Industrial water bath algae and chlorine dosing
Industrial water bath algae and biofouling were high at a US manufacturing plant, along with TDS and bacteria. The response, heavy chemical dosing and frequent blowdowns, was costing water as well as chemicals. In June 2025 one HydroFLOW® i150 was fitted to a six inch fibreglass pipe in the cooling loop for a 90-day evaluation. Algae and biofilm stopped establishing, chlorine dosing was cut gradually to 75% below the starting level, and water quality held throughout. Blowdown frequency fell alongside the chlorine, and the plant’s own water quality tests backed every stage of the reduction.
The Challenges
- Industrial water bath algae and biofouling were high across the baths
- TDS and bacteria levels were also high
- Heavy chemical dosing was required
- Frequent blowdowns were driving water usage
- Chlorine had to be reduced gradually, not switched off
The Solution
- Unit installed: one HydroFLOW® i150
- Installation point: cooling loop
- Pipe size: six inch fibreglass
- Installed: June 2025
- Trial: 90-day evaluation with staged chlorine reduction
The unit was fitted to the cooling loop, and chlorine was then cut in stages rather than switched off. The plant’s own water quality tests were the measure at every stage, so each reduction was backed by data rather than appearance. The signal disrupts the conditions that let algae and biofilm establish, and industrial water bath algae cleared as the chlorine came down.
