Demineralised water for steam boiler feed at a cheese processing plant
Customer Need
High-grade demineralised water needed to meet strict steam boiler feed water quality specifications
A Waikato dairy manufacturer needed demineralised water for their cheese processing facility and steam boiler feed. As per the strict regulations in New Zealand, the water used in dairy processing must be pure and free from harmful contaminants.
Demineralised water prevents scale formation on the steam boilers internal walls and piping and reduces boiler blow down frequencies. Minerals found in regular tap water, such as calcium and magnesium, cause scale deposits within the boiler.
To meet the strict water quality specifications, the dairy manufacturer needed a high-performing demineralisation plant capable of treating large volumes of water.
Client
Details
Project type:
Dairy, Demineralisation, Food & Beverage
Plant Capacity:
300 m3/day
What we did
Cost-effective in-house production of the demineralisation plant
FILTEC designed and built the demineralisation plant in-house, at our fabrication facility in Auckland, before installing it at the dairy site. With full control over the process, we ensured that the plant was constructed to the highest standards, meeting the customer’s exact specifications. Our in-house fabrication services helped our customer save on costs.
Developed an automated ion-exchange process
We developed an automated ion-exchange process resulting in a plant that can remove minerals and other charged particles from water, resulting in demineralised water. The process involves automatic regeneration of the ion exchange media using acid and sodium hydroxide chemicals. To prevent fouling of the media, we placed a carbon filter upstream of the ion-exchange vessels.
Provided demineralised water with minimal conductivity
The demineralised water treatment plant is capable of producing 300 cubic metres of purified water per day. The purity of the water is typically 1 microSiemens per centimetre which complies with the dairy manufacturer’s water quality standards. The low conductivity of the demineralised water also helps to reduce the energy consumption of the steam boiler.
Prevented scale formation within the boiler and pipe work
The ultrapure water produced by the plant prevents scale formation within the boiler and pipe work. Scale formation in a boiler occurs when minerals such as calcium and magnesium in the water accumulate and form a hard layer on the inside of the boiler. By preventing scale formation, FILTEC’s demineralisation plant supports the efficiency of the boiler.
Minimised risk of leaks and corrosion
All chemical pipework within the plant is welded with flanged or triclover connections instead of threaded connections. This minimises the risk of leaks and provides resistance to corrosion.
Reduced operator input through remote monitoring
The demineralisation plant is connected to the dairy manufacturer’s Supervisory Control and Data Acquisition (SCADA) system and can be controlled remotely. This approach helps to improve the efficiency and safety of the plant by providing operators with real-time data on the equipment status and plant performance.
The Results
Enhanced cheese quality and consistency from demineralised water supply
The demineralisation plant provided by FILTEC successfully meets the strict water quality regulations required for the dairy industry.
The plant effectively removes minerals and impurities from the water, ensuring the water used in cheese production is of the highest grade. Our system supports the dairy manufacturer in producing consistently high-quality cheese. Furthermore, the absence of minerals in the water supply helps to extend the lifespan of dairy equipment and reduces maintenance costs.
