Biofilm in cooling water system DYKA a thing of the past
DYKA is one of the largest manufacturers of plastic piping systems, where quality and sustainability are of the utmost importance. It is no coincidence that they promote themselves as Nature’s Network with their high-quality, recyclable products. Until last year, however, microbiological contamination in the cooling water system posed a threat to the quality of the end product. The cooling system plays a critical role in the extrusion process, where stable temperatures and quality are essential for dimensional accuracy and material properties.
Despite existing water treatment involving iron removal and continuous dosing of chlorine/bromine compounds, frequent blockages occurred on the 22 production lines. The filters in particular are susceptible to biofilm, which caused them to become clogged and required manual cleaning, a labor-intensive task. In addition, the annual costs of the chemical regime used proved to be substantial, without the desired result.
Given the high circulation volume (hundreds of m³/hour), a structural solution was required to comprehensively control microbial growth and blockages.
We were done with treating the symptoms of the biofilm problems in our cooling water system. We decided to look for a preventive, sustainable approach. In discussions with Watter, it quickly became clear that their system was exactly what we needed: a solution that tackles the problem at its source.
Trial period offered a solution
Like many companies, DYKA also took advantage of the trial period offered by Watter. During the trial period, a structured test plan was carried out under the supervision of our Senior Microbiologist Tim van den Toorn. The plan focused on monitoring the microbiological water quality and recording operational effects in the cooling water system.
The testing set-up included the following steps
- Proceswatersamples
Every week, an external party took a sample of the circulating cooling water. These samples were tested for microbiological quality, total bacterial count, and conductivity. - Filter cloth inspection
The filter cloths were visually inspected on a daily basis. The findings were recorded in logbooks and supported with photographic documentation. The consumption of filter cloth was also analyzed retrospectively. - Inspection of air conditioning filters on extrusion lines
One filter from the air conditioning units in the extrusion department was checked periodically, according to a rotation schedule so that all filters were covered.
At DYKA, we focus on safety, quality, and production, and we want to make progress every year. Thanks to Watter, we can now operate proactively instead of reactively. The consistently good water quality enables us to keep our production process stable and improve our quality.
An investment that rapidly pays for itself.
Based on internal calculations by DYKA, it has been determined that the investment in Watter's solution will pay for itself within three years. This has been calculated on the basis of the reduced frequency of replacement of, among other things, the filter cloth and the periodic investment in the chlorine solution they used previously. An additional advantage is that no hazardous substances are used within DYKA Netherlands anymore. This means a significantly safer working environment for our employees. In addition, there is no longer any transport or packaging waste from chlorine-containing agents, resulting in lower CO₂ emissions and chemical waste. The solution therefore contributes directly to their ESG objectives in the areas of Safety, Circularity, and Environment.
This has made it clear to DYKA that Watter offers the proven better solution for disinfection.
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