BACKGROUND: Hexavalent chromium (Cr(VI)) is toxic to humans, animals and plants. Conventional treatment technologies reduce Cr(VI) to the less toxic and mobile Cr(III), but these methods are usually expensive and generate secondary waste. Microbial Cr(VI) reduction has recently gained attention as a detoxification process, since it enables Cr(VI) reduction through relatively cheap and simple methods. The aim of this work was to investigate the mechanism and the performance of biological Cr(VI) reduction using mixed cultures originated from industrial sludge under continuous operation with recirculation in a pilot-scale trickling filter. RESULTS: Biological Cr(VI) reduction was studied using a pilot-scale trickling filter filled with plastic media under continuous operation with recirculation and the use of indigenous bacterial population. The effect of the organic carbon (electron donor) concentration was examined for constant Cr(VI) influent concentration at about 5.5 mg L-1 and volumetric flow rates ranging from 60 to 900 mL min(-1). The highest reduction rate achieved was 1117 g Cr(VI) m(-1) d(-1) for a volumetric flow rate of 900 mL min(-1). The system's reduction capacity was significantly affected by chromate loadings, resulting in frequent backwashing of the filter. The determination of the reduction mechanism was also studied using batch cultures of free suspended cells and culture supernatant. CONCLUSION: The high reduction rates combined with the low operating cost indicate that the above technology can be a viable solution for the treatment of industrial chromate effluents. (c) 2008 Society of Chemical Industry.