Challenge
Evolve's plastic manufacturing facility had an ongoing issue with bacteria across its three water cooling systems. Maintenance teams faced many hours of unscheduled work — plant downtime, production losses, and extensive cleaning of expensive moulds. As a secondary effect, water cooling lines were riddled with corrosion and thick sludge.
Solution
Blue Quest's trial skid was implemented alongside Chiller 1 as part of an initial trial. Immediately, results were realised in Chiller 1's cooling-system reservoir and associated cooling lines. Within two weeks, Chiller 1 was free of bacteria and sludge. Unscheduled maintenance — filter changes, cleaning — was reduced. With the immediate success of Chiller 1, Blue Quest added a second line for Chiller 2. Same result: cleaned free of bacteria and suspended solids in a similar time frame.
Before / after photographs from the original case study artwork — drop the cropped images into /Brand/Design_System/case-study-photography/ to display.
✓ INDEPENDENTLY VALIDATED BY ALS LABORATORIES · TWO-CHILLER ROLLOUT IN UNDER ONE MONTH
Benefits
Immediate return on investment
Major reduction in production losses and unnecessary maintenance costs. Improved head pressure resulted in lower power consumption — savings visible within the first month.
Continuous, automated treatment
Water treatment is ongoing with continual automated filtration and backwashing. The objective on bacteria and suspended-solid contamination is held continuously, not episodically.
Small footprint, non-invasive integration
The skid integrates without re-engineering the existing chiller plant. Minimal gel chemistry consumption alongside materially improved water quality.
What this proves
For any operator running closed-loop cooling water with bacterial-fouling pain — manufacturing, food processing, data centres, HVAC at scale — the economics here are repeatable. Restoring head pressure alone funds the system in months; the OPEX line on consumables, downtime and call-outs is gravy.