A leading UK soft drinks company was facing persistent failures in its multi-stream dealkalisation process, causing costly resin media losses, contamination risks, and production stoppages. Over three years, internal vessel distribution failures led to tens of thousands in repair costs and significant operational downtime.
PureTec Separations was engaged for a site analysis to investigate and resolve these issues, implementing a strategic solution to enhance operational security, reduce costs, and improve system efficiency.
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The Business Challenge
The soft drinks company was experiencing:
Frequent internal vessel failures, leading to resin media loss and process contamination.
Unregulated pH control and high static head pressures, reducing system efficiency.
Chlorine exposure in feedwater, degrading the resin and increasing replacement costs.
Health & safety concerns due to inadequate acid feed pipework design.
Production downtime, impacting overall business operations and profitability.
The PureTec Solution
To address these challenges, PureTec implemented a series of targeted engineering solutions. The regeneration feedwater pipework was modified to reduce static head pressures and prevent surging, significantly improving system stability. A full rewrite of the control logic was carried out, optimising pump and valve operations to minimise actuator failures. Additionally, adjustments to process flow rates and resin volumes were made to enhance performance and extend the lifespan of the resin.
The PH correction system was recalibrated to lower waste volumes to meet EA regulations and allow optimal waste tankage in the system, whilst the resin regeneration system was reprogrammed and accurately monitored to give effective regeneration, while chlorine neutralisation through chemical dosing was introduced to further extend resin longevity. Finally, hazardous acid feed pipework was replaced with high-density polyethylene, improving safety and ensuring long-term system security.
The Results
The improvements delivered by PureTec resulted in substantial cost savings and operational efficiencies for the soft drinks company. The reduction in pressure surging and the optimisation of flow rates minimised system failures, significantly decreasing production downtime and repair costs.
The recalibrated pH system and resin volume adjustments extended service runs, improving water treatment efficiency and reducing the need for acid consumption in resin regeneration.
Additionally, the introduction of chlorine neutralisation helped to extend the resin’s lifespan, reducing the frequency and cost of replacements. The replacement of outdated acid feed pipework also improved health and safety conditions, mitigating risks associated with hazardous materials and creating a safer working environment for employees.
Key Benefits at a Glance:
£60k+ annual ongoing savings through failure prevention
3x extended resin lifespan via chlorine neutralisation
Reduced downtime, enhancing system reliability
Improved efficiency, lowering operational costs and extending service runs
Enhanced safety with secure acid handling systems
Eliminated the possibility of EA fines
Why PureTec?
At PureTec, we specialise in delivering practical, cost-effective solutions that improve system efficiency, reduce operational risks, and maximise asset longevity. Our expertise in reverse osmosis, dealkalisation, and sustainable water treatment optimisation ensures that our clients achieve sustainable, long-term performance improvements.
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