Meeting Growth Demands with a High-Performance Dealkalisation System
- Chris Payne
- Jun 16
- 3 min read
Updated: Jun 18
How PureTec engineered a future-ready system with 125% increased capacity for a leading soft drinks manufacturer
The Business Challenge
With production volumes rising and an ageing water treatment plant nearing the end of its lifecycle, a leading soft drinks manufacturer needed a complete system redesign. The existing setup, made up of three fixed dealkalisation/organic scavenger streams each delivering 40 m³/hr, was capped at a total of 120 m³/hr and no longer met the site's evolving needs.
Alongside increasing capacity, the site required a more flexible system to improve uptime during regenerations, reduce water and chemical use, and provide better visibility and control of operational data. Any upgrade had to maintain the exact treated water specification to protect product taste and meet modern safety, environmental, and cybersecurity standards.
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Our Approach
PureTec designed and delivered a multimillion-pound, high-capacity dealkalisation and organic scavenger system built to support long-term production growth while reducing operational risk and resource use.
The new system features three dealk and three organic scavenger vessels, each capable of 90 m³/hr, increasing total flow to 270 m³/hr, which is a 125% capacity uplift. The vessels are configured for flexible pairing, allowing any dealk to feed any OS. Unlike the original system, which would take a full stream offline during regeneration, the new design allows only the vessel undergoing regeneration to be isolated, keeping the rest of the system fully operational.
To support real-time process control, we integrated a full suite of Endress & Hauser instrumentation, including digital flow meters, pressure and level transmitters, and pH and conductivity probes. All components are connected over Profibus and linked back to a Siemens PLC, giving the operations team high-level oversight of system performance and usage trends.
The system also includes high-efficiency UV treatment units, both pre- and post-treatment, to support water quality and hygiene standards. Although confirmed savings on regeneration cycles are yet to be measured, the system uses live pH and conductivity readings to advance through regeneration sequences, offering the potential for significant water and chemical reductions over time-based processes.
Enhances Safety and Control
Health and safety was a core priority for our client. The new design includes self-bunded hydrochloric acid storage tanks, automated dosing controls, and double-walled pipework to contain and manage chemical risk. Remote access capabilities, validated by Siemens, ensure full compliance with EU765/2008, EU768/2008, and IEC62443, and give engineers secure access to support recovery or troubleshooting.
All work was delivered to the highest technical standards, including welding procedures certified to EN287 and EN288/15614, and project planning ensured minimal disruption to existing operations during installation.
The Results
The new system is designed to deliver long-term operational resilience, smarter process control, and consistent treated water quality - all while supporting the site’s projected production growth.
With greater flexibility, built-in cybersecurity, and the potential for resource savings, the site now benefits from a modern, future-ready installation engineered to evolve alongside its operations.
Key Stats
125% increase in treatment capacity, from 120 m³/hr to 270 m³/hr
Flexible vessel pairing enables continuous operation during regeneration
Endress & Hauser instrumentation and Siemens PLC integration for real-time control
Smart regeneration design using live pH and conductivity feedback
Enhanced safety and compliance, including bunded tanks and remote access certified to IEC62443
Want to Learn More?
Speak to our team to find out how we can deliver a system that meets your operational, safety, and sustainability goals.
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