The landscape of water treatment for food production has been dramatically reshaped by two critical forces over the last two decades: increasingly stringent European regulations on chlorates and persistent Environmental, Health, and Safety (EHS) concerns around traditional chlorine disinfection. The EU’s 2017 decision to eliminate chlorate’s approval as a pesticide has had downstream impacts on the industrial water treatment industry, establishing a strict maximum residue level (MRL) of 0.01 mg/kg for all food products under Regulation (EC) 396/2005. This regulation, in turn, created unprecedented challenges for food producers that had traditionally used sodium hypochlorite. Simultaneously, ongoing safety incidents and concerns with traditional chlorine gas systems have pushed facilities to seek safer alternatives.

These dual pressures have catalyzed innovation in the water treatment industry, leading to the adoption of electrochemical chlorine gas generation technology. This advancement stands out as a direct response to both regulatory requirements and safety demands, providing facilities with chlorate-free disinfection while eliminating the risks associated with traditional chlorine gas systems.

Regulatory Landscape and Compliance

For decades, food manufacturing facilities have relied on chlorine gas cylinders or bulk sodium hypochlorite for their disinfection needs. While effective, these methods present significant challenges to modern operations. Safety risks from potential chlorine gas leaks remain a constant concern, while high transportation and storage costs impact bottom lines. Environmental concerns from chemical shipping add another layer of complexity, and the degradation of sodium hypochlorite during storage can lead to inconsistent treatment. Perhaps most critically, these traditional methods often result in the formation of unwanted byproducts like chlorates, which can affect product quality and safety.

The regulatory environment, particularly in the European Union, has become increasingly stringent regarding chlorate levels in food products. As of 2017, chlorate is no longer approved as a pesticide in the EU, leading to significant implications for food producers. According to EU legislation on Maximum Residue Levels (Regulation (EC) 396/2005), the default MRL of 0.01 mg/kg applies to all food products. This regulation has created new challenges for manufacturers using traditional chlorine-based disinfection methods, both for companies located in the EU as well as US exports.

For dairy producers and infant formula manufacturers exposed to the EU market, compliance with these strict chlorate limits has become a critical business requirement. Electrochemical chlorine gas generation provides these manufacturers with a practical solution to maintain effective disinfection while meeting these stringent regulatory requirements. The technology’s ability to produce chlorine without chlorate formation aligns perfectly with these demanding compliance needs.

The Solution: Electrochemical Chlorine Generation

In response to these regulatory and safety imperatives, EAI Water, in partnership with Dioxide Pacific, has developed an innovative approach to chlorine generation. This electrochemical generation technology directly addresses both the EU’s strict MRL requirements and safety concerns by producing chlorine gas safely and efficiently on-site, eliminating both hazardous chemical storage and chlorate formation issues. The process is remarkably elegant in its simplicity: sodium chlorite enters the electrochemical cell, electrical current passes through the solution, and fresh chlorine is generated on-demand – all without requiring acid or hazardous chemicals. In addition, minimal chlorine gas is ever stored on site, instead it is produced purely on demand, thus dramatically reducing the risk of chlorine gas leaks.

Key Benefits of Electrochemical Generation

The enhanced safety profile of electrochemical generation represents a significant advancement in water treatment technology. By eliminating chlorine gas leak risks and hazardous chemical storage, facilities can dramatically reduce workplace safety incidents while simplifying regulatory compliance.

From an operational excellence perspective, the technology delivers consistent value through on-demand production and reliable chlorine strength. Maintenance requirements are significantly reduced compared to traditional systems, leading to lower operating costs and improved efficiency.

The environmental impact of electrochemical generation aligns with modern sustainability goals. The minimal carbon footprint from eliminated transportation, reduced chemical waste, and lower energy consumption creates a more sustainable operation that benefits both the environment and the bottom line.

Quality control reaches new levels with this technology. Fresh chlorine production ensures minimal byproduct formation and controlled chlorate levels, while maintaining consistent disinfection efficacy throughout the treatment process.

Industry Applications

The food and beverage industry has particularly benefited from this technology, especially in sensitive applications where chlorate-free disinfection is crucial for product quality and safety. Dairy manufacturers, particularly those producing infant formula and nutritional products, face stringent requirements for chlorate levels in their finished products. EAI Water’s systems help these facilities maintain the highest sanitation standards while ensuring their products meet strict regulatory requirements for chlorate content.

The dairy industry faces unique challenges in this regard. Modern dairy facilities require comprehensive disinfection programs for their processing equipment, storage tanks, and distribution systems. However, traditional sodium hypochlorite-based disinfection can lead to chlorate formation, potentially affecting product quality and regulatory compliance. Electrochemical generation provides these facilities with an effective disinfection solution that doesn’t compromise product integrity.

In the infant formula and nutrition sector, where product purity is paramount, the ability to maintain effective disinfection without introducing chlorates has become a critical operational requirement due to both the regulatory and public perception concerns surrounding chlorate formation. These manufacturers must meet exacting standards for their products while maintaining rigorous microbiological control throughout their processes.

In healthcare settings, hospitals and medical facilities benefit from the consistent disinfection power without the risks associated with traditional chlorine storage. The technology provides reliable pathogen control while improving workplace safety for healthcare professionals.

Industrial processing facilities have embraced the technology for its reduced chemical handling and storage requirements, along with the consistent quality of disinfection that helps maintain production standards across various manufacturing processes.

Cost Considerations and ROI

While the initial investment in electrochemical generation technology may be higher than traditional systems, the long-term benefits typically deliver ROI within 12-24 months. This return comes through multiple channels: reduced chemical costs, lower transportation expenses, decreased maintenance requirements, improved operational efficiency, reduced safety incident risk, and minimal chemical waste all contribute to the technology’s strong financial performance.

The EAI Water Advantage

EAI Water’s approach sets new standards in the industry by combining innovative technology with comprehensive service support. We provide custom system design based on facility needs and seamless integration with existing infrastructure. Each system comes with 24/7 monitoring capabilities, preventive maintenance programs, technical support and training, and performance guarantees in order to ensure optimal system performance and customer satisfaction.

Looking to the Future

As regulations around chlorates and chemical safety continue to evolve, electrochemical generation represents the future of safe, sustainable water disinfection. EAI Water’s technology provides a proven solution that meets today’s challenges while preparing facilities for tomorrow’s requirements.

Conclusion

Electrochemical chlorine generation is more than just a technology upgrade – it’s a transformation in how facilities approach process water disinfection. By eliminating safety risks, reducing environmental impact, and providing consistent, high-quality disinfection, this innovation is setting new standards for water treatment across industries.

Ready to learn more about how electrochemical generation can transform your facility’s water treatment program? Contact EAI Water to schedule a consultation and site assessment.