Case Study Summary
This case study examines how Apex reduced microbial fouling and operating costs in a manufacturing chilled water system by implementing automated biocontrol, enhanced filtration, and real-time monitoring. The program eliminated unplanned downtime, restored heat transfer efficiency, and generated more than $50,000 in annual savings.
Chilled water systems play a critical role in manufacturing environments where consistent temperatures, process reliability, and product quality are essential. When microbial growth and biofouling go unmanaged, system efficiency declines, energy consumption increases, and equipment reliability is compromised.
A Midwest manufacturing facility producing plastic and aluminum food packaging began experiencing recurring biofouling issues in its chilled water system. These issues led to reduced heat transfer, rising energy costs, increased chemical usage, and repeated unplanned shutdowns. The facility partnered with Apex to identify the root causes and implement a comprehensive biocontrol and system optimization strategy.
Results at a Glance
Over $50,000 in Annual Operating Cost Savings
ATP levels reduced from >10,000 RLU to <500 RLU
Unscheduled downtime reduced from four events per year to zero
Facility Background
- Industry: Manufacturing [Food Packaging]
- Application: Chilled water system biocontrol
- Primary Issue: Biofouling, energy loss, and inconsistent chemical control
- Apex Solution: Automated dual-biocide program with filtration and real-time monitoring
The facility relies on chilled water to support thermoforming and extrusion processes used in food packaging production. Prior to working with Apex, manual chemical feed and limited system visibility resulted in persistent microbial growth. Biofouling reduced heat exchange efficiency, increased energy consumption, and placed the facility at risk of unplanned downtime and compliance concerns.
The Challenge
The chilled water system faced multiple challenges:
- Manual biocide feed resulting in inconsistent microbial control
- Elevated ATP readings exceeding 10,000 RLU
- Organic debris and solids entering the system
- Biofilm formation reducing heat transfer efficiency
- Heat loss measured at approximately 18%
- Frequent unplanned shutdowns (approximately four per year)
These conditions increased operating costs while threatening production continuity.
The Apex Solution
Apex partnered with facility personnel to implement a comprehensive chilled water biocontrol and optimization program.
Key elements of the solution included:
- Replacement of manual chemical feed with an automated dual-biocide dosing system
- Installation of side-stream sand filtration to continuously remove suspended solids and organic matter
- Cleaning of the cooling tower basin to eliminate accumulated debris
- Strengthening of the chemical treatment program with advanced dispersants
- Deployment of IoT-enabled monitoring tools for real-time data logging
- Routine microbial testing using ATP swabs, dip slides, and scheduled lab analysis
- On-site training for operators focused on corrective actions and system maintenance
This integrated approach addressed both the biological and mechanical contributors to fouling.
Results & Operational Impact
Within six months of implementation, the facility achieved significant and sustained improvements:
- ATP levels dropped from >10,000 RLU to below 500 RLU, indicating effective microbial control
- Heat loss improved from 18% to less than 3%, restoring thermal efficiency
- Biocide usage was reduced from 30% above target to within optimal control range
- Unscheduled downtime was eliminated, dropping from four events per year to zero
- Approximately 15% water savings were achieved through optimized blowdown and chemical control
- Total annual savings exceeded  $50,000, driven by reduced energy use, chemical efficiency, and avoided downtime
These improvements also enhanced system reliability and reduced long-term asset risk.
Applicable To
This solution is relevant for:
- Manufacturing facilities using chilled water for process cooling
- Plants experiencing biofouling, microbial growth, or energy inefficiencies
- Facilities relying on manual chemical feed systems
- Operations seeking cost savings through automation and monitoring
Conclusion
This case study demonstrates how automated biocontrol and system optimization can dramatically improve chilled water performance in manufacturing environments. By addressing microbial growth at its source and improving system visibility, Apex helped this facility restore efficiency, eliminate downtime, and achieve meaningful cost savings.
For manufacturers seeking reliable chilled water performance and lower operating costs, Apex delivers integrated solutions backed by data, expertise, and field support.Â
Case Study Summary
Why is automated biocide dosing important in chilled water systems?
Automated dosing ensures consistent microbial control, preventing the fluctuations that allow biofouling to develop under manual feed programs.
How was microbial activity measured in this system?
Microbial activity was monitored using ATP testing, dip slides, and routine lab analysis to verify sustained control.
Can biocontrol improvements reduce energy costs?
Yes. In this case, restoring heat transfer efficiency significantly reduced energy consumption and operating costs.
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