Is Your Industrial Water Filtration System Wasting Money?

For industrial businesses that use water filtration systems, it is very possible that as a result of inefficiencies, you could literally be watching your money flow down the drain, without even realising it.

However, the real cost goes beyond just wasted water. Industrial water filtration systems impact everything from energy consumption to maintenance expenses and equipment longevity. In fact, outdated or poorly maintained industrial water treatment solutions can increase operational costs by as much as 30%.

Here we take a look at the hidden costs of inefficient water filtration, how to identify inefficiencies and evaluate your current system as well as advice on how to choose the right filtration system to boost your bottom line.

The Hidden Costs of Inefficient Filtration Systems 

Let’s examine the true financial drain of inefficient water filtration systems.

A poorly maintained industrial water filtration system can increase utility costs dramatically. Specifically, even a thin 1/16 inch of scale on condenser tubes leads to a 12% spike in power consumption. Additionally, older treatment plants consistently show lower energy performance, with studies revealing potential energy savings of up to 80% in many facilities.

Here are the primary cost factors we’ve identified:

• Annual maintenance expenses ranging from £200 to £400 per system
• Replacement costs varying between £100 to £500 yearly
• Emergency repair costs reaching up to £1,000 for electrical failures

Moreover, the expenses multiply when considering equipment longevity. Scale, corrosion, and fouling accelerate wear and tear on critical components. Consequently, this leads to more frequent maintenance cycles and unexpected shutdowns.

Furthermore, improper maintenance can reduce system lifespan by up to 50%. This reduction not only affects immediate operational costs but also forces premature system replacement, creating a significant burden on long-term budgets.

Identifying System Inefficiencies 

Identifying inefficiencies in your industrial water filtration system starts with proper monitoring. We’ve found that many facilities lack adequate instrumentation to catch problems early.

Obviously, the first step is knowing what to measure. Our experience shows that successful facilities monitor these critical parameters:

• Silt Density Index (SDI) for fouling potential
• Normalised Permeate Flow (NPF) for membrane performance
• Pressure measurements across each stage
• Percentage Salt Rejection
• UV intensity levels

Even excellent feed water combined with top-quality membrane units isn’t enough to ensure optimal performance. Generally, there are three main categories of inefficiency:

Post-filtration contamination – this occurs when treated water encounters problems in the distribution system. Accordingly, old plumbing can reintroduce contaminants after filtration.

Filter degradation – happens gradually over time and isn’t always obvious until problems arise. Watch for signs like contaminant breakthrough or reduced flow rates.

Bacterial growth – which can seriously impact system performance. This typically occurs when maintenance schedules aren’t followed properly, leading to blocked absorption and reduced filtration effectiveness.

Another crucial aspect is data recording. Many facilities fail to maintain proper records, making it impossible to spot patterns or plan preventive maintenance. Without consistent monitoring, system performance can drop significantly, requiring costly repairs or replacements.

ROI Focused Upgrades 

Smart investments in industrial water filtration systems often deliver remarkable returns and upgrading your filtration infrastructure can pay for itself faster than most business owners expect.

Essentially, the ROI calculation needs to consider both initial investment costs and ongoing operational expenses. Above all, analysis shows that water recovery systems can significantly reduce water bills while increasing operational efficiency.

Here’s what to look at when calculating potential returns:

• Initial equipment and installation costs
• Ongoing maintenance requirements
• Energy consumption rates
• Water bill reductions
• Operational efficiency gains

Certainly, the benefits extend beyond direct cost savings. Modern filtration systems can extend equipment lifespan and reduce solid waste disposal costs. Treating water for internal reuse creates a ‘virtuous cycle’ that makes the entire production process more economical. Some facilities achieve ROI in as little as three weeks, though typically it takes a few months.

There’s also an often-overlooked financial advantage in that some insurance companies offer reduced premiums for properties with advanced filtration systems. Furthermore, these systems help ensure compliance with water quality regulations, helping avoid costly penalties and fines.

Choosing the Right Industrial Water Filtration System  

Once you’ve identified system inefficiencies and calculated potential returns, it’s time to implement practical solutions that work, and the most effective approach combines innovative technologies with proven methods.

Choosing the right industrial water filtration system is vital, and here are some of the key aspects you will need to focus on when making the decision on which one is best suited to your business.

• Firstly, you will need to consider what specific impurities need to be removed from the water as this will help to narrow down your options and find the right industrial water filtration system for your needs.
• You also need to consider the flow rate of the system which is the amount of water in gallons per minute that can be filtered through the system. This is an important consideration because you need to ensure the system can handle the volume of water that needs to be filtered.
• Be sure to factor in the size of the system as this will determine the amount of water it can filter before a media changeout, or backwash cycle is necessary.
• Look at the warranty on any filtration system that you are considering and make sure that you are covered in the event that any problems arise.
• Finally, you need to consider the system’s price because you need to make sure it is within your operating budget and can offer some sort of ROI.

Rather than viewing water filtration as an expense, consider it a strategic investment and take action. By evaluating your current system’s efficiency and making the necessary improvements or replacements, you can help prevent major expenses later, protecting both your equipment and your bottom line.