Expanding the foundations of process-water treatment

In this blog we explore why PureTec is strengthening its capability in coarse and process-water filtration. It looks at the rising pressure on industrial water systems and the need for a more complete view from intake water through to advanced treatment. It introduces the experience brought into the business through our newest team member, Dan Norman, and shares lessons from past projects in manufacturing and offshore environments.

Industrial water systems are evolving as plants work to manage energy use, stabilise production and reduce waste. These pressures are pushing operators to look more closely at the early stages of their water processes. Intake water, coarse filtration and the first steps of process-water control now carry more weight, because they shape how well the rest of the system performs.

PureTec has traditionally focused on membrane and fine-filtration treatment. Microfiltration, ultrafiltration, nanofiltration and reverse osmosis remain core strengths within the team. These stages will continue to play a major role in the way we support customers. To meet growing demand from industry and to give clients a more complete route through the water cycle, we have widened our capability with the addition of coarse and process-water expertise brought in by our newest team member, Dan Norman.

Why early-stage filtration matters

Coarse filtration is often seen as a simple mechanical step, yet its impact carries through the entire plant. Intake water sets the conditions for pumps, heat exchangers and downstream filtration. When grit or debris enters the process, it affects heat transfer, fouling rates and chemical demand. These problems then show up later in the system, sometimes long after the original cause has been forgotten.

Dan brings long experience in this space, covering filtration from 10 millimetres down to one micron. This strengthens PureTec’s ability to support the earliest stage of a plant’s water process. It also means customers can work with a single partner from intake water through to their membrane plant, instead of splitting responsibility across multiple suppliers.

The importance of this early stage is easy to overlook. Many issues that appear in fine  filtration systems have their roots in coarse filtration and process-water control. With the right foundations, the rest of the system performs more predictably. Without those foundations, operators face hidden costs and recurring downtime.

Learning from real process-water challenges

Past project work in the PVC extrusion sector shows how early-stage improvements can transform process-water performance. The manufacturer had been dealing with subtle but costly defects in its profiles. These marks came from particles in the cooling baths. The plastic entered the cooling water while still soft. Any grit left a visible line along the length of the product. Each line meant waste, rework and lost production time.

Dan had worked on the filtration upgrade for this site. The solution delivered cleaner cooling water, better protection for the heat exchanger and lower downtime. The results recorded also showed how backwash-water recovery reduced water losses from several percent to less than half a percent. This change cut water use, discharge fees and chemical consumption. It also lowered the energy needed to chill replacement water. These combined benefits brought the payback period down to around nine months.

This type of challenge is common in manufacturing. Operators often look first at the point where the defect appears. In reality, the cause usually begins upstream. When the early stages of filtration and process-water control are stable, the rest of the system becomes easier to manage.

Understanding risk in harsh environments

The same principles apply in harsher settings. Offshore operations offer a clear example of how filtration ties directly to production. Dan’s previous work in oil and gas involved upgrading gearboxes on offshore filters before they reached the end of their availability. Failure would have carried a significant cost. Downtime figures were estimated in hundreds  of thousands of pounds per day.

This project required a full assessment of the equipment across the platform. Some units were older models. Others were newer. Compatibility needed to be confirmed. Engineers were sent offshore to inspect the filters and plan the upgrade. Once confirmed, the new gearboxes were produced, shipped and installed, with training delivered to site technicians. 

The work kept the system reliable and avoided unplanned interruption to the plant’s output.

These environments highlight the value of experience. Decisions are made with a direct link to operational risk. Planning, inspection and compatibility checks play just as big a role as the equipment itself. Bringing this thinking into PureTec strengthens the way we support customers in sectors where reliability is critical.

A broader view of process-water performance

As water challenges grow more complex, industrial sites are looking for partners who can support more than a single stage of treatment. Many want a full view of their system, from intake water to final polishing. Strengthening our team with coarse and process-water experience allows PureTec to offer that wider perspective.

This broader view helps customers understand the connections between early filtration, process-water stability and membrane performance. When the upstream stages are well managed, membranes last longer. RO plants run more efficiently. Chemical demand falls. Downtime reduces. This joined-up approach is becoming more important as plants seek to manage both cost and environmental pressure.

Building on the strengths of the existing team

PureTec already supports a range of sectors including food and beverage, pharmaceutical, industrial, power, hydrogen, data centres and water utilities. These industries rely on consistent water quality to maintain production. The arrival of coarse-filtration and process-water expertise builds on the strengths already present within the engineering team. It does not change our focus. Instead, it allows us to solve more of the problems customers face long before they reach the membrane stage.

The combination of upstream capability and advanced treatment creates a more complete service. It allows PureTec to design, audit and improve systems across the full process-water journey. This also strengthens our ability to help customers reduce water loss, protect assets and improve the stability of their operations.

Looking ahead

PureTec will continue to invest in knowledge that supports practical improvements for our customers. Adding expertise in coarse and process-water filtration is part of that. Bringing Dan’s experience into the business allows us to cover more of the water cycle with confidence. It helps us respond to growing industry pressure and support cleaner, more reliable and more efficient systems.

As plants continue to adapt to new demands, PureTec now offers a wider scope of support. Intake water. Coarse filtration. Process-water control. Microfiltration. Ultrafiltration. Nanofiltration. RO. Planned service. Assessments. Long-term performance support. This combined capability will help customers across our sectors meet future challenges with greater stability and clarity.

To find out more about how we can help you meet your sustainable water goals, please contact us today.