Case Study: How Our DM Water Plants Enhanced Industrial Operations

Industry: Pharmaceutical Manufacturing

Location: Metro Pharma Ltd., an established pharmaceutical company

Challenge: Maintaining consistent high-purity water for critical manufacturing processes

Solution Provider: Aquafit Technologies

Implementation Period: 8 months

Background

Metro Pharma Ltd., a leading pharmaceutical manufacturer, faced challenges in meeting the stringent water quality requirements for its operations. Their existing water treatment setup struggled to consistently produce USP-grade water, leading to:

Frequent equipment downtime.
Variations in product quality.
Non-compliance with regulatory standards.

The company needed a reliable and efficient deionized water (DM water) solution to address these issues while optimizing operational costs.

Challenges Identified

Inconsistent Water Purity: Existing ion exchange systems failed to deliver consistent conductivity levels below 1 µS/cm.
High Operating Costs: Frequent resin regenerations increased chemical usage and maintenance costs.
Production Downtime: Equipment fouling and contamination from suboptimal water quality disrupted manufacturing processes.
Regulatory Compliance: Difficulty meeting USP Purified Water standards jeopardized certification and market trust.

Solution Provided

AquaPure Systems proposed a customized DM water treatment plant tailored to the specific needs of Metro Pharma Ltd. The solution included:

1. Pre-Treatment System

Sand Filtration: To remove suspended solids and reduce turbidity.
Activated Carbon Filter: To eliminate chlorine and organic impurities, preventing damage to resins and membranes.

2. Reverse Osmosis (RO) System

A high-efficiency RO system was installed to remove up to 98% of dissolved salts, significantly reducing the ion load on the DM system.
This step also lowered the frequency of resin regeneration, reducing operating costs.

3. Mixed-Bed Deionization (MB-DI) System

A mixed-bed ion exchange unit was integrated to achieve ultrapure water with conductivity <0.1 µS/cm, meeting USP standards.
Automated regeneration controls ensured precise chemical dosing and minimized waste.

4. Real-Time Monitoring

Installed IoT-enabled sensors for continuous monitoring of conductivity, pH, and flow rates.
Data analytics provided predictive maintenance alerts, reducing unexpected downtime.

5. Distribution and Storage

Constructed a stainless-steel distribution system to prevent recontamination.
Integrated UV disinfection units in the storage system for microbial control.

Implementation Process

Site Assessment: Conducted a comprehensive water quality analysis and flow requirement study.
Design and Customization: Developed a modular system design to allow scalability for future expansion.
Installation and Commissioning: Executed installation with minimal disruption to ongoing operations.
Operator Training: Provided hands-on training for plant operators on system management and troubleshooting.

Results Achieved

1. Improved Water Quality

Consistently achieved ultrapure water with conductivity <0.1 µS/cm.
Fully compliant with USP Purified Water standards.

2. Increased Operational Efficiency

Reduced equipment fouling, minimizing production downtime by 40%.
Decreased resin regeneration frequency by 50%, cutting chemical costs significantly.

3. Cost Savings

Lowered operating costs by 35% through optimized chemical use, reduced maintenance, and energy-efficient components.
Reduced reliance on third-party water quality testing due to in-house real-time monitoring.

4. Enhanced Compliance

Passed regulatory audits with zero deviations related to water quality.
Strengthened trust with stakeholders and ensured consistent product quality.

5. Scalability for Growth

Modular design allowed the company to expand production capacity seamlessly without major upgrades.

Key Learnings

Tailored Solutions Work Best: Customizing the water treatment system based on specific industry needs maximized performance and efficiency.
Pre-Treatment Matters: An effective pre-treatment system significantly extends the life of downstream components.
Monitoring and Analytics: Real-time data ensured proactive issue resolution, minimizing disruptions.
Sustainability Wins: Optimized chemical use and reduced waste contributed to the company’s sustainability goals.