The competitive nature of the food and drink industry leaves little room for errors. When a blue-chip soft drinks producer experienced sudden downtime on its ion exchange water treatment plant, they turned to Envirogen who leveraged the benefits of its remote water monitoring system, PureCare RemoteView, to have the plant back online in under two hours.
Production up and running within two hours of stoppage
“We were alerted to the fact that the manufacturer had suffered a loss of production due to accidental data loss brought about when an internal processor was reset by site staff during replacement of a water pump invertor,” explains Mike Lacey, Service Manager, Envirogen Group. ‘This had a knock-on effect as it caused the loss of operating data critical to the running of their ion exchange water treatment system.”
“18 months previously we had installed the ion exchange water treatment system, and they had signed up for our PureCare RemoteView digital monitoring and management system,” continues Lacey. “This meant that our service team was able to react fast to the emerging situation and play a leading role in disaster recovery.”
“Our team promptly accessed their processor to remotely re-instate all key operational parameters necessary for the water treatment plant, so that it was back up and running in under two hours. Envirogen’s meticulous record keeping, and commissioning data reports, made the entire process very efficient and played a pivotal role in avoiding shutdown over a sustained period.”
Envirogen’s remote water monitoring equipment: PureCare RemoteView
Monthly KPI reporting – production and cost analysis for operational transparency
The manufacturer receives monthly process reports on the performance of the ion exchange water treatment plant. By combining smart devices, expert knowledge, and water treatment plant performance data, Envirogen water process experts have been able to add data capture software to monitor events for different purposes. For example, to highlight process variations in batch volumes and efficiencies between regeneration.
Key performance indicators reported:
- Production/cost analysis
- Regeneration cycles, production cycles, water produced
- Chemical draw volumes and effluent produced per regeneration
- UV intensity trends
- Chlorine dose rates
- Product volumes produced
Monthly reporting and analysis has helped the customer better understand asset operation and put in place a proactive style condition monitoring approach. They’ve also benefitted from identified cost savings in salt, energy, water, and waste with tangible savings in operational expenditure.
Key outcomes
- Shutdown over a sustained period was avoided saving significant sums of money plus engineer callout costs.
- Monthly reporting and assessment of production output and performance to achieve maximum efficiencies.
- Rapid ROI through reduced cost, improved site management, operational transparency.
- PureCare RemoteView technology now rolled out across multiple production sites.
- Remote water monitoring system requires no IT investment.
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About the client
The client is a leading soft drinks company with factories in Great Britain, Ireland, France and Brazil with strong management teams on the ground alongside teams located in the US, Benelux, Asia and the Middle East.