Food Engineering logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • TOPICS
  • EXCLUSIVES
  • MEDIA
  • FOOD MASTER
  • EVENTS
  • RESOURCES
  • EMAGAZINE
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest Headlines
  • Manufacturing News
  • People & Industry News
  • Plant Openings
  • Recalls
  • Regulatory Watch
  • Supplier News
  • PRODUCTS
  • New Plant Products
  • New Retail Products
  • TOPICS
  • Alternative Protein
  • Automation
  • Cannabis
  • Cleaning | Sanitation
  • Fabulous Food Plants
  • Food Safety
  • Maintenance Strategies
  • OEE
  • Packaging
  • Sustainability
  • More
  • EXCLUSIVES
  • Plant Construction Survey
  • Plant of the Year
  • Sustainable Plant of the Year
  • State of Food Manufacturing
  • Top 100 Food & Beverage Companies
  • MEDIA
  • Podcasts
  • Videos
  • Webinars
  • White Papers
  • EVENTS
  • Food Automation & Manufacturing Symposium and Expo
  • Industry Events
  • RESOURCES
  • eNewsletter
  • Custom Content & Marketing Services
  • FE Store
  • Government Links
  • Industry Associations
  • Market Research
  • Classified Ads
  • EMAGAZINE
  • eMagazine
  • Archive Issue
  • Advertise
Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!
Case Studies & Field Reports

Field Reports

U.S. Water helps feed mill solve alkalinity problem

Feed mill turns to U.S. Water to help address high levels of alkalinity

By Casey Laughman
EnergyOUT system
U.S. Water’s EnergyOUT system offers processors an energy efficient, sustainable system to treat water feeds for issues such as alkalinity.
June 25, 2018

A Midwest feed mill was treating its incoming boiler feed water with amine chemical to combat high levels of alkalinity.  While amine can be effective at addressing alkalinity, it is one of the most expensive chemicals used in boiler water treatment. 

If the facility chose not to treat the well water for alkalinity, it could result in failure of the steam piping and condensate return lines, a costly plant shutdown and capital equipment replacement expenses. U.S. Water’s EnergyOUT system presented an integrated solution to address the alkalinity issue and improve plant efficiency, which the facility’s current water treatment provider could not match.

U.S. Water representatives completed a plant audit with on-site wet testing to identify an opportunity that could improve the makeup water to reduce chemical consumption and boiler blowdown. By introducing a Reverse Osmosis (RO) unit in front of the boiler feed water system, 90 percent of the alkalinity could be removed, thereby reducing 90 percent of the amine chemical required to treat the system. Feed mills must meet certain total amine concentration restrictions, which the FDA/FSMA limit to less than 25 parts per million present in the steam. Implementing this solution could provide both a cost savings on chemicals and ensure the facility did not exceed the total amine concentration limit.

Available through an operating lease, the EnergyOUT integrates equipment, service and chemicals to enhance a facility’s sustainability by reducing fuel demand, carbon emissions, chemical use and water discharge. Its small footprint also reduces the need for plant expansions or layout changes. The prebuilt skid-mounted frame can be as small as 13 feet long by 8 feet wide and includes all equipment, pumps and controls.  The size of the skid varies based upon the size of the RO, with larger RO’s requiring a larger skid. The ready to install skids also reduce the installation time and costs commonly experienced with similar programs. 

Built with a VFD controlled pump and low energy membranes to reduce electric consumption, the EnergyOUT boiler pre-treatment solution provided the facility with:

  • A complete RO with carbon filtration and prefilters to protect the membranes
  • RO product water storage tank with level controls and water forwarding pump
  • Planned maintenance and warranty repairs
  • pH adjustment of RO permeate to prevent corrosion

With the EnergyOUT unit installed, the reduction of the boiler blowdown provided a significant energy savings, as the hot water can be reused in the boiler for a longer period of time before blowdown. In addition, most of the solids that normally end up in the boiler system are removed on the front end and captured by the RO membranes. The RO allows only pure water through to the boiler. As steam is produced, the boiler water becomes more saturated with impurities, and during blowdown, the concentrated boiler water is released. By utilizing pure water, scale formation on the boiler tubes is minimized, resulting in more efficient boiler operation. Plus, the reduction of the blowdown rate of the boiler ensures the total BTUs can be maintained within the system and not wasted down the drain.

In addition to the energy savings presented by the EnergyOUT system, 90 percent less chemical was needed to treat the water overall. Not only did this save the facility $34,000 in chemical costs in the first year of implementation, but it also prevented the facility from exceeding its total amine concentration limit. The U.S. Water service agreement also includes regular maintenance and replacement of all pre-filters and membranes, reducing the facility’s system maintenance and operator time.  


For more information, visit  www.uswaterservices.com

KEYWORDS: water

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Casey laughman0031

Casey Laughman is the former Editor in Chief of Food Engineering magazine. He has almost two decades’ experience as a writer and editor for mainstream and trade publications. He spent several years as a writer and editor for two news services before becoming the editor of a legal publication and managing editor of a trade magazine that covered the commercial facilities market.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Global Organic Food & Beverage Market to Grow

    Global Organic Food & Beverage Market to Grow

    With a CAGR of 12.07%, Bonafide Research estimates this...
    People & Industry News
  • skilled MEP worker

    Predicting Food and Beverage Manufacturing Trends for 2024

    The two words that should be kept in mind are labor and...
    Automation
    By: Derrick Teal
  • cleaning and sanitation

    The basics of cleaning and sanitation in food plants

    Sanitation maintains or restores a state of cleanliness...
    Food Safety
    By: Richard F. Stier
Subscribe For Free!
  • eMagazine
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Customer Service

Food Plant Openings and Expansions May 2025

Food Plant Openings and Expansions May 2025

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Food Plant Openings and Expansions April 2025

Food Plant Openings and Expansions April 2025

More Videos

Popular Stories

Vilter IHP in plant

Industrial Heat Pumps: Sustainable Energy Solutions for Now and the Future

FMTE Formed by Four Food Manufacturing Companies

Coalition Unites Europe’s Food Manufacturing Technologies and Equipment Sector

Butterfly pea flower

FDA Approves Three Food Colors from Natural Sources

CHECK OUT OUR NEW ESSENTIAL TOPICS

Alternative ProteinAutomationCleaning/SanitationFabulous Food Plants

Food SafetyMaintenance StrategiesOEE

PackagingSustainability

Events

June 5, 2025

Mass Customization Driving Innovation in the Food and Beverage Industry

The food and beverage industry is at the nexus of transformative global manufacturing trends, driving a shift toward personalized, customer-centric solutions. 

June 5, 2025

How Cafe Spice Uses Automation to Propel Private Label

Learn about Cafe Spice’s new, state-of-the-art, highly automated manufacturing facility in Beacon, New York. 

View All Submit An Event

Products

Recent Advances in Ready-to-Eat Food Technology

Recent Advances in Ready-to-Eat Food Technology

See More Products

Plant of the Year

Related Articles

  • Pipeline

    First organic and non-GMO supply chain company opens in U.S.

    See More
  • SaltWorks employee using controls for grinder

    Salt processor uses MPE grinder to cut down on fines

    See More
  • cdc

    E. coli outbreak hits U.S., Canada

    See More
×

Elevate your expertise in food engineering with unparalleled insights and connections.

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Food Master
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!