An industrial bakery based in Wagga Wagga, NSW, faced persistent scale buildup in their evaporative cooling tower. The root of the issue was hard water with high levels of calcium and magnesium, which over time precipitated out as scale deposits. These deposits severely reduced heat exchange efficiency, increased power consumption, and encouraged biofilm formation — posing not only energy losses but also hygiene risks.

The situation was worsened by the client’s continuous 24/7 production schedule. Conventional descaling methods, which typically required shutting down the system for chemical treatment, were not feasible. Previous attempts with off-the-shelf descalers caused corrosion to critical metal components or left residues incompatible with food production environments.

We started with a comprehensive water chemistry audit, testing the incoming water supply and identifying ion concentrations and hardness levels. This allowed us to tailor a precise treatment plan.

Next, we developed a custom-formulated chelating agent specifically designed to sequester calcium and magnesium ions effectively without corroding the metal infrastructure. The formulation was non-corrosive, food-safe, and compatible with existing materials used in the cooling system.

To avoid costly downtime, we implemented an in-line dosing system. This allowed continuous low-dose application of the chelating agent directly into the cooling water stream, meaning the treatment occurred while operations continued uninterrupted.

Finally, we added a biofilm-inhibiting surfactant package to reduce microbial adhesion inside the system. This improved the hygienic safety of the cooling loop while simultaneously optimizing thermal efficiency.