The effect of three variables, namely sludge dose, initial pH and fresh coagulant (poly-aluminium chloride, PACl) dose was studied using response surface methodology. About 87% phosphate removal could be obtained at the optimum conditions of sludge dose 13.8 g/L, initial pH 6, and fresh PACl dose 5.8 mg Al/L. In order to achieve a similar phosphate removal, a dose in the range of 30–40 mg Al/L of fresh PACl was required.