Saving over 26 million litres through backwash water recovery
- Chris Payne
- Aug 18
- 3 min read
Pilgrim's Europe, an industry leading UK and European food company, approached PureTec Separations to explore options for cutting mains water consumption. Their daily washdown process for livestock lorries used a lot of municipal water. With rising costs and pressure to meet environmental goals, the site needed a practical solution. PureTec worked closely with the team to create a simple and effective system. Since 2022, it has saved over 26.5 million litres of water by using recovered backwash and rinse water.
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The business challenge
The site’s lorry washdown used mains water exclusively. With growing demand, rising water costs, and sustainability targets to meet, the business needed to reduce municipal water use, without disrupting operations or compromising hygiene.
The question was if the waste water from the softener regeneration process could be safely reused. This reuse would be for non-critical tasks like washing down lorries. The challenge was to find the cleanest parts of the waste stream for recovery. This needed to be done without impacting the softener performance or system control.
The PureTec solution
PureTec carried out a site survey and analysed softener regeneration patterns. On average, the site ran 3.46 regenerations per day across three softener streams, producing a combined 40.48 m³/day of low-salinity waste from backwash and fast rinse cycles.
By excluding the high-salt brine draw phase, PureTec proposed diverting only the cleanest portions of the waste to a reuse system.
To deliver this, working alongside Pilgrim's Europe and Arc Fabrications:
Two air-actuated valves (one normally open, one normally closed) were integrated into the pipework.
These valves were connected to the site’s control loop, allowing the system to automatically switch flow during the brine draw phase.
The result was a fully autonomous recovery system that required no manual input or interference with existing softener performance.
System upgrades included
Pipework modifications to introduce a dual-leg configuration
Integration of air-actuated valves for automated switching
Full connection to the site's existing control system
Use of a dedicated break tank for storage and reuse
Control logic tailored to isolate suitable waste streams only
The results
Since its completion in May 2022, the system has saved over 26,587,000 litres of water (as of June 2025), based on continuous reuse of softener backwash and fast rinse water. The site has reduced reliance on mains water without affecting hygiene or interfering with the core softening process.
The system runs automatically with no need for manual oversight and has integrated seamlessly with existing operations.
Additional Outcomes
No operational disruption during install or commissioning
Delivered with minimal capital investment
Improved resource efficiency with no impact on regeneration performance
Supports environmental compliance and long-term water reduction goals
Key Benefits at a Glance
Over 26.5 million litres saved between May 2022-June 2025
40.48 m³/day of water reused, reducing strain on municipal supply
Fully automated system, integrated with existing controls
Sustainable upgrade, with measurable impact and minimal cost
Why PureTec?
PureTec specialises in sustainable water treatment systems that combine innovation with practicality. Every system we design is tailored to meet real operational needs, whether that’s reducing water usage, meeting compliance, or extending system life.
For Pilgrim's Europe, we delivered a straightforward, reliable system that proved how even small interventions can deliver big results. By repurposing waste and reducing consumption, we’re helping clients take smart steps towards long-term sustainability.
If you're looking to improve your water recover, reuse and sustainability, contact PureTec today.
