Gatorade Case Study
OVERVIEW
The bottling plant has 11 cooling towers which are an integral part of the cooling process for both equipment and comfort cooling.
Prior to Capture H2O, the plant utilized a traditional chemical program to treat the cooling tower water. This resulted in wasting millions of gallons of water and poor protection of the cooling towers themselves, with scale and corrosion of the towers being an ongoing issue.
CUSTOMER: GATORADE
PROJECT SCOPE: 8 COOLING TOWERS DISTRIBUTED THROUGHOUT THE DALLAS PLANT
PROGRAM: HIGH CYCLE
DATA SUMMARY: 28 MILLION GALLONS SAVED IN 2022, WASTEWATER REPURPOSING, IMPROVED CONTROL
OUR SOLUTION
In 2018, Capture H2O installed the High Cycle program. This program couples patented technology with improved processes, resulting in significant savings of water and expenses. Over the course of 2022, the plant owner realized the following benefits:
1. Installing the patented, high efficiency softeners on the makeup water line allowed the plant to raise the cycles of concentration, which saved the site an estimated 13 million gallons of water in 2022.
2. The new program allowed the plant to utilize an alternative, less expensive water source. The wastewater produced from the reverse osmosis process used to purify the product water now became the makeup water source. In 2022, this saved an estimated 15 million gallons of water and $197,000.
3. Sending wastewater down the drain results in sewer charge expenses from the local government. With the wastewater being redirected back into the cooling system, a large percentage of the wastewater is evaporated, avoiding this additional sewer charge. In 2022, this saved the plant an estimated $80,000.
4. The new program coupled with Capture H2O’s extremely high level of service have significantly reduced the amount of scale, corrosion and bacteria in the plant’s cooling towers and ancillary cooling equipment. This will result in lower maintenance and equipment replacement costs.
SUMMARY
In total, Capture H2O was able to save this plant an estimated 28 million gallons of water, 76,000 per day, $277,000 in 2022. As we continue to work with the innovative team at this plant, additional savings of water and money will be achieved through raising the average cycles of concentration and evaporating more wastewater.