News Releases

April 23, 2004: Orenco's Injection-Molded Fiberglass Tanks Set New Industry Standard

April 23, 2004: Spanish Homeowner's Manual Available Online

Articles about Orenco

Pump-Panel Solutions / Where the Grass is Always Greener / Orenco Flows to Top of the Field / LCDC Should Get Out of the Wastewater Business

The following article about Orenco's MVP control panels appeared in the October, 1999 issue of CEE News:

Pump-Panel Solutions - By Brent W. Ballow

Orenco Systems, Inc. (OSI), an engineering/manufacturing firm in Sutherlin, OR., discovered that pump panels with control and alarm features were the key to their packaged systems' reliability.

The company specializes in residential and commercial wastewater treatment, re-use, and disposal. OSI creates products primarily used for collecting and conveying septic tank effluent and for treating it through filtration, usually on-site. All of OSI's packaged systems include pump panels, which are manufactured at OSI's Sutherlin facility.

The control panels are important because OSI's treatment philosophy is centered around "timed dosing," in which wastewater effluent is treated whenever it flows through the tank. Timed dosing produces better treatment of wastewater and prevents overloading of drainfields and sand filters.

In order to ensure panel reliability and maintain affordability, OSI's engineering staff recently revamped many of its panel designs to take advantage of a new digital logic module given the trade name, "LOGO!," by its manufacturer, Siemens Energy and Automation. It was soon clear that the inclusion of a logic module would allow them to reach the goal of reliability and affordability.

Pump panel requirements

Pump panels require varying degrees of intelligence, depending on the application. The typical OSI system consists of a septic tank and a pump that moves liquid effluent from the tank's "clear zone" to a drainfield or sand filter. In systems with a sand filter, a second pump is needed to pump from the sand filter to the drainfield. In all of the systems, float switches provide signals to activate or deactivate the pump and trigger alarms, depending on the liquid level. These switches are conventionally hard-wired to relays, timers, and counters.

It is also recommended that the panels have cycle counters and elapsed time meters to keep track of pump operation, providing useful maintenance and troubleshooting information. All these electromechanical devices control and monitor activity in the main tank or sand filter.

Until recently, these relays, timers, and counters were separate hard-wired electromechanical devices, purchased from a variety of suppliers for as little as $60 to as much as $400 for some of the larger items. While digital products have been replacing electromechanical devices for some time, they have been large devices requiring a PC interface with proprietary software and programming language. If you wanted to reprogram a unit in the field, or even set up the controller for the first time, you needed a laptop computer or an expensive operator interface. Consequently, OSI had been sticking to hard-wired electromechanical devices until learning about logic modules.

Installing a Logic Module

Using logic modules, OSI has been able to replace many electromechanical components with a single digital one. Imagine a product small enough to fit in the palm of your hand, yet digitally capable of replacing all of a pump panel's electromechanical relays, timers, counters, and alternators. Imagine too that such a device snaps easily onto a 35 mm DIN rail and has its own built-in programming keys and display. Now imagine that all of this is no more than one-fourth the combined price of the six or eight electromechanical devices that it replaces.

The small module being used has a relatively large LCD screen on its face, as well as built-in programming keys. It can operate on 12 V dc, 24 V dc, or 115/230 V ac control voltage. The standard model measures 72mm by 90mm by 55mm. The wider version, which is 126mm wide, offers more memory and features. Both versions have been introduced into OSI's panel designs including the standard model with single pump applications and the wider version with multi-pump applications.

Although a PC can be interfaced to the device, it is really not necessary since there is minimal programming to learn. All of the functions are stored in a library of function blocks. These blocks include timers, counters, and relays. They come in a variety of types: on-delay and off-delay timers, pulse relays, latching relays, UP/DOWN counters, 24-hour clocks, and more.

The wider version of the logic module also has an impulse relay function and an operating hours counter. All of these device functions are complemented by a library of Boolean functions such as AND, OR, NOT, NAND, NOR and XOR. The basic model features six digital inputs and four digital or relay (8A) outputs. The wider version has 12 digital inputs and eight digital or relay (10A) outputs.

More features at less cost

Logic modules have allowed OSI to increase the versatility and reliability of its control panels, while reducing costs. Cost savings are achieved in many ways. As noted earlier, the company was able to replace many expensive components with one component. For example, the sequencing relay previously built into multiplexing applications cost more than the logic module unit itself.

The logic module also requires minimal wiring, which can cut assembly time in half, saving labor cost. Finally, the decreased space requirement has allowed OSI to reduce the size of its enclosures, which cost less and are less expensive to ship.

By reducing the size and cost of components, OSI has been able to build in additional components that give customers increased capabilities. Previously, its panels offered a single timer to control pump cycles. Now they can have two or more timers with different settings to adjust to the flow conditions.

Size reduction not only gains more panel space for more timers, but the timers are now digital and very accurate. Also, as mentioned earlier, elapsed time meters and counters are a highly recommended option for pump maintenance and troubleshooting. These features are included in the wide logic module unit and will shortly be included in all units.

Other functions that were difficult or impossible in previous panel designs are now practical options. For example, using a clock generator function in a logic module, OSI can program the panel to give different alarm light signals depending on whether the alarm is for a high-level condition (steady light) or a low-level condition (blinking light). Previously, another light would have been added, as well as two additional relays to differentiate between high and low levels. Audible alarms can also be programmed to reactivate after a specified time if the homeowner or operator silences it without fixing the underlying problem.

In addition, all versions of the logic module feature a non-volatile, removable EEPROM card as an option. That can be particularly useful, as it allows field technicians to make changes or upgrades simply by plugging in the EEPROM card that has been programmed back at the shop.

Previously, a change required taking a system down, shipping the panel back for retrofitting, and reinstalling the panel. This process could sometimes take a week or more. Now changes can be made by mailing a new EEPROM card.

Logic modules have also made OSI's control panels more reliable. With previous panels, a bad float switch could cause chattering of the contacts, which can burn out the main contactor. Built-in delay timers on a logic module eliminate any potential for chattering and lengthen the life of the contactor.

International versatility is another important consideration. OSI's New Zealand distributor will be able to use the newly designed panels with only minor modifications to the panel. None of the modifications involve the LOGO!, since the unit can operate on a 240VAC/50Hz system and is VDE0631,IEC1131,CSA approved and UL listed. The module's enclosure is IP20 and NEMA 1 protected.

Future applications

Now that logic modules have proven themselves versatile and reliable, new options are being explored. For example, OSI is looking at an ASi-interface for more complex applications. AS-i is a modular bus system for connecting field devices and has the same advantages. Adding AS-i even expands the available digital input and output capability currently available in the module itself.

The following article appeared in the March 12th issue of The Independent, in Edgewood, New Mexico:

Where the grass is always greener - By Monika Parker

Have you ever noticed that the grass is always greener over your septic leach field? What if you could reuse the water growing all those weeds to grow a garden that could include any zone 5 plant imaginable, except those used for food?

Imagine a small lawn area for the kids to play on and for you to curl your toes into after a long day. Think about a cut flower or perennial garden that would provide you with fragrance and beauty for most of the year.

Visualize absolutely huge trees shading your patio and windbreaks that would shelter you in spring. Think about being able to create a sanctuary for you and your family to come home to.

Think about having this without an astronomical water bill at the end of the month. Think about adding to the water table instead of depleting it.

All this becomes possible with the addition of sand or peat moss filters that can be fitted to your existing septic system. First, put away anything you are eating, and then I'll tell you how to garden in the East Mountains, guilt-free.

Raw sewage flows from your house into your septic tank. The solids sink to the bottom of the tank, and the liquids, called effluent, flow out into the leachfield. A septic tank is so watertight that when five gallons of sewage enter from a toilet flush, five gallons of effluent must flow out of the tank.

This and all the other water piped to your septic is lost as it drains into the leachfield. Because New Mexico is so dry, some of the water seeks the dry soil on top of the leachfield, creating the greenery that is so evident. Instead of using those extra nitrates and water to raise a crop of weeds, you could be reusing the water to create your own little paradise.

By using sand or peat moss filters that attach to your existing system and then combining it with drip irrigation products, you can water your garden or windbreak knowing that you are reusing a precious resource. For more information on installing a sand filter kit call 1-800-348-9843 and ask for a brochure or get online at www.orenco.com.

Now, on a more personal note, I want you to imagine one more thing. Imagine all future businesses in Edgewood using this system and creating shaded parking lots and windbreaks to make shopping more comfortable. Imagine Old 66 lined with trees and medians blooming with perennials and shrubbery. Imagine all of this not costing you a cent. Bringing beauty to others is the goal and wish of all gardeners. Help me persuade the Edgewood town fathers (or mothers, if you prefer) to consider this alternative to a town sewer plant.

The following article about Orenco's growth appeared in an October issue of the Douglas County News-Review:

Orenco Flows to Top of the Field - Sutherlin onsite wastewater systems company flourishing

By Eric Fetters, The News-Review

Sutherlin - Inside the metal warehouse buildings at the old Sutherlin airport, workers are building new products, putting together pump systems and gathering parts that will be shipped as far away as new Zealand and Scandinavia.

Outside, stacks of white and mint-green plastic pipes occupy the asphalt where small planes used to take off and land.

Near the piles of pipes sit stacks of molded fiberglass manhole covers. Jeffrey Ball, general manager for Orenco Systems Inc., picks up one of the lids, which look a bit like huge green Frisbees.

These lids, designed to cover access entries to septic tanks, are one of the unique products his company can boast about.

Ball's brother, Eric, who serves as Orenco's vice president of development, designed them. The resin-transfer molding process he suggested for making the lids was new at the time.

"When Eric first proposed making these lids with the process, some experts said it couldn't be done with fiberglass. Eric defied them all," Ball said with pride.

Orenco, now 18 years old, has carved out a niche and gained a reputation for being on top in the relatively unknown business of onsite wastewater systems, Ball said. In 1983, the company received its first patent for a new pump vault design. The company now holds several patents, including a few international ones, for some of its homegrown technology.

"We have quite a few competitors but I don't think there's one that offers as comprehensive a product line as we do," Ball said. "We have a reputation as being leading edge, and we devote a lot of time, commitment and money to new product development."

The activity and growth at Orenco is impressive. It also often goes unnoticed outside the company's manufacturing site and headquarters. But the maker of wastewater collection systems and related products is enjoying success and planning to expand its facilities. Orenco now employs 152 people.

As Ball admits, most people - even those with septic tanks at their homes - like to "flush and forget." No one likes spending time thinking much about where the wastewater goes.

More than 20 years ago, with many old septic systems failing, the state and Douglas County were forced to face up to wastewater problems, however. The state Department of Environmental Quality began denying permits for a large number of new septic systems until those problems were corrected. Douglas County started an ambitious program to clean up local problems and a group of engineers, soil scientists and other experts started working on solutions.

During that process, the group discovered much of the equipment they wanted to solve wastewater problems was not commercially available. So in 1981, several engineers founded Orenco to manufacture the specialized hardware. Ball's father, Hal Ball, and Terry Bounds were two of the founders of the still family-owned company.

"Basically, it all started in a farmhouse near Roseburg. It's quite a story," said Wayne Luzier, director of the Coos Curry Douglas Business Development Corp. He assisted in Orenco's effort to move in 1994 from its location in the Melrose area west of Roseburg to the old airport site in south Sutherlin.

At that site, Orenco's office, warehouse, and manufacturing buildings sprawl over more than 10 acres located in the Sutherlin-Oakland Enterprise Zone. Behind the doors of the large metal buildings, Orenco's workers develop and put together pump and filter systems, many of them custom-built for different commercial-scale projects. In the manufacturing buildings, metal racks rising toward the high ceilings hold an endless array of pipes, plumbing joints and parts.

Though Orenco has managed to develop an efficient manufacturing process, Ball said, much of the equipment it makes has to be tailored specifically.

"That's because there's a lot of different needs and problems to do with wastewater. And there's a lot of different regulations across the country. ...It's not like we're here making Hula-Hoops," Ball said.

Orenco also makes electrical control panels for municipal wastewater pump stations and similar uses. Sandra Huffstutter, Orenco's marketing manager, points out the company has been able to diversify outside the wastewater industry with the panels - some are used by utilities, others for large ventilation or refrigeration systems.

But onsite wastewater systems, such as sand filters, and parts used in septic systems are Orenco's focus. It's an expanding field as small communities and developers of new subdivisions are increasingly looking for alternatives to using traditional septic systems.

"There's a trend toward using onsite wastewater systems as a solution for new development. Not only because people are moving to rural areas, but also because they are becoming more accepted technology," Ball said.

The Environmental Protection Agency and an increasing number of states are more receptive to the newer systems as well.

In Douglas County, Orenco's practical successes include Elkton, where the company installed a specialized effluent sewer system to fix problems caused by failing septic systems.

The company completed a project to handle wastewater at Seven Feathers Hotel & Casino Resort, and its components are in use in Glide and Sutherlin as well. Orenco's systems also are now in use in the African nation of Guinea and it has donated pumps to improve sanitation in Guatemala.

Orenco has distributors across North America, but the company also deals directly with contractors, municipalities and commercial customers for large projects. Next month, the company will unveil a flashy new Web site that will outline its products to the general public and potential customers. Huffstutter said it will help the company get its word out easier. After all, it's not always easy to explain in words the ins and outs of things such as hydrosplitter enclosures and high-head effluent pumps.

"Essentially, it's really hard to explain to people all that we do," she said.

Though Sutherlin might seem like an unlikely home for a specialized manufacturing company that does international business, Ball said the location on the Interstate 5 corridor is beneficial. More importantly, the company was founded in Douglas County and intends to stay here, he said. Ball said the business plans to expand its office building and construct a new 40,000 square foot manufacturing building at its location within the next two years.

"We think we have a very bright future."

The following article appeared in the Wednesday, August 10th issue of the Oregonian:

LCDC Should Get Out of the Wastewater Business

I'm in the process of buying a five-acre lot in a new, 26-lot subdivision in West Roseburg, less than three minutes from I-5. The young man subdividing the property, Duane Dominguez, could be a poster child for enlightened development. Working to meet or exceed the requirements of 20 different government agencies, he's preserved one-third of the site as a greenway. Planted 2,000 trees along the creek to enhance the riparian zone. Required all home owners to add wildlife enhancements to their properties. Restricted road building activities to July and August. And now he's shopping for large quantities of wildflower seeds to sow along the roadside.

So when my plat map arrived in the mail last week, I was surprised to see the plans called for 26 septic drainfields, one for every lot. Knowing something about rural wastewater systems, I knew that this was not an enlightened approach. Our 130-acre subdivision is ideal for a small community wastewater system . . . ideal for a low pressure sewer (sometimes called an "effluent sewer") with centralized collection and treatment of the wastewater for all 26 homes, and centralized monitoring and maintenance to protect the environment.

The federal Environmental Protection Agency (in a 1997 Report to Congress) has come out strongly in favor of these small community wastewater treatment systems. When properly designed and constructed, they can treat wastewater to within one percent of drinking water quality. They're easy to build and maintain. They allow reclamation of treated wastewater for irrigation. And they meet and exceed the goals of the federal Clean Water Act.

So I called Duane to find out why he hadn't specified a community collection and treatment system for our subdivision. Turns out, he had! His soil scientist had recommended it, and Duane wanted to do what was right for the environment. Douglas County supported the idea. So did the DEQ. So who stopped it? Our state's Land Conservation and Development Commission (LCDC). How? With Goal 11.

Goal 11 forbids "the establishment of sewer systems outside urban growth boundaries"-even low-impact, small-pipe effluent sewers for neighborhoods. In fact, it's LCDC's unwritten policy to prohibit rural property owners to connect more than three homes for the purpose of treating their wastewater. When I called LCDC for an explanation, one of the amendment's authors, Bob Rendy, said that the rule is intended to limit rural development. Without it, rural densities would be higher. When I asked if it wouldn't make more sense to just mandate the desired densities, he said that restricting utility services is just "one more tool" that's available for that purpose.

If LCDC's intent is to restrict rural development, the amendment to Goal 11 doesn't work. The area is zoned for five-acre lots, and Duane subdivided the property into five-acre lots. He did not exceed the designated densities. LCDC's restrictions didn't do a thing, other than to deny our enlightened developer the option of installing a well engineered wastewater system that is environmentally sound and centrally managed.

If LCDC's intent is to restrict rural utilities, the amendment to Goal 11 doesn't do that, either. The lots are serviced by a community water system (Umpqua Basin Water), by a community cable system (Falcon Cable), and by a community electrical system (Pacific Power & Light.) LCDC only forbids community wastewater systems. . . the one utility that could do the most to protect the rural environment.

I know what I'm talking about. In addition to being an angry property owner, I also work for Orenco Systems, a Douglas County company that designs and makes products for small community wastewater systems. My company also makes products for individual septic systems. And thanks to the stupidity of LCDC's rules, Orenco stands to earn more by selling individual septic systems to the individual property owners in my subdivision than they would have if my neighbors and I had been permitted to jointly purchase a community system from my company.

Even though my company profits from the illogic of Goal 11, the company's founders - Hal Ball and Terry Bounds - have been fighting it. They've written letters, appealed to their state legislators, and submitted testimony. Not because Goal 11 hurts them financially - just the opposite - but because it's wrong! To be good stewards of our land, wastewater treatment systems - even rural ones - should be centrally monitored and maintained. The Environmental Protection Agency knows it. The Department of Environmental Quality knows it. My company knows it. And Duane knows it.

Goal 11 prevents the most appropriate wastewater technology from being used on rural lands. Clearly, wastewater regulations are not within LCDC's area of expertise, and the agency should get out of the wastewater business. As for me, I can't help but conclude that LCDC's control of land uses and densities must be very fragile if the agency sees the need for such tenuous rule-making. LCDC's Goal 11 isn't a "tool" - it's a crutch.

By Sandra Huffstutter

Sandra Huffstutter left Southern California 21 years ago, partly out of concern over the region's unsound water and wastewater policies. For the past year, she has been Marketing Manager for Orenco Systems, Inc. a Douglas County company with an international reputation for its expertise in designing decentralized wastewater treatment and collection systems.