A Food & Beverage Packaging Facility Reduces Water Waste and Improves Softener Efficiency with EAI Water

A large food and beverage packaging facility in Southern California was facing increasing water waste, excessive chemical usage, and frequent maintenance issues due to hard water. Their aging softener system struggled to meet production demands, leading to scaling in boilers and cooling systems, high blowdown rates, and rising operational costs. To address these inefficiencies, the facility turned to EAI Water for a customized retrofit solution to improve water efficiency, system reliability, and long-term sustainability.

Background

In early 2024, the facility’s operations team identified major inefficiencies in its water softening system after bringing EAI Water onboard to treat their boiler system. Hard water was causing scale buildup, reducing heat transfer efficiency, increasing energy consumption, and requiring frequent maintenance by the short-staffed service team. The facility relied on steam boilers, open-loop cooling towers, and closed-loop process water systems, making efficient water softening essential for operational success​.

The facility’s key challenges included:

• Scaling in heat exchangers and steam boilers, forcing the system to work harder and increasing energy costs.
• Excessive water and chemical use, leading to rising operational costs, higher wastewater discharge fees, and increased environmental impact.
• Frequent maintenance and equipment failures, leading to unplanned downtime, production inefficiencies, and a drain on the service team.

To optimize performance and sustainability, the facility sought a custom softener retrofit that would:

• Lower blowdown rates and minimize water waste.
• Improve softener efficiency to extend equipment lifespan.
• Enhance automation and monitoring for consistent water quality.

After evaluating multiple options, the facility selected EAI Water to design and implement a site-specific water softener system upgrade, ensuring compliance with best water treatment practices.

The Challenge: Hard Water Inefficiencies Impacting Operations

Before partnering with EAI Water, the facility experienced significant inefficiencies due to its outdated water softening system.

Scaling in Steam Boilers & Cooling Towers

Mineral buildup in heat exchangers reduced heat transfer efficiency, forcing the system to work harder and consume more energy. Increased scaling required frequent chemical treatment and manual descaling, raising costs and contributing to maintenance downtime​.

Excessive Water & Chemical Usage

The existing softener system required frequent regenerations, consuming excessive water and salt. Increased blowdowns led to higher sewer discharge costs, affecting overall facility water efficiency​.

Aging Softener Equipment & Control Limitations

The outdated softener system lacked automation and real-time monitoring, making it difficult for operators to track performance consistently. Without automated controls, the facility relied on manual adjustments, increasing the risk of inconsistent water quality and reactive maintenance instead of proactive system management​.

With rising costs, inconsistent performance, and increasing maintenance demands, the facility sought a customized softener retrofit to restore efficiency and ensure long-term reliability.

Solution: EAI Water’s Softener System Retrofit

EAI Water implemented a comprehensive water softening retrofit, addressing the facility’s specific challenges with a customized solution.

Softener Re-Bed and Resin Upgrade

• Replaced aging resin beds with high-performance resin media to improve ion exchange capacity and reduce hardness levels​.
• Optimized regeneration cycles, reducing water waste and extending softener lifespan​.

Control Head Replacement and System Automation

• Upgraded to programmable logic controllers (PLCs) for automated softener regeneration cycles​.
• Integrated remote monitoring capabilities, allowing operators to track system performance and water quality in real-time​.

New Piping Assembly for System Reliability

• Installed new high-durability piping and control valves to enhance flow rates and pressure regulation​.
• Reduced flow disruptions and mechanical wear, minimizing long-term maintenance requirements​.

By implementing these targeted system upgrades, EAI Water provided the facility with a high-efficiency, low-maintenance water softening system that improved water efficiency, reduced operating costs, and optimized plant performance​.

For more on how industrial water softeners can improve facility efficiency, visit EAI Water’s Industrial Water Softeners.

Results: Measurable Water & Cost Savings

Following the system retrofit, the facility experienced significant improvements in water efficiency, system performance, and operational costs​.

Key Outcomes

• Optimized water softening performance, achieving near-zero hardness levels and improving heat exchanger and boiler efficiency​.
• Reduction in blowdown waste, lowering water discharge and reducing sewer costs​.
• Decreased chemical consumption, minimizing the need for scale inhibitors and acid treatments​.
• Extended equipment lifespan, with reduced scaling leading to longer-lasting heat exchangers and lower maintenance needs​.

The main facility operator shared their feedback on the project:

“Just wanted to reach out and say thank you for the work done on the softeners. The softeners are working great. The water coming out of the polisher is 0 hardness, and your team did a great job.”

BEFORE

AFTER

Conclusion

Through a data-driven, site-specific approach, EAI Water delivered a high-performance water softening solution that aligned with the facility’s efficiency and sustainability goals​. By reducing hard water inefficiencies, optimizing softener cycles, and minimizing chemical consumption, the new system not only improved daily operations but also contributed to long-term cost savings and environmental compliance​.

The plant lead expressed his satisfaction with the entire process:

“The team did an awesome job, and I’m very happy. It’s nice NOT to have to worry about hard water anymore.”

For industrial facilities looking to maximize water efficiency and system performance, EAI Water offers tailored water treatment solutions designed for long-term success​. Our Total Water approach ensures that we take care of both the equipment and chemical treatment needs that your facility faces day in and day out.

Contact us today to schedule a consultation and learn how EAI Water can optimize your facility’s water efficiency​.