A primary sludge fermentation-elutriation pilot plant was operated using in-line and side-stream schemes. The influence of solids retention time, recirculation sludge flow-rate and solids concentration on the fermentation-elutriation process performance has been assessed in this paper. The use of high elutriation flows (12% of influent flow) improved the volatile fatty acids (VFA) concentration in the effluent stream. Suspended solids removal efficiency decreased in the primary settler when the solids retention time (SRT) was increased from 4 to 8 days. Disintegration step during hydrolysis process was pointed out as the main reason for that decrease. Maximum VFA productions were achieved at SRT between 6 and 8 days at the highest elutriation flow tested for both configurations. Propionic, butyric and valeric volatile fatty acids percentage increased when total solids sludge concentrations above 23,000 mg l−1 were used. Hydrogen accumulation, causing acetogenic bacteria inhibition, was indicated as the reason for C3-C5 fatty acids accumulation.