Industrial and Manufacturing Companies Make the Switch to Solids

Industrial and manufacturing companies around the globe are making the switch to solids. These companies recognize the financial opportunities and the environmental opportunities that solids present. Many industrial segments have been transforming their approach to water treatment by implementing solids. These include:

  • Pharmaceuticals
  • Aerospace
  • Automotive
  • Electronics
  • Food Processing
  • Cold Storage
  • Boxboard
  • Beverage



Click on a link below to take you to the case study:

Poultry Plant | Aerospace Company | Pharmaceutical Facility

Case Study – Solids provide a safe solution for a poultry plant

Water Treatment Challenge:

A poultry processing plant in the southwestern U.S. was experiencing severe problems in its 3,500- ton ammonia refrigeration system. The evaporative condensers were located on the roof so a “pulsed power” non-chemical water treatment device was used to treat one of the seven evaporative condensers, while the remaining six systems were only treated by heavy manual bleed. These practices were not effective and allowed heavy scale deposits to form on the evaporative condenser tubes, which resulted in high condensing pressure and increased energy costs. Severe corrosion occurred, which significantly reduced the life span of the evaporative condensers. The plant was considering an expensive coating to help avoid premature replacement of the corroded system. Plant personnel considered a liquid chemical water treatment program but were concerned about the safety and handling requirements associated with transporting and storing hazardous liquid water treatment chemicals on the roof. The limited space available for drum storage around the evaporative condensers and in the compressor room was also an issue.

Solving the Water Treatment Challenge with Solids:

AP Tech’s solid chemistry for water treatment provided as non-hazardous program in recyclable plastic bottles rather than liquid in drums. The solids are dissolved as needed into a small plastic reservoir using a dissolving board. The feed solution is then pumped into the system being treated, as is done with liquid chemicals. The dissolving boards were installed inside an enclosure located on the roof near the condensers, and the blended solid concentrates were provided in 11-pound bottles that can be easily transported to the roof as needed. Solids provided benefits of:
  • Simplicity of use (solid concentrate is easily moved throughout the facility and product loading only requires handling a single bottle)
  • Reduction of splash and spill concerns
  • Elimination of drum handling, storage and disposal
  • Ideal for use in hard-to-reach locations
  • Reduction of fuel and greenhouse gas emissions associated with product delivery

Case Study – Aerospace company saves money while improving safety and sustainability


Water Treatment Challenge:

One aerospace company with a manufacturing facility in the Midwest decided to make the switch to solids to help save money and to improve safety and sustainability. They had been utilizing liquid chemistry water treatment for four cooling towers in support of its manufacturing processes and facility.

AP Tech’s solid chemistry water treatment program helped the aerospace manufacturer achieve their business goals:

  • Maintain the same or better level of cooling tower system cleanliness
  • Eliminate chemical drum handling and disposal
  • Reduce inventory and related storage issues
  • Reduce costs and environmental concerns of, and need for containment areas

Solving the Water Treatment Challenge with Solids:

The installation of AP Tech’s solid chemistry water treatment program included a scale and corrosion inhibitor, a dispersant and a registered biocide. Results included:

  • Eliminated all liquid chemicals previously used to treat the cooling towers, while still providing effective water treatment.
  • The work area around the cooling towers is significantly neater. The installation reduced the space which had been required for drum storage by at least 75%.
  • The heaviest container of solids an operator has to handle is a 44-pound case of solids in recyclable plastic bottles. Previously, the operator handled 55-gallon drums of hazardous liquid chemicals, weighing 500 pounds.
  • The solids water treatment program is cost competitive with the previous liquid program. When hidden costs — such as costs for shipping drums, drum washing and disposal, storage space usage, and personnel handling — are factored in, the company reports the facility is saving approximately 15% with solids versus liquids.

Case Study – Solids Simplify Water Treatment for a Pharmaceutical Facility


Water Treatment Challenge:

A pharmaceutical facility in the Southeastern U.S. used liquid chemicals in their four cooling towers. Due to limited space around the cooling towers there was great difficulty moving large drums of liquid product to the point of use.

The cooling towers had to be hand fed several times a week due to the space constraints as well as lack of proper feed and control equipment. Furthermore, the cooling towers were not being properly treated for corrosion and microbiological fouling. The facility wanted to replace their problematic program with one that eliminated heavy drums and provided a feed system that would fit within their limited space.

Solving the Water Treatment Challenge with Solids:

AP Tech’s solid chemistry and dissolver technology along with automated controllers were installed for each cooling tower and have provided the proven results of a liquid program while allowing the facility to eliminate several challenges and safety hazards.

The new solids program is simple to use:

  • Reduced splash and spill concerns
  • Eliminated drum handling, storage, and disposal
  • Provided automated feed for a corrosion inhibitor, oxidizing biocide, and non-oxidizing biocide to enable proper treatment

Solids proved to be an innovative technology that solved a space and storage issue for a hard to reach location while improving upon the overall water treatment program results.

Our experienced team of water treatment experts (chemists, chemical engineers, chemical and equipment lab technicians, along with our operators and logistics team) are here to support you in making the switch to solid chemistry water treatment.
What are you waiting for?