Online Biofilm Monitor Optimizes Biocide Usage and Results for Fiberglass Composite Manufacturer

GoalOptimize microbiological control while reducing chemical usage, downtime, and operating costs through real-time biofilm monitoring.

<p><!-- wp:acf/two-cols-text {"name":"acf/two-cols-text","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"blue","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a1b96b768f","block_title":"","_block_title":"field_6629f36ac5d6b","block_content_clone":"","_block_content_clone":"field_662a1b96b76fb","text_list_0_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eIndustry: \u003c/b\u003eFiberglass Composite Manufacturing\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_0_text_item":"field_662a1bf77d245","text_list_1_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eApplication: \u003c/b\u003eAir Washer System\u003c/li\u003e\r\n\u003c/ul\u003e\r\n\u0026nbsp;","_text_list_1_text_item":"field_662a1bf77d245","text_list_2_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eProblem: \u003c/b\u003eHigh biocide usage and difficulties monitoring microbiological control in a large air washer system with a history of severe biofouling and frequent downtime for cleaning.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_2_text_item":"field_662a1bf77d245","text_list_3_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eSolution\u003c/b\u003e: bioDART Biofouling Monitor installed to continuously measure the potential for biofilm formation and evaluate microbiological control.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_3_text_item":"field_662a1bf77d245","text_list_4_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eResult: \u003c/b\u003ebioDART data allowed the microbiological control program to be optimized to proactively respond to upset conditions and reduce biocide costs.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_4_text_item":"field_662a1bf77d245","text_list":5,"_text_list":"field_662a1bb97d244"},"mode":"edit"} /--><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Customer Challenge</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>When Chem-Aqua took over the treatment of the air washer, an aggressive chemical treatment program was implemented to control the reoccurring biofouling problems. Despite achieving over $100,000 in annual operational savings due to better microbiological control, the plant was challenged with reducing chemical usage without risking&nbsp; downtime due to compromised results.</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Recommended Solution</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p class="PDq2pG_selectionAnchorContainer" data-start="1412" data-end="1726">Chem-Aqua installed its patented <strong data-start="1445" data-end="1457">bioDART&reg;</strong> real-time monitoring system to continuously track microbiological activity and biofilm growth within the process air washer system. The bioDART uses a side stream of system water flowing through an optical detector tube to quantify the potential for biofilm formation.</p> <p data-start="1728" data-end="2205">The BioFouling Index (BFI) provides a predictive indication of biofilm control and alerts users to upset conditions requiring corrective action. A gradual increase in the BFI is considered normal, while a significant increase in the BFI slope indicates an increased potential for biofilm growth. This enables operators to quickly identify issues such as loss of biocide feed or filter failures and confirm when effective microbiological control has been re-established.</p> <p data-start="1728" data-end="2205"><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/6c6b29a281a746a8b51e0be43e5fd2c5.aspx" alt="" width="800" height="287" /></p> <p><!-- /wp:paragraph --><!-- wp:image {"id":6962,"sizeSlug":"full","linkDestination":"none","align":"center"} --><!-- /wp:image --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Results Achieved</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p class="PDq2pG_selectionAnchorContainer" data-start="1635" data-end="2004">The bioDART identified events that could have generated serious biofouling issues without proactive remedial measures. This enabled Chem-Aqua to significantly reduce the downtime and operational costs previously associated with reactive chiller cleaning. Improved monitoring also allowed chemical usage to be reduced while maintaining effective microbiological control.</p> <p><!-- /wp:paragraph --></p> <p><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/c918a52241f04e269a2798cb99e3341f.aspx" alt="" width="812" height="514" /></p> <p><!-- wp:image {"id":6965,"sizeSlug":"full","linkDestination":"none","align":"center"} --><!-- /wp:image --><!-- wp:heading {"level":5} --></p> <p class="wp-block-heading">The visuals below show how the bioDART responds to upset conditions like a loss of biocide feed or a filter failure, and how it is confirms when control is reestablished.</p> <p><!-- /wp:heading --><!-- wp:paragraph --><!-- /wp:paragraph --><!-- wp:image {"id":6963,"sizeSlug":"large","linkDestination":"none","align":"center"} --><!-- /wp:image --></p> <p><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/ee5d10890a804899a4b480f8cbdc9af6.aspx" alt="" width="1024" height="441" /></p> <p><!-- wp:image {"id":6964,"sizeSlug":"large","linkDestination":"none","align":"center"} --><!-- /wp:image --></p> <p><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/0b98bce306d44fc9b477908e1730fcb3.aspx" alt="" width="1024" height="512" /></p> <p><!-- wp:heading {"level":5} --><!-- /wp:list --><!-- wp:paragraph --></p> <p><em>CS2-003</em></p> <p><!-- /wp:paragraph --><!-- wp:acf/two-cols-text-ctas {"name":"acf/two-cols-text-ctas","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"white","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a2539a7d03","block_text_list_0_block_title":"","_block_text_list_0_block_title":"field_662a2573bc047_field_6629f36ac5d6b","block_text_list_0_block_excerpt":"","_block_text_list_0_block_excerpt":"field_662a2573bc047_field_6629f37dc5d6c","block_text_list_0_show_cta_button":"1","_block_text_list_0_show_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f386c5d6d","block_text_list_0_block_cta_button":{"title":"Download PDF","url":"https://www.chemaqua.com/en-us/wp-content/uploads/sites/6/2024/07/CS2-003.pdf","target":""},"_block_text_list_0_block_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f39cc5d6e","block_text_list_0_use_special_button":"0","_block_text_list_0_use_special_button":"field_662a2573bc047_field_663af6cb5a467","block_text_list":1,"_block_text_list":"field_662a2550bc046"},"mode":"edit"} /--></p>