Reducing maintenance costs and improving reliability for a leading soft drinks manufacturer

A major soft drinks manufacturer was experiencing recurring issues with its water treatment system, leading to frequent service call-outs, rising operational costs, and occasional production disruptions. PureTec was brought in to deliver a long-term solution focused on safety, reliability, and efficiency. Following a full system review, targeted upgrades were implemented to improve performance, reduce risk, and secure sustainable gains.

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Reducing Maintenance Costs and Improving Reliability for a Leading Soft Drinks Manufacture.

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The Business Challenge

The site had inherited a number of issues from a previous service provider, including:

• Frequent breakdowns and service call-outs

• A hazardous and outdated acid handling system

• Ageing stainless-steel regeneration pipework prone to failure

• Inconsistent water pressure and inefficient distribution

• A dealkalisation vessel setup that caused pressure drops and system stress

With system performance affecting both operational reliability and running costs, a more efficient and resilient setup was urgently needed.

The PureTec Solution

PureTec carried out a full assessment of the system and identified a range of improvements. These included both engineering and safety-led upgrades to support sustainable, long-term performance.

System upgrades included:

• Replacement of the acid handling system with a safe, independent day tank and valve setup

• Swap of failing stainless-steel pipework with robust polypropylene for improved chemical resistance

• Installation of a booster pump with PID control and break tank to regulate pressure and ensure compliance

• Upgrade of the dealkalisation vessel top lateral system to reduce pressure drops and improve efficiency

• Integration of a free chlorine removal system to protect resin lifespan and support optimal regeneration

  
  

These targeted interventions were delivered with minimal disruption to operations and designed with serviceability in mind.

The Results

The upgraded water treatment system now operates with improved stability and significantly reduced service requirements. Over a five-year period, only two service call-outs were recorded — a marked reduction that reflects both the reliability and long-term cost savings achieved through PureTec’s solution.

Additional outcomes included:

• Extended resin life thanks to reduced chlorine exposure

• Safer operation through modernised acid handling

• Lower maintenance costs due to fewer breakdowns and simpler servicing

• Proactive maintenance strategies enabled by a more intelligent and stable system

Key Benefits at a Glance:

• Reduced Maintenance Costs – Fewer call-outs and optimised regeneration cut operational expenses

• Enhanced System Reliability – Intelligent upgrades enabled consistent performance and minimal downtime

• Improved Safety – Day tank and valve system reduced risks in acid handling

• Longer Equipment Lifespan – Chlorine removal and design optimisation extended resin durability

• Greater Operational Efficiency – Stable water pressure and improved flow distribution supported production

Why PureTec?

At PureTec, we specialise in engineering intelligent water treatment systems designed to reduce operational risk and deliver measurable cost savings. Our expertise spans everything from dealkalisation and chemical management to turnkey system upgrades and performance appraisals.

We work closely with manufacturers to understand their infrastructure, pressures, and priorities — then apply practical engineering know-how to deliver future-ready solutions.

The bedrock of our philosophy is to provide our customers with the best practical solutions when faced with the challenges presented to us.