Process water is purified and treated water that industries rely on for manufacturing, production, and other industrial operations. For example, when a soft drink manufacturer makes beverages or a pharmaceutical company produces medicines, they need this specially treated water rather than regular tap or utility water.
Process water undergoes specific treatments to achieve precise quality parameters essential for industrial applications. These parameters might include controlled pH levels, specific conductivity ranges, precise mineral content, and strict microbiological standards.
Where Does Process Water Come From?
Process water typically starts as raw water from various sources:
- Municipal water supplies
- Surface water (rivers, lakes, reservoirs)
- Groundwater (wells and aquifers)
- Recycled industrial water
Each source presents unique challenges, requiring specific treatment approaches to meet industrial standards.
How is Process Water Created?
Process water is created through a series of specialised treatment steps, each designed to remove specific impurities from the source water. The journey typically begins with pre-treatment, where larger particles and some organic contaminants are filtered out using sand filters and carbon filters.
Next, the water passes through advanced purification processes such as reverse osmosis, which removes dissolved solids and contaminants at a molecular level. Depending on the industry's requirements, additional steps might include deionisation to remove minerals, UV sterilisation to eliminate microorganisms, or membrane filtration for ultra-fine purification. The entire process is carefully monitored and controlled to ensure the final water quality meets exact specifications for its intended industrial use.
What Is Process Water Used For?
The applications for process water span an impressive range of industries, each with unique requirements and challenges:
Pharmaceutical and Healthcare
Purified water is essential for drug production, pure steam generation, and equipment rinsing. Healthcare facilities rely on high-purity water for everything from pathology work to sterilisation services.
Food and Beverage Production
Process water is crucial for product formulation, ingredient mixing, and equipment cleaning. The industry demands flexible purification systems that can deliver consistent quality while adapting to different production needs.
Chemical and Petrochemical Industries
These sectors utilise process water extensively in cooling tower systems, boiler feed applications, and production processes, focusing on efficiency at scale.
Microelectronics
The semiconductor and electronics industry requires ultra-pure water for chip manufacturing, circuit board cleaning, and precision processes where even microscopic impurities can cause defects.
Power Generation
Power plants require high-purity water for boiler feed, cooling systems, and emissions control, where water quality directly impacts equipment longevity and operational efficiency.
Aerospace
Precision cleaning, testing, and manufacturing processes in aerospace demand consistently high-quality water to maintain strict quality standards and ensure component reliability.
Data Centres
Efficient cooling water treatment is crucial for maintaining optimal operating temperatures in data centres, where reliability and energy efficiency are paramount.
Automotive Manufacturing
From paint shops to parts cleaning, the automotive industry relies on process water for various applications, ensuring business continuity and operational control.
Pulp and Paper
Quality process water is essential for paper production, with specific requirements for different grades of paper and at various stages of the manufacturing process.
Primary Metals
Metal processing requires carefully treated water for cooling, cleaning, and processing applications, with a focus on maintaining water quality while managing environmental impact.
Mining Operations
The mining industry uses process water for mineral processing, dust suppression, and various extraction processes, often requiring solutions for water recycling and environmental protection.
What options are available to generate Process Water?
We offer comprehensive process water solutions through our advanced range of treatment systems and expert support. Our flagship technologies include:
Orion™ - A sophisticated purified water system specifically designed for pharmaceutical applications, offering multiple configurations to match sustainability and operational goals. Available in three series (S, E, and C), Orion can significantly reduce water and energy consumption while meeting stringent quality standards.
SENSA™ - An intelligent water treatment solution particularly suited for cosmetics manufacturers, delivering up to 90% water recovery and 50% energy savings compared to conventional systems. Its user-friendly design and flexible flow rates (1.4 to 10m³/h) make it ideal for various production scales.
IonPro™ - An integrated water purification system combining reverse osmosis with continuous electrodeionisation (CEDI) technology. This compact solution produces high-purity water with low bacteria levels, perfect for industries ranging from pharmaceuticals to microelectronics.
Sirion™ - Our extensive range of reverse osmosis systems offers solutions from small-scale (40 l/h) to large industrial applications (up to 120m³/h). Available in multiple configurations, including Advanced, Pro, Mini, Midi, and Mega versions to suit different industry needs and budgets.
TERION - A comprehensive water treatment solution combining RO and CEDI technology, specifically engineered for power generation and industrial applications. Available in two variants (TERION and TERION S), this system removes 99.9% of dissolved inorganics while featuring Hubgrade IoT monitoring for real-time analytics across 50+ parameters. The system offers significant power savings through variable speed pumps and requires minimal maintenance with no regeneration downtime.
CaptuRO™ - An advanced semi-batch reverse osmosis system achieving up to 98% water recovery from industrial, brackish, and wastewater sources. This innovative technology reduces brine waste by 50-75% and energy consumption by 35%, while preventing membrane scaling through optimised salt purging. Ideal for healthcare, chemical, and food/beverage industries.
Beyond equipment, we provide:
- Comprehensive system design and engineering
- Installation and commissioning support
- Operator training and ongoing maintenance
- 24/7 remote monitoring through our Hubgrade digital platform
- Expert consultation for process optimisation
- Full regulatory compliance support
With our solutions, industries can achieve consistent water quality while reducing operational costs and meeting sustainability goals.
The Future of Process Water
As industries evolve and environmental pressures increase, effective process water management becomes increasingly critical. Water scarcity, stricter regulations, and sustainability requirements are reshaping industrial water use. Process water may be just one component of industrial operations, but its importance cannot be overstated. With the right expertise, technology, and support, it becomes a driver of efficiency, quality, and sustainability.
Our expert team is here to help you design, implement, and maintain the perfect water treatment solution for your industry needs. Whether you're in pharmaceuticals, food and beverage, or manufacturing, we'll ensure you get the exact water quality your operations demand.
Contact one of our process water experts now.
