Saving over 1 million litres of water and £45K in one year: how EcoSoft transformed water efficiency at a major beverage site
- Chris Payne
- Jan 23
- 3 min read
A smarter, high-efficiency softener system from PureTec helped an international drinks manufacturer cut waste by 80% and save more than £45,000 in just 12 months.
At a busy production site in Beckton, one of multiple UK locations for a major international drinks manufacturer, persistent issues with hard water were creating inefficiencies and high operating costs. The site’s existing softening system was consuming excessive water and salt, generating high volumes of effluent, and lacking the control needed to optimise performance.
PureTec was brought in to deliver a more sustainable, cost-effective solution, and the results speak for themselves. In just one year, the upgraded EcoSoft system achieved a 80% reduction in effluent, saving over £45,000 and recovering more than 1 million litres of water.
To download the full case study use the link below:
The Business Challenge
The incoming water at the site contained high levels of calcium and magnesium, which led to limescale build-up in pipework, vessels, and critical equipment. This was reducing efficiency, increasing energy use, and driving up maintenance needs across the site.
The legacy softener system added to the problem. Each regeneration cycle consumed large volumes of water and salt, creating unnecessary waste and high effluent discharge costs. PureTec analysis revealed the system was generating around 1,250 m³ of effluent annually, costing over £45,000 per year.
A smarter approach was needed, one that would reduce waste, cut costs, and align with the client’s long-term sustainability goals.
The PureTec Solution
A comprehensive site assessment and analysis identified the existing system's performance patterns. The old softener was generating excessive waste through inefficient regeneration cycles and lacked the advanced control needed for optimisation.
PureTec replaced the site’s softening system with a volume-controlled high-efficiency EcoSoft unit, designed to reduce water and salt use without compromising output or water quality.
Advanced control logic and modern instrumentation were introduced, including a Programmable Logic Controller (PLC) and conductivity meter. These enabled real-time monitoring and allowed regeneration to pause automatically when the ion exchanger was clean and preventing unnecessary flush cycles and water loss.
Deliveries Included
Advanced PLC control system was integrated for precise automated operations
Conductivity monitoring was installed to measure flush water and stop regeneration when ion exchangers are clean
Volume-controlled regeneration replaced time-based cycles, eliminating unnecessary water loss
Modern instrumentation was added to optimise each regeneration cycle
A crucial aspect of this installation was that it was carried out without interrupting the business's daily operations, ensuring that water treatment continued smoothly while enhancements were made. The result was a fully automated, high-efficiency system that required minimal manual intervention while dramatically reducing waste.
System Upgrades Included
Installation of EcoSoft high-efficiency softening technology
Integration of Programmable Logic Controller (PLC) for automated control
Advanced regeneration logic with conductivity-based monitoring
Volume-controlled regeneration system to minimise waste
Complete system configuration tailored to site demands
The Results
The new system delivered a dramatic improvement in performance:
80% reduction in effluent water and discharge costs
£45,000 in savings within the first year
1 million litres of water saved through reduced regeneration
Reduced salt use and less limescale build-up, extending equipment life
Improved operational reliability with fewer interventions and lower labour demands
This install enables it to run automatically with advanced control logic and has integrated seamlessly with existing operations, requiring minimal maintenance intervention.
These gains also supported wider ESG goals, helping the site reduce its environmental impact while improving efficiency across the board.
The return on investment for our EcoSoft installations is under two years, meaning that in addition to lower operational expenses, this installation represents a wise financial choice.
Additional Outcomes Included
Lower energy use and improved equipment longevity due to reduced scaling
Less regeneration cycles needed due to automated monitoring
Fewer maintenance callouts and interventions
Quieter operation and improved on-site reliability
Less strain on wastewater systems and associated compliance tasks
No operational disruption during installation or commissioning
Key Benefits at a Glance
80% reduction in wastewater
£45,000 saved in one year
Up to 60% lower salt consumption
< 2-year ROI through reduced water, salt, and energy use
Fully automated system with PLC control and advanced monitoring
Why PureTec?
PureTec delivers smart, sustainable water treatment solutions that are engineered around real-world challenges. Our EcoSoft range is designed to deliver measurable operational and sustainability benefits, from reducing salt use and water waste to cutting energy bills and extending asset life.
At every stage, our focus is on practical innovation, working closely with clients to create systems that are efficient, compliant, and built to last.
