Enhanced UF System performance and reliability for a global hygiene and health manufacturer

A leading global hygiene and health manufacturer was facing persistent challenges with the performance and reliability of its ultrafiltration (UF) system. Frequent service call-outs, unplanned downtime, and outdated components were disrupting operations and driving up maintenance costs. PureTec was appointed to deliver a robust, future-ready solution that would restore system stability, improve energy efficiency, and reduce the ongoing service burden.

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The Business Challenge

The existing UF system was operating on ageing infrastructure and limited automation. Key issues included:

• Occasional pipework failures

• An unsupported programmable logic controller (PLC)

• A lack of feedback functionality, limiting visibility and control

• Outdated components that were increasingly difficult to service

  
  

These challenges were leading to increased service call-outs, higher running costs, and operational inefficiencies across the plant. As a critical part of the site’s water treatment process, the UF system needed to be upgraded to meet the site’s current and future needs.

The PureTec Solution

Following a full system review, PureTec designed and delivered a state-of-the-art UF system upgrade, with a focus on improving operator control, system efficiency, and long-term resilience.

The solution included:

• A new human-machine interface (HMI) for intuitive, real-time operator control

• Valve positioning feedback to support diagnostics and rapid fault identification

• An inverter pump-controlled system to reduce energy usage and provide consistent performance

• A built-in membrane integrity test function for monitoring system health

• An integrated Clean-in-Place (CIP) system to streamline maintenance and safeguard membrane performance

• The use of modern, readily available components to simplify servicing and future-proof the system

The Results

The upgraded system has delivered significant operational improvements. Service call-outs have been dramatically reduced, while improved system intelligence has allowed for more proactive maintenance strategies. The client also saw measurable energy savings through inverter technology and better process control.

Additionally, the inclusion of a larger filtrate storage capacity helped provide further production resilience, supporting consistent operations even during peak demand.

Key Benefits at a Glance:

• Reduced Downtime – Fewer service call-outs and improved system reliability

• Energy Efficiency – Inverter-controlled pumps optimised energy consumption

• Simplified Maintenance – Modern parts and built-in CIP system reduced manual intervention

• Improved Operator Visibility – HMI and valve feedback enabled better control and diagnostics

• Future-Proofed System – Latest technology and instrumentation extended system lifespan

Why PureTec?

At PureTec, we specialise in solving complex water treatment challenges through engineering-led, practical solutions. Our expertise in membrane technology, system optimisation, and sustainable water management helps clients extend asset life, lower running costs, and reduce operational risk.

We partner with our clients to understand their processes, goals, and pressures—then deliver solutions that support long-term performance and business continuity.