Case Studies

I. Challenges A large gypsum manufacturing plant had two reverse osmosis (RO) trains (A and B) but they were inefficient: Recently, neither RO train have been serviced with a complete Clean-In-Place (CIP) and the plant had a CIP skid available but they still needed additional support to use the equipment. Their current water treatment vendor…

I. Challenges A Midwest ethanol manufacturing plant replaced the membranes of their large reverse osmosis (RO) system but the differential pressures increased rapidly and exceeded the recommended operating ranges. If failure occurs, they will lose $200,000 in revenues per non-operational day. To cope with the problem, the ethanol plant carried out a Clean-In-Place (CIP) procedure…

I. Challenges A lumber company in East Texas experienced high corrosion in their steam kilns resulting in expensive replace/rebuild costs. They were going through the following issues: II. Approach Garratt-Callahan’s team analyzed the site’s source water and kiln chemistry. They found that the company’s boiler water carry-over and high levels of chloride problem were due…

I. Challenges Commercial facilities such as hotels, restaurants, bakeries, butcher shops, hospitals, and prisons often suffer from the following problems: Like many hospitality-related properties, this high-rise casino resort had many of the same challenges. They were experiencing problematic drain lines and grease traps. As a result, they were: II. Approach Garratt-Callahan’s team introduced Formula BZ…

I. Challenges A high-volume beverage plant in Puerto Rico was processing well water at 85% recovery. The plant was performing monthly chemical cleanings and needed to replace the system’s 78 membrane elements every year. As a result: II. Approach Garratt-Callahan’s water treatment professionals began to troubleshoot the system. They uncovered a faulty check-valve that allowed…

Persistent reverse osmosis fouling threatened a particle board manufacturer’s productivity until Garratt-Callahan implemented a tailored water treatment program. By prioritizing proactive monitoring, the facility extended RO membrane life and significantly improved system reliability. This success proves that expert industrial water management is vital for preventing costly production downtime while maintaining rigorous, high-purity water standards for efficiency.

Snapshot of Success Industry: Data CenterChallenge: Elevated iron levels prevented closed-loop water from meeting equipment manufacturer specificationsSolution: Full system repassivation + component chemistry retreatment + upgraded monitoring panelsResults: Iron reduced from ~0.82 ppm to 0.15 ppm and maintained for 10+ monthsWhy This Success Matters: Data center systems with strict control requirements need the right passivation…

Challenges The boiler – a 1000-hp tube unit – at a plywood manufacturing plant in the Pacific Northwest had scale so bad that it had to be shut down after only a year and a half of operation. Treatment chemicals for the boiler were being mixed daily, however, the feed system was not working properly….

Challenges Garratt-Callahan was the water treatment chemicals supplier for a Texas-based automotive parts manufacturer when the company opened up bidding on a new cooling tower as part of a major HVAC renovation at its plant. The bidding also included one company that was supplying the plant with processing equipment and services, and another that had…