Complete Water Solutions provides controls upgrades to existing water treatment systems. A customer had an old Osmonics HR PA 144K DLX DT Reverse osmosis system with an old Allenbradley PLC. The Allen Bradley PLC was outdated and no longer in production. Complete Water Solutions provided a turnkey solution to update the whole PLC panel along with controls. The Old control system had a Thorton 770 Max and Complete Water Solutions upgraded the 770 Max to the new 800’s controller. Complete Water Solutions also provided new sensors along with the new controller.

If you’re having problems with your older system, or looking to upgrade, Complete Water Solutions can help assess the current status of your system and offer you the best options for upgrading or replacement parts.

Contact us for a quote

View our Osmonics Manuals library

View our RO Troubleshooting Guide for more tips and help.

With the ever-growing population, water is something that is crucial to maintaining life. Due to the population increase, the demand for water has increased meaning having and maintaining high-quality water levels have become more necessary. Water quality is becoming more and more important in industry, firstly due to international standards for the production of equipment and products with a higher degree of purity, and secondly because the water supply sources suffer from contamination due to population growth, and waste regulation is slower than the level of growth. Used to remove unwanted organisms and material from water supplies, water filters play a pivotal role in maintaining high water quality levels.

Depth Filtration 

Depth filtration is one of the many water filter options available. This filtration system focuses on cleaning organic substances like dirt, grit, sand, etc. Made with materials like cotton, carbon, and glass fiber, depth filtration absorbs the particles to keep them from entering the water. A filter like this is primarily used in industries such as: food and beverage, pharmaceuticals, chemical processing, power generation, municipal water treatment, and mining and metal processing

Surface Filtration

The surface filtration process, also known as surface filtering, does exactly what the name suggests. It retains particles on the surface of the filtration system. All of the particles retained on the media’s surface mean that the layer formed on the surface can improve the efficiency or the fineness of particles. You see this filter used in industries like cosmetics, electronics and semiconductor manufacturing, and laboratory and research facilities.

RO and UF

Reverse Osmosis (RO) and Ultrafiltration (UF) filters are the most potent and effective methods when it comes to filtering water. “In an RO system, 95-98% of inorganic dissolved material is separated from the water molecule by a semipermeable membrane” (BOLEFIL – brother.com). You will typically see systems like these used in the pharmaceutical industry, as bacteria and virtual contaminants can be harmful to production.

UV

Finally, we look to UV water treatments, which are the most environmentally friendly of all the filter options. With the lack of chemical and disinfectant byproducts used in this water filter system, this is the optimal substitution for chlorine-based disinfecting systems. UV water systems act on the genetic material, DNA of the organisms found in disinfected water. This caused DNA to be damaged, leading to the death of bacteria, viruses, and more. This method is used on water meant to be used as drinking water.

• Hotels
• Automotive industry
• Drinking Water Treatment
• Petrochemicals
• Mining
• Paper Mill
• Chemicals
• Pharmaceutical water treatment
• Agricultural and irrigation applications

• Improved efficiency and productivity
• Reduction of solids
• Reduction of contaminants
• Protection of equipment
• Having a high-quality system consistently
• Environmental benefits (reduced chemical waste)

Contamination Level

Inspecting the amount of impurities will allow you to figure out the proper frequency your water filter will run. This will also account for how often filters will need replacement.

Filtration Volume

Your filtration volume is calculated by taking into account the layout of your supply source, pumping and pipe size, and the use that the water will be given. This will help sort out how many filters are needed for the desired outcome and how continuous the filtration process is. 

Quality Standards for Required Filtration

The standards for your water filter are dependent on what water is desired after it goes through the filtration process. This will determine what filters are needed. 

Nature and Characteristics of Contamination

Sizing of the impurities is important in determining what water filter is best. Figuring out what contaminants are also important to assess the health risks and how to properly filter them.

With the demand for water increasing, it has become more important that the water being used is safe. This has caused industry standards and regulations to become more strict. Utilizing an industrial water filter has become an essential part of almost every industry. When you need a new water filter or need new cartridges for your water filtration, reach out to us at Complete Water Solutions! We have filtration system solutions and our team would love to help you find the right solution for your business.

CWS is excited to announce Jack has joined the Tech Team

Help us welcome Jack to the Complete Water Solutions Tech Team!

Jack started getting into water treatment out of high school and worked for another water treatment company prior to coming to Complete Water Solutions. While working there, he realized he was good with tools and decided that he wanted to grow a career in the water industry.

His skills and dedication to getting the job done are already making an impact here at Complete Water Solutions.  We are excited to have Jack part of the team and watch him grow.  Welcome aboard Jack!

Looking for a new and rewarding career? Learn more about Complete Water Solutions Careers here – https://www.complete-water.com/resources/careers/

Meet our new security Officer Siwash

Complete Water Solutions would like you to meet our newest member of the team. Mascot Security Officer Siwash. Named in honor of Sergeant Siwash of the Marine Corps second division.

Who Was Sergeant Siwash aka “The Devil Duck”

In 1942, the Marine Second Division was in New Zealand gearing up to go into combat with the Japanese during World War II. According to the Marine Corps, Sergeant Francis Fagen won Siwash in a poker game at a local bar.

The duck followed Fagen everywhere and developed quite a taste for beer. He was soon given the rank and name of Sergeant Siwash, named after Sgt. Jack “Siwash” Cornelius of Skagit Country, Washington and become a part of the Marine’s Second Division mascot.

In November 1943 it came time for the Marines to engage in the battle of Tarawa and it was one of the bloodiest battles in marine history.  The Japanese had 4,000 soldiers dug in heavily into Tarawa and were building a fortified airfield complex. They were fixed with heavy caliber weapons and were so confident in their defenses, that Japanese admiral Kenji Shibaski reported “it would take 1 million men 100 years to conquer the island”.

Little did they know that on November 20^th, 1943, at 3:00 am 18,000 marines, including Siwash, loaded into their salamander tractors and prepared for their launch. Japanese soldiers watched in horror as dawn approached and American soldiers were landing on the island.

On the first day of combat, the Marines were pinned down by heavy machine gun artillery and mortar fire and were only able to secure the first 70 yards of the beach. After hours of combat, the marines were charged by an enemy rooster and Sergeant Siwash charged out past the Marine line to meet the winged enemy and fight in one -to-one winged combat in the middle of the battlefield. After several pecs to the head, Siwash was able to declare victory and save his fellow Marines, earning him the nickname “The Devil Duck”.

Over the next few days, 18,000 Marines and 1 duck completely took over the island from the Japanese. The Marines tried to get Siwash a purple heart for his brave actions on the battlefield but was instead given a written citation for the courageous actions and wounds received on the battlefield “with utter disregard for his own personal safety and without hesitation to engage in fierce combat with one rooster of Japanese ancestry.” Though wounded on the head by repeated pecs, he refused medical attention until all wounded members of his section were taken care of first.”

His service didn’t stop here. He went on to serve during the battle of Saipan – though no winged enemies were present, and he stayed back in the safety of a destroyer.

They couldn’t keep the Devil Duck back for long though, and at the battle of Tinian, Siwash hit the beach and captured a tiny Japanese duck. Afterwards, it was finally time to retire and upon returning home, the Devil duck was given a hero’s welcome before parting ways with his division and Fagan and went to live out the rest of his life at Chicago Lincoln Park Zoo. Upon moving to the zoo, it was discovered that Siwash was not a he duck, but a she and the hard drinking lass lived out the rest of her years before passing away from liver disease in 1954.

Her funeral was held at a taxidermy shop, where she was stuffed and presented to the National Museum of the Marine Corps.

Semper fi Siwash

If you work in manufacturing, you’ve probably heard about membrane technology. It’s a growing industry as it can help you boost quality and cut down on manufacturing costs. Membrane technology is revolutionizing manufacturing by improving water filtration and cutting costs. With the global market projected to grow at a CAGR of 6.5%, from $7.38 billion in 2022 to $11.46 billion by 2029, more businesses are turning to membrane solutions for efficiency. However, membrane fouling can threaten the performance and lead to costly downtime. Let’s explore what membrane fouling is and how you can prevent it to keep your operations running smoothly.

So, “What is membrane fouling”? Simply put, membrane fouling is a process where there are deposits of buildup that reduce both the functionality and efficiency of operating systems. Membrane fouling occurs by the deposition and accumulation of undesirable materials (i.e., organic compound, inorganic compound, or a combination of both) on membrane surfaces. As mentioned above, this reduces the function of your membrane systems, but it can also contaminate the membrane production system. Don’t worry though, as “Membrane fouling is a common issue for all of the membrane-based water and wastewater treatment technologies.

• Colloidal/Particulate Fouling – Suspended solids or colloidal materials are left on the surface or in the spacers of the membrane 

• Microbial/Biological Fouling –  Fouling – plants, algae living, and microorganisms grow on the surface of the membrane 

• Precipitation or Scaling – Soluble salts concentrate and show up in the brine stream of a reverse osmosis system  

• Organic Fouling – Carbon-based materials are collected on top of the membrane or in its feed spacer

• Temperature –  When temperature limits are exceeded, thermal damage occurs for the membrane, leaving it generally useless. – complete water 

• • Range: The absolute maximum temperature limit for cellulose acetate membranes is 35 degrees Celsius. If are working with most thin film composites, the temperature maximum is 45 degrees Celsius
    • Anything above these two thresholds will result in the complete loss of the membrane

Preventing membrane fouling is a lot easier than it may seem. One solution to preventing membrane fouling is to test pH and ionic level strength to minimize absorption. The longer the fouling process allows absorption, the more dire the consequences. Simply testing the pH level or ionic levels in your systems can ensure that your systems are not producing buildups. You can also remove large molecule particles by utilizing a pre-filtration system. This approach can be less hands-on than testing the different levels in your systems, meaning you and your team can maintain the same level of production! Lastly, you can prevent membrane fouling by simply increasing transmembrane pressure to increase flux and reduce membrane fouling. This is only helpful if your system has been partially fouled. The slight increase can still help to restore some of the flux if this is the case.

You want to make sure that your systems are always running efficiently. Membrane fouling is probably bound to happen, regardless of the precautions you take, but being on top of spotting membrane fouling can make or break how much you can produce in a day. At the end of the day, there are some relatively easy ways to prevent membrane fouling. If you are looking for water testing solutions or filtration systems to help you prevent membrane fouling, contact our team at Complete Water Solutions. We would be happy to walk you through the best option for you and your company!

First, it is important to start with the basics and understand what industrial water is. According to h20-de, “Industrial water is the generic term for water used in industry during production and processing operations. This includes, for example, water for cleaning surfaces, for preparing rinses, acid treatments or active baths, and much more”. To put it simply, industrial water is the water that industrial businesses use to clean and aid in their business processes. This is why it is extremely common for this water to become contaminated.

There are a number of ways to ensure the safety of the water being used in a variety of industries. Making sure to identify what contaminants your industry is most prone to seeing is critical to identifying them when they end up in your water source. Once identified, you can be proactive in treating it right away to mitigate the chances of it causing health issues. Keep your water supply safe and check out our wide range of water treatment solutions to ensure your water is treated today!

Complete Water Solutions recently announced the acquisition of the Osmonics™ trademark, a milestone that reflects the companies dedication to bring new products and services under the Osmonics™ brand.

Alongside this achievement, Complete Water Solutions has created a new Osmonics™ logo. The logo combines modern design elements with a timeless appeal that will set the foundation for a strong  impactful brand moving forward.

Carbon tower media can be used to remove many things in water. Some applications include removing chlorine upstream from reverse osmosis equipment or removing any impurities that may cause issues with the quality of a product that uses the water as an ingredient. An example of using water for a product would be Beverage Manufacturing. In beverage manufacturing, carbon media can help with items such as color and odor, allowing for a more consistent product.

Carbon media can come in various sizes and some material options. The most common carbon used is coconut shell and coal-based materials.

When To Change Your Carbon Media Or Carbon Tower?

This question can sometimes be complicated to answer, as water sources and quality can vary causing the carbon media to have a shorter or longer life. Carbon media can be tested to get a general idea of media life. One common test is an iodine test. When looking at a data sheet of carbon, you may find a section that provides an iodine number. This iodine number is in reference to the potential color removal from an iodine solution. The same test can be performed on carbon media that has been in service to give you a general idea of the effectiveness of the current carbon bed.

Application or validation may also dictate when the media needs to be changed out.  For example, in beverage production, carbon may need to be changed on a routine schedule or validated schedule of every three years.

How To Change Out Carbon Media?

Depending on the size of the system and set up can lead to the answer of “how to change carbon media”.  Before disposing of carbon media, always check with your waste removal company as they may require a test to be performed prior to disposing of.

Fiberglass media tanks: Some smaller fiber glass and poly tanks may allow extraction that can be used to slurry the carbon media out of the tanks into a waste container that will allow you to dispose of the media.

Larger steel tanks: Larger steel tanks may have access to a manway or large enough access to use a pump to slurry the carbon or even a vacuum truck to remove carbon.

Large stainless steel tanks: Common in the food and beverage industry are large stainless steel vessels that have the ability to slurry the carbon media out of the tank (typically the bottom of the tank) and then slurry it back in the tank through the top. This is one of the cleanest and potentially easiest ways to complete a carbon exchange. If you’re looking to install or replace a carbon tower in the future, looking at this style of equipment can be beneficial.

Preparing New Carbon Media for Use

Once new carbon has been installed, it is essential to properly condition it:

Soak the carbon: Fill the vessel with water to submerge the carbon and allow it to soak for at least eight hours. This will remove many of the air pockets within the carbon, and total de-aeration may take over a week.

Backwash the carbon: Initiate a backwashing cycle to remove fines and stratify the carbon bed. The backwash flow rate should be sufficient for a minimum of 30% bed expansion, and flow rate should be done gradually until the desired flow rate has been achieved. The backwashing cycle should be continued until the water runs clear for at least 20 minutes, but we recommend 30-60 minutes. Conduct a turbidity test or use a white cup to inspect the carbon fines to ensure water clarity thorough the backwashing cycle.

Sanitization Of New Carbon

There are typically 2 options to sanitization of carbon media, steaming and hot water sanitization.

Steaming: Steaming is a highly effective method for GAC (Granular Activated Carbon) sanitization, reaching temperatures that kill most microorganisms, including thermophilic bacteria and penetrates areas where hot water would not contact. This process typically involves:

Temperature and duration: Carbon needs to be heated completely to 85°C (180°F), with steam cycles running for 8-10 hours at temperatures above 105°C (220°F). The maximum steam temperature should not exceed 110°C (230°F).

Procedure: The vessel should be backwashed before and after steaming to remove debris and fines. Ensure face piping and valves are sanitized by exercising them to expose all wetted surfaces.

Advantages: Steaming penetrates areas that hot water may not reach, especially useful for thorough sanitization in larger, complex systems.

Important steps: Include a complete cycle of backwash, settle, heat-up, steaming, cool down, and refill. Condensate should be removed during the cycle, and upflow steaming is preferred for more effective results.

Hot Water Sanitization: Hot water sanitization, while different, also provides effective GAC treatment and biofilm control. Here’s how it works:

Temperature and recirculation: Hot water should be at minimum 85°C (180°F); recirculating through the vessel until the exit temperature reaches 82°C or higher. When exit temperature is 82ׄ°C or higher, continue this process for 1-3 hours for new media, or longer (4+ hours) for older, compacted media.

Process: During recirculation, the vessel is filled, ensuring maximum contact with the GAC surface and internal components. Sample ports should be opened briefly during recirculation to expose all parts to heat.

Cooling phase: Hot water is pushed to the drain, gradually cooling for 45 minutes to an hour. Afterward, the vessel should be backwashed and rinsed to clear any remaining carbon fines or dislodged biofilm.

Controlling Microbiology in GAC Systems

GAC filters are effective at reducing chlorine in the upper portion of the bed and removing organic compounds, but this can create an environment conducive to microbiological growth if not managed. Proactive, routine sanitation practices are critical:

Routine sanitation: Sanitize regularly to prevent excessive biofilm buildup. Effective sanitization must address all system components, including face piping, valves, and interior surfaces to keep excessive growth of these organisms under control.

Monitoring and treatment: Total bacterial count in treated water can indicate biofilm shedding, necessitating immediate sanitation. Biofilms are almost unavoidable, so you must stay ahead of them.

Best practice: Ensure that the face piping has full CIP capability including chemical CIP without requiring chemicals for that CIP to come in contact with the GAC in the vessel.

Sterilization of GAC with Caustic

Caustic sterilization is another approach for deep cleaning.

Isolate the adsorber but leave it filled with enough water to completely submerse the GAC.

Add NaOH in a safe manner as detailed by instructions on the container or as prescribed by established procedures.

When the pH of the water has reached 12 or 13, stop adding caustic and allow the filter to remain in this state, off-line overnight.

Backwash slowly until effluent reaches an acceptable pH and put filter back on-line.

Addressing pH Changes with New Carbon

When new GAC is installed, it’s not uncommon to see a pH rise at startup. This can vary based on source water and carbon surface chemistry. To manage this:

Drain, fill, and soak cycles: Run these cycles to expedite stabilization.

Acid adjustment: In severe cases, lower inlet pH to speed up stabilization.

Product selection: If past installations experienced prolonged pH excursions, select GAC processed for faster stabilization.

Ensuring thorough and effective sanitation practices not only keeps water systems compliant but also enhances long-term performance and reliability. Whether through steaming or hot water, proper sanitization is a critical aspect of maintaining optimal GAC function and water quality.

Let The Experts at Complete Water Solutions Help

Clean and safe water is essential for keeping industrial operations running smoothly. Whether it’s protecting equipment, ensuring product quality, or meeting strict regulations, reliable water treatment is a must. That’s where UV water treatment comes in!

UV water treatment is the process of water disinfection that uses UV light to kill harmful water microorganisms such as bacteria, viruses, and protozoa. It is a safer and more environmentally friendly approach to disinfecting water compared to traditional methods that rely on chemical disinfectants. 

The UV water treatment market is currently growing at a rapid pace, as there are increasing concerns about waterborne diseases. There are also stricter water quality regulations that have been set in place to push for more sustainable solutions. This market is “projected to grow from $5 billion in 2022 to $9.1 billion by 2027” according to WasteWater Digest. The growth we are seeing is reflected as businesses and governments alike are searching for more reliable, cost-effective, and environmentally friendly water treatment solutions.

During a UV water treatment, the ultraviolet rays break down the bacteria, pathogens, and other water-born microorganisms found in wastewater. This leaves them unable to reproduce. According to Smart Water Magazine, UV water treatments can “eliminate up to 99.9% of microorganisms”. Now what sets UV water treatment apart from other water treatment solutions? Other water treatment solutions use chemicals, which can be effective, but also cost money and can be harmful. Chemical water treatments can also potentially change the quality and taste of the water. UV water treatment, on the other hand, is a non-chemical approach to water treatment. This is what sets it apart from other water treatment solutions.

The largest benefit of using a UV water treatment solution is that it is highly effective when it comes to water disinfection. As mentioned above, the strong ultraviolet light destroys bacteria and viruses. This leaves water clean and ensures that there are few illnesses caused by water consumption. 

Another major benefit to UV water treatment is the fact that it is a non-chemical process. This process uses UV radiation, meaning no chemicals are used at all while the treatment is taking place. This results in the preservation of the water’s quality and taste. Not to mention, your company will be saving money on no longer needing to buy chemical solutions!

UV water treatment is also a low-maintenance solution. It requires minimal upkeep. There are no moving parts on this water treatment solution, so there are very little maintenance repairs needed on the treatment machine other than replacing the UV lamp every so often. With less people working on machine maintenance, your company will see increased productivity within your company. You will also see cost savings as you will see less chemical products being purchased with the UV treatment. 

This water treatment also allows businesses to stay in compliance with industry water regulations. Whether you are a larger corporation or a smaller, local company, UV water treatment ensures companies meet strict water quality standards set locally, federally, or even internationally. UV water treatments can be scaled for all industrial needs too. Each treatment can be tailored to different capacities so whether you’re a small-scale or large-scaled company or industry, you’ll be able to find a UV water treatment solution that best fits your specific needs.

With UV water treatments, you could be saving your company time and money. It’s also a good way to remain environmentally friendly and energy-efficient. If you’re ready to switch over to a UV water treatment solution, contact our team at Complete Water Solutions. We’d love to help you get your UV water treatment system up and running!

Complete Water Solutions is a rapidly growing water treatment business located in SE Wisconsin that designs, manufactures, sells, and services Commercial and Industrial Water Treatment Equipment. From the time it enters the facility to the time it leaves – we handle everything in between. Come and grow with us!

We are currently searching for a Full-time (40 hours/week) Field Service Technician to support our water treatment business. This position is for an experienced water treatment field service technician. Responsibilities include but are not limited to the following:

• Diagnose and repair water treatment equipment (Industrial Reverse Osmosis)
• Starting up new or replacement water treatment systems
• Servicing of water treatment equipment (i.e. Water Softeners, Reverse Osmosis, DI)
• Assist with electrical including control wiring, motor controls, relays and switches
• Installing new or exchanging preexisting water treatment equipment
• Installing new or replacing plumbing to and from the system
• Cleaning RO Membranes
• Replacing RO Membranes
• Rebuilding Valve Heads & Controls
• Re-bedding Filters
• Completing all paperwork related to tasks in an accurate and timely manner
• Maintaining company vehicles, tools, and equipment
• Collect, log, and analyze field data including water, resin, etc.

ESSENTIAL FUNCTIONS:

• Seeking a highly motivated, independent, and mechanically-inclined individual.
• Must be able to provide detailed and accurate documentation of any and all service work performed, both on written and electronic (computer) work tickets
• Consistent and dependable job attendance
• Clean Driving Record
• Ability to pass a drug screening test
• Must be able to lift 50 lbs frequently and Up to 150 lbs at times.
• Occasional late night and overnight trips required
• Participation in a rotating on-call schedule, for when emergency service is needed

For the complete job listing, visit our careers page to apply online, or email your resume to tsnow@complete-water.com.