Cutting corners on water treatment can cost companies far more than they realise – especially when boilers are involved. That’s the message from Lionel Maasdorp, Managing Director at Allmech, a leading South African manufacturer of boilers and supplier of water treatment equipment and chemicals.
“All too often, clients come to us requesting a specific softener size or quoting a specification from another supplier,” says Maasdorp. “They might be offended when we ask for a water analysis to substantiate their request, but the truth is, one size doesn’t fit all when it comes to water treatment. Proper system sizing depends on the unique composition of the incoming water. We often find that small changes in the plant can give the client better results than what they had asked for initially. Sizing the plant based on proper data has better results than just guessing and saves the client from spending money unnecessarily.”
Maasdorp says that some customers have insisted on buying an undersized plant and have then had to upgrade at a later point, which has been extremely costly. Ignoring specifications can cause bigger headaches down the line through causing downtime and production challenges.
“We’ve had customers who insisted on using less salt in their softeners or diluting boiler chemicals to cut costs,” he explains. “When their systems are serviced, the results are clearly visible – corrosion, scale, and fouling that could have been avoided. In the worst cases, we’ve seen boilers requiring acid washes or even tube replacements, which are extremely expensive and can reduce the lifespan of the equipment.”
Why adhere to specifications?
Customers who follow a water treatment specialist’s recommendation and maintain their systems according to specifications are more likely to enjoy outstanding results. “We have customers who’ve been with us for more than 15 years who’ve only needed a handful of acid washes – and in some cases, only one was necessary,” says Maasdorp. “They make sure the brine tank always has salt, the chemical tanks are topped up, and the dosing pumps work properly. They’ve been rewarded with lower servicing costs, less downtime, and improved efficiency.”
Maasdorp explains that poor-quality feedwater can have devastating effects on boiler performance. Calcium, magnesium, and silica scale can build up inside boilers, forming insulating layers that prevent heat transfer and reduce efficiency. “In electrode boilers, for example, scale can act as an insulator, preventing the current from passing through the water,” says Maasdorp. “That means more fuel must be burned to produce the same amount of steam – and that’s money wasted.”
While some clients view water treatment as an unnecessary expense, Maasdorp encourages them to look at the bigger picture. “Yes, chemicals and maintenance have a cost, but the savings in fuel and reduced downtime more than make up for it,” he says. “We often compare our annual service and chemical costs with the savings we generate, and the numbers speak for themselves.”
The importance of ongoing care and maintenance
Allmech’s commitment to training and aftersales support helps clients stay on spec. “We commission every system we install, train operators, and continue to support them through monthly check-ins,” Maasdorp explains. “When staff change, we train the new team. We even use WhatsApp groups with some clients to help them troubleshoot on the go.”
His advice to companies? “Stick with a reliable partner rather than jumping between suppliers,” he says. “Keep records and photos of your equipment so you can track the impact of your maintenance regime. And most importantly, implement the recommendations you’re given. Following the system operating procedures isn’t just about ticking boxes – it’s about protecting your investment.”
