New screen sizing guideline
After much experimentation and observation, there is a new guideline that can be followed for sizing your scrubber screen. Instead of sizing the screen based on the size of the display tank or system water volume, you can size the screen based on how much you feed the tank. This actually makes a lot of sense if you think about it, because the nutrient load is directly proportional to the amount of food you add to the tank.
Here's the guideline:
Each cube of frozen food you feed per day needs 12 square inches of screen, with a light on both sides totaling 12 watts. So if you feed 1 cube of food per day, then a 3x4 screen with a 6 watt lamp on each side (actual, not equivalent) will adequately filter the system. If you have a larger tank and you feed 10 cubes per day, you would need a 120 square inch screen with 120 total watts, or 60 watts per side (again, actual wattage).
If you feed flake food, feeder fish, etc, then you need blend it up super-thick, strain out the excess water, pour it into a cube, and see how many cubes that comes to. For Nori, 8 square inches is equivalent to 1 cube.
Just so you know, I run a screen that is about 120 square inches with 4 24W T5HOs and really good reflectors, and I feed my tank roughly 6-8 cubes per day or a DIY food, and grow a ton of green algae, and I have zero waste buildup anywhere in the tank. So this really is a pretty accurate way of sizing your system.
Now, I realize that there are a lot of people who have already built systems that are looking at this now and thinking that their scrubber is way too big. Feeding 10-12 cubes per day to a 100 gallon system is a lot of food, and costs a lot of money, so in reality, most people aren't doing this. Unless you're like me, and feed a total tank food that costs $10 for a bag that is roughly 2x as big as a bag of Rod's Food, it costs way too much.
Having an oversized scrubber is not a bad thing, as long as there is enough light and flow. IMO, a larger scrubber is better, as long as the flow and lighting are good, because it can more adequately handle variances in the system such as overfeeding, or an organism death that cannot be removed (or is not even known about), addition of new corals, fish or inverts, or an outbreak of algae, cyano, dinos, etc. It also allows you to maximize the use of your system, meaning you can pack it with corals and fish and feed them all they can physically eat. A large scrubber, sized as has been recommended up until now, is a very robust and forgiving filtration system.
Sizing a scrubber based on quantity and frequency of feeding means that the quantity and size of livestock in the system must be limited. That being said, most people are used to feeding sparingly, as little as every other day or maybe every 3rd day, so minimal feedings are where they are at and where they plan to stay. So if you build a feeding-scaled scrubber, you just have to be aware of the limitations of that system.
Now that this option exists, it releases many other possibilities for new builds, and solutions for existing problems. This is potentially good news for many out there trying to fix issues such as flow rate due to plumbing and pump restrictions or space restrictions preventing adequate lighting.
If you have a screen that doesn't have enough flow (less than 35 GPH/in of screen width) and you don't have any way to increase the flow short of a total or partial tear-down, then just shorten the screen.
If you don't have the space for additional light fixtures, don't sweat it. Just realize the limitation of your system. Ideally though, you do want the screen to match the size of the area that is fully illuminated, as that area is really getting the effective growth. Or at least, you only want to consider the area that is adequately illuminated as being your effective filter size. If your scrubber is inadequately lit and you are experiencing issues, consider increasing the lamp wattage and adjusting the photoperiod (discussed in the next update)
If you aren't getting thick green growth, it is most likely because you don't have enough flow, don't have enough light, you're not feeding enough, or a combination of those factors. Green growth does the best filtering, so that is what you want. If you keep the same lighting and flow, then reduce the width of the screen, you bring the same amount of nutrients to a more compact area of algae growth which receives more intense light.
Next subject: Over-lighting your screen