How Kalabas works

Kalabas combines the full water treatment process into a single pre-engineered module—eliminating complex infrastructure while delivering consistent, high-quality output.
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7 core treatment stages in one
pre-engineered module

Kalabas is a fully integrated, modular water treatment system that transforms contaminated or variable-quality raw water into potable water through a sequence of engineered processes contained within a single circular unit. Instead of requiring multiple structures, tanks, and subsystems (as conventional plants do) Kalabas combines all core treatment stages into one pre-engineered module.

This architecture eliminates the most expensive parts of water infrastructure: sprawling civil works, complicated interconnections, and duplicated equipment. It is a complete treatment train inside one product.

The seven integrated stages

Each Kalabas unit performs the full treatment process from intake to safe drinking water:

  • Dosing

    Raw water enters the unit, where carefully controlled chemical dosing begins the clarification process. This step prepares suspended particles to bond together for efficient removal.

  • De-gritting

    Large sand and grit particles that damage pumps and clog systems are removed immediately. Conventional plants require standalone grit chambers; Kalabas embeds this inside the product.

  • Desilting

    Fine silts and sediment are extracted, enabling the system to accept water that would overwhelm traditional plants, including raw sources measuring beyond 400 NTU during floods or turbidity spikes. This capability was one of the engineering “aha” moments — the plant sustained performance even under three times the expected load.

  • Flocculation

    The patented circular flocculation chamber creates a gentle, controlled mixing environment that allows particles to bind without being broken apart, improving downstream efficiency.

  • Flotation (DAF: Dissolved Air Flotation)

    Kalabas uses advanced microbubble technology to lift the bonded particles to the surface for removal, achieving 98–99% turbidity reduction, even under high-load conditions. Engineers highlighted this integration as a breakthrough: DAF traditionally requires a separate tank; here it’s built in.

  • Filtration

    A continuous moving-bed sand filter (the largest of its kind globally) polishes the water without downtime. Automated backwashing keeps the system running without scraping, manual intervention, or shutdowns.

  • Disinfection

    Final disinfection ensures the treated water meets potable standards, ready for municipal, industrial, rural, or emergency application.

The 7 stages in action: How water flows through the system

Raw water enters the Kalabas structure, typically at the bottom where there is a cone design. This is where the grit naturally falls out due to gravity. Simultaneously, chemicals are added and flocculation begins. The circular design creates optimal hydraulic mixing conditions while maintaining velocities that prevent sediment from settling prematurely (a common problem in conventional plants where sediment accumulates in flocculation tanks even when dedicated sediment tanks exist upstream).

The flocculated particles then move to the dissolved air flotation stage, where microbubbles attach to the particles and float them to the surface for removal. Clean water passes through the continuous moving-bed sand filtration system, which operates without interruption. The automated backwash system cleans the filter media without stopping water production. Finally, disinfection occurs before the treated water exits the system.

Integration advantage

What conventionally requires four or five separate structures has been integrated into a single structure with multiple processes happening simultaneously.

This integration is the result of iterative design refinement that eliminated the need for:

  • Dedicated sediment removal tanks
  • Separate flocculation chambers
  • Multiple structural foundations
  • Complex interconnecting piping between separate units

Modular architecture

Each module functions independently or in parallel, supporting configurations from 0.1 MLD to over 100 MLD.

The current standard unit size is approximately 16 megalitres, though this is not a permanent limitation and can be expanded.

Multiple units can operate together, enabling future expansion without major civil modifications. If one unit requires maintenance, others continue operating.

Performance under variable conditions

Conventional plants must reduce capacity by 30-40% when water quality deteriorates. Kalabas can handle water up to 400 NTU without backing down on performance.Conventional plants must reduce capacity by 30-40% when water quality deteriorates. Kalabas can handle water up to 400 NTU without backing down on performance.

The design accommodates storm events and seasonal variations. For example, in areas like KZN where rivers pick up huge amounts of sediment during high rain seasons (water quality changes by 1000% over short periods), Kalabas maintains consistent treatment capacity.

Operational mechanics

The system uses less water, energy, and chemicals compared to conventional solutions. Continuous filtration means no downtime for backwashing, and automated systems reduce manual intervention requirements.

The external microbubble generation system for the DAF process ensures consistent performance with minimal maintenance needs.

Equipment count is significantly lower than conventional systems, reducing maintenance requirements, spare parts inventory, and operational complexity.

Start with a better way to deliver water treatment

Tell us about your project and we’ll show you how a modular approach can simplify design, delivery, and long term operation.
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