During routine on-site maintenance at a prominent UK brewery, it became evident that inefficiencies in the brewing water supply and treatment processes were creating unnecessary cost burdens. The potential for critical equipment failures also posed a significant risk to production, with reactive maintenance frequently dominating operations.
Understanding the business challenge
The brewery faced several pressing challenges:
High operational costs driven by outdated, energy-intensive equipment.
Frequent maintenance requirements, including costly filter rebeds and premature Reverse Osmosis (RO) membrane replacements caused by iron and manganese fouling.
Increased energy consumption and the risk of production disruptions due to equipment breakdowns.
Our tailored Solution
To tackle these issues, we undertook a comprehensive appraisal of the brewery’s water treatment system, with a focus on optimising the Reverse Osmosis (RO) and pre-treatment processes. The solution was multi-faceted and tailored to address both immediate inefficiencies and long-term sustainability.
We focused on improving the brewery’s water treatment system by upgrading the instrumentation and control software to optimise filtration processes and enhance efficiency. Restructuring and increasing backwash frequencies significantly improved the removal of iron and manganese, helping to minimise fouling. To ensure consistent water quality and system performance, we introduced a new sampling and testing programme.
Additionally, inefficient single-stage horizontal impeller pumps were replaced with energy-efficient multistage inverter-driven motors and installed low-energy RO membranes, which together greatly reduced energy consumption. Finally, we implemented a periodic cleaning regime for the borehole feed tanks to prevent sludge accumulation and further minimise fouling.
Delivering tangible benefits
Our solutions have enhanced plant performance, reduced operational costs, and increased system reliability.
By implementing energy-efficient pumps and low-energy RO membranes, we achieved substantial annual energy savings of approximately £50,000, with a rapid capital expenditure payback period of just three years.
These changes, combined with improved filtration efficiency, extended the lifespan of key equipment and reduced maintenance frequency. Additionally, a proactive cleaning and monitoring approach ensured consistent water quality, minimised production risks, and helped prevent downtime.
The PureTec ethos
At PureTec, our guiding principle is to deliver practical, innovative solutions that meet the unique challenges of each client. Our team of water treatment experts is committed to:
Maximising system longevity.
Minimising operational costs.
Optimising efficiency for both new and established systems.
Through bespoke, cutting-edge solutions, we strive to exceed expectations while identifying additional opportunities for improvement along the way.
Our success stories, such as this collaboration with the UK brewery, exemplify how we transform water treatment challenges into opportunities for efficiency and growth.
If your organisation is seeking solutions to optimise water treatment and reduce operational costs, connect with us today to discover how we can help.
Ready to explore transformative water treatment solutions? Let’s start the conversation.
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