the mixing zone and increasing overall system efficiency.
At the same time, the Vaughan Chopper Pump continuously reduces solids size, improving mixing performance and preventing clogging.
This dual-zone hydraulic mixing produces higher, more consistent velocities throughout the tank—preventing solids from settling and eliminating dead zones.
System Components
Nozzle Assemblies
- Fixed-position design with no adjustment required
- Available in single or dual configurations
- Glass-lined ductile iron construction for durability
- Abrasion-resistant and clog-resistant
- Backed by a 10-year warranty from Vaughan
Vaughan Chopper Pump
- Handles tough solids without clogging
- Continuously reduces particle size
- Heavy-duty construction for long service life
- Designed for reliable, low-maintenance operation
Foambuster™ Foam Control (Optional Add-On)
The Vaughan Foambuster™ is a simple, effective solution for controlling foam in digesters and sludge tanks. Using a specialized nozzle and stainless steel splash plate, the system creates a broad spray pattern that wets and breaks down surface foam.
The Foambuster™ nozzle, mounted above liquid level, can be installed near the tank periphery and aimed radially inward toward the center, or mounted at/near the tank center and aimed outward toward the tank wall—providing flexible coverage based on tank design.
When paired with the Rotamix® system, tank contents rotate beneath the spray, allowing a single Foambuster to suppress foam across the entire surface. This integrated approach improves gas recovery, reduces maintenance, and helps maintain stable operation.
Energy Efficiency
The Rotamix® system’s hydraulic mixing design maximizes efficiency, and when paired with a VFD, can reduce energy consumption by up to 50%.
High-velocity nozzles induce additional flow, significantly expanding the effective mixing volume without increasing energy input.
Reduced Energy Advantage designs are the result of Computational Fluid Dynamics Analysis as applied, installed and evaluated in the field.
Applications
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What Sets Rotamix® Apart
Unlike conventional mechanical mixers, Rotamix® uses a fully hydraulic approach to achieve complete mixing without in-tank moving parts. This results in greater reliability, lower maintenance, and improved long-term performance.
Each system is engineered using advanced computational fluid dynamics (CFD) modeling to match the exact tank geometry and process requirements. This ensures optimal nozzle placement, eliminates dead zones, and maximizes mixing efficiency before installation.
Additional advantages include:
- Proven Vaughan Chopper Pump technology for solids reduction and clog prevention
- High-velocity nozzle design that induces additional flow and expands mixing coverage
- Ability to serve multiple tanks with a single pump system
- Consistent, uniform mixing even during fluctuating tank levels
See the Rotamix® System in Action:
Talk to Kelso About Your Application
Every Rotamix system is engineered for the specific application. The Kelso team can help design a system tailored to your tank, process, and performance goals. We will help you identify pump solutions that meet performance in harsh environments, compliance, and operational requirements.
We respond to all inquiries within 24 hours.