Case Study • Industrial Water Treatment Skid Design

Engineered Industrial Water Softener System: 25,000 GPD Skid Design

Spec’d, supplied, and integrated by LibertyCES to eliminate hardness scale, stabilize water quality, and support Title 22-ready reuse with UV disinfection and SCADA-ready control logic.

25,000 GPD Capacity
UV Microbial Control
Ion Exchange Softening
SCADA-Ready Integration
Before / After Component Stack Engineering Standard Engineering FAQ Explore More

Industrial Water Treatment: Before vs After

LibertyCES does not manufacture tanks — we engineer the system architecture, then spec and supply the exact components needed to hit performance, safety, and compliance targets.

BEFORE Common Transactional Problems

  • Hardness scaling reduced heat-transfer/boiler efficiency and drove high operating cost.
  • Valve & piping corrosion accelerated maintenance and shortened asset life.
  • Inconsistent water quality disrupted batches and triggered audit risk.
  • Manual intervention created slow response during production spikes.
  • Downtime exposure from unstable flow and quality swings.

AFTER LibertyCES Engineered Solution

  • Automated regeneration logic reduces hands-on intervention and stabilizes output quality.
  • UV disinfection delivers microbial control without chemical biocides in the loop.
  • Corrosion-resistant storage & buffering supports steady, surge-free delivery.
  • SCADA-ready visibility enables alarms, trending, and remote operating confidence.
  • Uptime-first architecture designed to protect production from scale-related events.

Core Components of This Precision Skid

This is where LibertyCES wins: application-first spec. We match chemistry to mechanics, materials to environment, and controls to real operating conditions.

Industrial ion exchange vessel fiberglass pressure vessel for industrial water softener system

Industrial Ion Exchange Vessels (Fiberglass)

ASME-code pressure vessels spec’d for high-flow resin capacity. Selected for corrosion resistance over standard steel tanks.

Purpose: removes dissolved calcium/magnesium that causes scale, protecting valves, piping, and downstream equipment.
Cross-linked polyethylene brine tank for industrial water softener regeneration system

Chemical Storage & Brine Tanks

High-density cross-linked polyethylene (XLPE) tanks engineered for safe containment of concentrated brine.

Purpose: supports regeneration performance and stable soft water delivery without resin fatigue.
Industrial UV disinfection system for microbial control in industrial water treatment skid

Industrial UV Disinfection System

Non-chemical sterilization using 254nm ultraviolet light. Spec’d to meet strict Title 22 water reuse standards.

Purpose: microbial control without biocides that can contaminate product or disrupt downstream treatment.
SCADA monitoring and automation interface for industrial water treatment control logic

SCADA & Pump Control Logic

The brain of the skid. We integrate sensors with pumps/valves to automate regeneration cycles based on real operating conditions.

Purpose: predictable operation, alarms/visibility, and less manual intervention when production surges or quality shifts.

Why We Spec, Not Just Sell: The Liberty Engineering Standard

Most suppliers ship components. LibertyCES engineers the solution — so the system runs clean, stable, and compliant in the real world.

Engineering Deep Dive

For this 25,000 GPD project, the challenge wasn’t only “hard water” — it was maintaining consistent soft-water delivery during regeneration windows while preventing microbial growth in storage/holding loops.

  1. Hydraulic sizing: We sized the industrial water treatment skid around peak flow dynamics (not just average daily volume) to reduce pressure-drop risk during production spikes.
  2. Material selection: We prioritize corrosion-resistant plastics and compatible wetted materials to reduce scale/corrosion exposure and simplify maintenance planning.
  3. Automation architecture: We integrate SCADA-ready control logic so operators can monitor trends, receive alarms, and run consistent cycles without manual guesswork.

Engineering FAQ

Clear answers for engineers, operators, and project teams evaluating industrial water softener systems and treatment skids.

How do you size an industrial water softener system?
We size based on source-water hardness (GPG), peak flow rate (GPM), and total daily volume (GPD). A 25,000 GPD system commonly uses an architecture that maintains soft-water availability during regeneration windows, aligned to the facility’s true operating profile.
What is the difference between a water softener and an industrial water filtration system?
A softener removes dissolved minerals (calcium/magnesium) via ion exchange to prevent hardness scale. An industrial filtration system typically removes suspended solids (sediment) or organics using media or membranes. LibertyCES often integrates both into a single skid when the application demands it.
Why use UV disinfection instead of chemical biocides?
Industrial UV disinfection inactivates microbes physically by disrupting DNA — without adding chemicals that can contaminate product streams or interfere with downstream equipment. It’s an excellent option for reuse targets and sensitive industrial processes.
Does LibertyCES manufacture the tanks?
No. LibertyCES is a specialized systems integrator. We leverage direct relationships with top-tier manufacturers to spec and supply the exact pumps, valves, tanks, and controls required for your facility constraints — then integrate it into a solution that performs in the field.

Want an engineered solution like this?

Send your water analysis, peak flow, constraints, and goals. James will spec the right architecture and components so the system runs right the first time.

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