“The hard well water was hard on the equipment due to the constant clogging, making cleaning and sanitizing difficult. Everything was a challenge,” explains the company’s President, describing the water quality issues that had plagued their facility for years.
The transformative solution? A dual-system ozone water treatment approach from Sublime Environmental that finally resolved water quality issues that had persisted for generations.
The Premium Producer’s Challenge: Hard Water Impact on Quality & Equipment
Operating a BRC-mandated facility with Safe Quality Food Institute Gold Level Certification, the ice cream producer had built its reputation on exceeding quality standards. However, their groundwater from on-site wells presented significant operational challenges:
Production & Quality Issues in Food Manufacturing Water
- Iron-Contaminated Water: High iron concentrations caused staining and residue on equipment
- Hard Water Problems: Mineral content created persistent cleaning difficulties
- Production Quality Concerns: Water quality directly impacted their premium ice cream
- Multiple Water Needs: Different operations require varying water quality specifications
Equipment & Maintenance Challenges in Process Water Systems
- Cooling Tower Degradation: Biofilm and bacteria buildup require replacement every five years
- Excessive Chemical Use: Compensating for poor water quality requires substantial chemicals
- Constant Maintenance: Cleaning, descaling, and equipment issues diverted resources
- Operational Inefficiency: Water problems affected everything from production to packaging
For a premium food producer with a multi-generational legacy of quality, these ongoing water challenges threatened operational efficiency and product excellence.
Limitations of Conventional Food Industry Water Treatment
The ice cream producer had previously attempted several traditional water treatment methods, all of which fell short:
- Chemical Treatments: Required constant monitoring, adjustment, and created residue concerns
- Softener Systems: Addressed hardness but not iron contamination or bacterial issues
- Filtration Alone: Failed to address the full spectrum of water quality challenges
- Heat-Based Approaches: Energy-intensive and ineffective against many contaminants
- Multiple Specialized Systems: Created complexity and high maintenance requirements
- Inconsistent Results: Quality fluctuations impacted production consistency
These conventional approaches failed to fully resolve the water quality issues and created additional operational challenges and costs.
The Sublime Solution: Dual-System Ozone Process Water Treatment
After assessing the ice cream producer’s specific needs, Sublime Environmental implemented a comprehensive dual-system solution tailored to different aspects of their operation:
Food Production Water System Specifications
The custom water treatment solution featured:
- Production Water System (20 GPM)
- NSF-61 certified for food production safety
- 20 GPM flow rate with 20 GR/HR ozone generation
- Advanced monitoring and control capabilities
- Supersaturation injection with de-gas removal
- Automatic backwashing filters for sediment and final carbon polishing
- Optional CIP sanitation line with manual dose control
- Facility Treatment System (5 GPM)
- Designed for drinking water and general facility use
- 5 GPM flow with 4 GR/HR ozone generation
- Injection and mixing system for effective treatment
- Flow-activated for on-demand operation
- Automatic filtration system
Water Treatment Implementation Process for Food Manufacturing
The system installation was carefully planned to minimize disruption to ongoing operations:
- Comprehensive Assessment: Detailed analysis of water quality issues and operational impacts
- Custom System Design: Engineering of a dual-system approach based on specific facility needs
- Strategic Installation: Implementation timed to avoid production interruptions
- Integrated Testing: Verification of performance across all water applications
- Staff Training: Comprehensive instruction on system operation and monitoring
- Ongoing Support: Regular performance reviews and optimization as needed
Transformative Results for Food Manufacturing Excellence
The implementation delivered multiple significant benefits that extended throughout the ice cream producer’s operations:
Equipment Life Extension Through Superior Water Treatment
The most dramatic result was the complete elimination of biofilm and bacteria buildup in the cooling tower:
- Before Treatment: Required replacement approximately every five years
- After Treatment: Remained “virtually spotless with no residue buildup”
- Capital Savings: Significant reduction in equipment replacement costs
- Maintenance Reduction: Dramatic decrease in cleaning and maintenance requirements
Operational Advantages of Ozone Water Systems
- Superior Water Quality: Effective removal of iron and contaminants at just $0.05 per 1,000 litres
- Chemical Elimination: Complete removal of water treatment chemicals
- Cold Water Disinfection: Energy savings through effective cold water treatment
- Streamlined Operations: Continuous treatment without production disruptions
- Automation Benefits: Minimal maintenance requirements, reducing labour needs
Quality & Compliance Benefits in Food Production
- SQF Gold Certification: Water quality improvements supported the maintenance of certification
- Product Excellence: Consistent water quality enhances production consistency
- Environmental Alignment: Chemical-free approach improved wastewater quality
- Regulatory Compliance: Simplified adherence to food safety regulations
Case Study: Century-Old Ice Cream Producer’s Water Transformation
A premium ice cream manufacturer in Ontario with over 125 years of production history implemented our dual-system ozone water treatment solution to address persistent well water quality issues that had plagued their operation for decades.
The system delivered transformative results:
- Complete elimination of biofilm and bacteria in cooling towers
- Extended equipment life, avoiding 5-year replacement cycles
- Significant reduction in maintenance and cleaning requirements
- Enhanced product quality through consistent water characteristics
- Operational cost savings through chemical elimination
“Everyone with a cooling tower should use ozone. The Sublime Environmental ozone solution has completely eliminated any biofilm and bacteria buildup, reduced our maintenance costs and extended the life of our equipment. I wish I had known about the benefits of ozone 40 years ago when I began my career at the company!”
– President of the Ice Cream Manufacturing Company
FAQs About Food Manufacturing Water Treatment
Q: How does ozone treatment affect food-grade water quality?
A: Ozone provides superior disinfection without chemical residues, making it ideal for food production. It effectively removes contaminants while breaking down to pure oxygen, leaving no taste, odour, or harmful byproducts that could affect product quality.
Q: Can ozone systems be integrated with existing cooling towers?
A: Yes, our systems are designed for seamless integration with existing cooling towers and water systems. The installation process typically requires minimal modifications and can be completed with minimal production interruption.
Q: What maintenance is required for food processing water systems?
A: Our food-grade process water systems are designed for minimal maintenance, typically requiring only quarterly inspections and annual component checks. The system features automated operation and self-monitoring, significantly reducing maintenance requirements compared to chemical treatment alternatives.
Q: How effective is ozone against hard water problems?
A: While ozone primarily addresses biological contamination and iron issues, our comprehensive groundwater treatment systems include appropriate pre-filtration and treatment components to effectively manage hardness when required. The combined approach delivers superior water quality across all parameters.
Q: What is the typical return on investment for food manufacturing applications?
A: Most food processing facilities experience complete ROI within 12–24 months based on chemical elimination, reduced maintenance, extended equipment life, and energy savings. The exact timeframe depends on your operation, water quality challenges, and current treatment costs.
Transform Your Food Processing Facility’s Water Quality
For food processors facing challenging water quality issues, particularly those using healthy water or managing cooling towers, ozone water treatment offers a comprehensive solution that addresses multiple operational challenges while supporting product quality and equipment longevity.
Sublime Environmental specializes in designing custom water treatment systems for food and beverage producers, with solutions tailored to your specific production requirements, facility needs, and quality standards.
Learn more about how our chemical-free water treatment solutions can enhance production operations, extend equipment life, and reduce maintenance costs.
Sublime Environmental is committed to supporting food manufacturing excellence through innovative, sustainable water treatment technologies that deliver superior quality and operational efficiency. Our solutions integrate seamlessly with both process water and sanitation & CIP requirements.
