Success Story: Metal Coating Equipment Manufacturer in IL

When a metal coating equipment manufacturer in Illinois faced critical production challenges due to underperforming water purification systems, Complete Water Solutions delivered a seamless, cost-effective solution through a DI Exchange Tank Service and a full turnkey system upgrade.

This customer manufactures precision metal coating equipment used across multiple industries. High-purity water is essential in their process, both for hot water testing and for cooling UV lamps within the machinery. To maintain top performance and prevent scale buildup, the customer required water quality of 1 microsiemen or better.

However, the company’s existing setup relied on five Millipore EMD Elix 100 RO/EDI units, and the system was failing. Two units were leaking, and even when fully operational, the output totaled just 2.2 gallons per minute (GPM) at 77°F. Seasonal temperature drops further reduced production capacity, and upcoming process expansions required an additional 1 to 1.5 GPM of pure water.

The cost of purchasing and repairing additional Millipore units would have been significant, between $67,200 and $112,000, not including installation or maintenance.

In addition to restoring reliable water production, the customer had a crucial requirement: all installation work had to be completed without disrupting operations. Production could not stop, even during the system transition.

To meet these demands, Complete Water Solutions designed and implemented a turnkey industrial water system tailored to the manufacturer’s needs. The solution included:

• Performa Carbon Filtration System for chlorine removal

• GE Osmonics E4-6600-DLX (Part #1234818) reverse osmosis unit

• Electronic Deionization (EDI) system for high-purity polishing

• New sonic level sensor and wastewater reclaim system to optimize efficiency

But the real game-changer came during installation. To keep the facility running without interruption, Complete Water Solutions provided a Temporary DI Exchange Tank Service. This temporary setup maintained consistent high-purity water supply throughout the demo and installation phases.

The result? The customer didn’t miss a single drop of water.

After the upgrade, the new system achieved impressive results:

• Output: 3.5 GPM of DI water

• Quality: 0.04 – 0.06 microsiemens (16–18 ohms)

• Savings: Estimated $37,200 – $82,000, excluding installation and ongoing maintenance savings

With Complete Water Solutions, the manufacturer not only restored reliable water performance but also exceeded previous system specifications — all while staying within budget and maintaining production uptime.

For industrial facilities that rely on high-purity water, a DI Exchange Tank Service can be a critical bridge during system repairs, upgrades, or emergency situations. It allows continuous operations while maintaining required water quality standards.

In this case, the service provided flexibility and ensured uninterrupted testing and cooling operations. This approach is particularly valuable for industries such as:

• Beverage Manufacturing (e.g., Pepsi, Coca-Cola, Dr Pepper)

• Pharmaceutical and Animal Health Manufacturing (e.g., Baxter, Abbott)

• Food Manufacturing (e.g., Johnsonville, canned goods)

• Power Generation and Mining Operations

Whether for planned system upgrades or unexpected failures, DI exchange tank solutions provide cost-effective, temporary access to high-purity water without the expense of permanent equipment downtime.

From reverse osmosis and EDI systems to emergency DI tank services, Complete Water Solutions helps industrial clients across the country maintain consistent water quality and reliability.

If your facility is experiencing challenges with aging water treatment equipment or you need temporary high-purity water support, our experts are ready to help.

Contact Complete Water Solutions today to discuss your water treatment needs or to learn how a DI Exchange Tank Service can keep your operations running smoothly.