- Industry: Plastic piping production
- Application: semi-closed cooling water loop
- Problem: biofouling and poor water quality damaging product and slowing production
- Solution: Get Clean, Keep Clean approach included bioDART® biofilm monitoring, equipment updates and improved chemical package and monitoring.
- Results:
No unplanned downtime and costs20-40% boost in productivity, yielding 16,000 km of pipe production increase – equivalent to ~€120,000/yr more revenue.
Problem
This plastic extrusion company produces over 100 meter/minute of HDPE pipe and conduit at their factory in Poland. The production line was experiencing daily stoppages and quality issues due to water quality issues. As much as 10-15 km of product was being lost every day. The interruptions were resulting in scrapping considerable lost product and the facility was experiencing a staggering 20-40% slowdown in production.
Knowing how critical the cooling water quality is for the quality of their product, plant leadership contacted Chem-Aqua for help.
Analysis
The Chem-Aqua team evaluated the facility. The factory uses a semi-open system of cooling water. The water in the 45 m3 water system was visibly turbid and discolored throughout the system, including open tabs and tanks. This was due to microbiological contamination and biofouling. Considering how critical water quality, pressure, temperature and flow are for the integrity of the final product in this industry, Chem-Aqua team decided to deploy a comprehensive, 360 approach including a number a different chemical and equipment solutions, including several patented products designed specifically for challenging microbiological and biofilm control.
Solution
The Get Clean, Keep Clean program was implemented. This program brings forth a combination of chemical, equipment, and best practices solutions tailored to the individual problems of the location.
In response to the plant management request to minimize the time related to downtime and cleaning, the program was tailored to get the system cleaner first and then keep it clean, all while operations continued.
360° approach: Get Clean, Keep Clean™
Chem-Aqua implemented a extensive range of measures designed to control the impervious nature of microbiological growth in such open cooling systems. The key element chosen to clean the system was the new, patented bioeXile®-L. This non-toxic, non-biocidal product disintegrates the protective biofilm layer, under which the bacteria are protected and thrive. The exposed bacteria are then killed by registered biocides.
In addition, a bioDART® biofouling monitor was installed. This unique, patented device measures biofilm formation and growth in real-time, facilitating a swift reaction to any changes in microbiological load. As an additional benefit, the 24/7 monitorisation with the bioDART allowed also refining the microbiological control program, which now includes:
- Periodical addition of bioeXile-L to disrupt any additional biofilm formation
- A regular dose of persistent non-oxidizing biocide combined with as needed application of a swift reacting oxidizing biocide.
Additional measures included filtration, latest generation corrosion and scale inhibitor program as well as modernized equipment package to ensure optimum chemical dosage for system preservation.
As best practice, a full system disinfection is now applied every year during planned technical downtime.
Results and Impact
- The system is now clean and disinfected and is able to remain that way, with water that is visibly clear. This virtually eliminated the lost production from the water contamination induced defects.
- There has been no unplanned downtime, which has eliminated a 20-40% slowdown in line capacity
- Energy efficiency has been greatly improved by eliminating the insulation effect of the biofilm on the heat exchange equipment.
- Consistent product quality is being achieved, which is helping to preserve the brand image.
Customer testimonial
“ We recommend cooperation with Chem-Aqua. They have been providing us with chemicals and mechanical treatment of the cooling water circuit for over two years. They used technology that was individually tailored to our needs, which significantly improved cooling efficiency our devices. Their employees provide professional technical advice and all services are performed professionally and on time.
We recommend Chem-Aqua to other interested parties as a fully professional and reliable partner in the field of cooling water treatment.” – Maintenance Manager
Contact Us Today
Transform your water treatment strategy with aquaDART™ and experience unparalleled control, efficiency, and cost savings. Reach out to our team at Chem-Aqua to discuss how aquaDART™ can elevate your water system performance.
