In our ongoing content series, Donaldson explores key process filtration challenges in the food and beverage industry. In Part Two, Dominik Michel, Donaldson’s Non-Alcoholic Beverages Sector Lead, unpacks a filtration breakdown in spring water production and offers practical strategies to help manufacturers safeguard uptime and product quality.
Scenario: Filter Blockage Halts Spring Water Production
A spring water producer in the U.S. was fulfilling a major retailer’s order. Previously, they used Donaldson LifeTec® PES-WN 0.2MIC membranes and LifeTec® P100-N 1MIC prefilters. Seeking cost savings, the purchasing team switched to a lower-cost filter brand without consulting the quality department.
Initially, the new filters performed adequately. But during high-volume production, the filters became blocked, halting operations and jeopardizing delivery timelines.
What Went Wrong in the Filtration Process?
Q&A with Donaldson’s Filtration Expert
What role does filtration play in bottled water production?
Filtration removes suspended solids and ensures microbiological safety, which is critical for product quality and regulatory compliance.
What’s at risk when filters fail?
Production halts lead to missed deadlines, increased labor costs, and internal friction. The Total Cost of Ownership (TCO) rises sharply when filters underperform.
What do you think caused this situation?
While filters may share nominal ratings (e.g., 0.2 µm), actual filtration performance varies. Lower-cost filters often lack the durability and validation needed for high-throughput environments.
What are the implications for plant managers?
They face operational stress, overtime costs, and cascading delays. This highlights the need for cross-functional collaboration and long-term filtration planning.
Is this a common issue in food and beverage manufacturing?
Yes, absolutely. Plant and production managers are responsible for managing the fallout when production halts. This highlights the importance of equipping them with the ability to communicate with their management teams about Total Cost of Ownership.
While cost-efficient alternative products may seem appealing, our field experience shows they often come with risks, including shorter lifespans and increased susceptibility to clogging and failure.
What filtration solution does Donaldson recommend?
- Use filters with a Log Reduction Value (LRV) > 7 for Brevundimonas diminuta to ensure microbiological safety.
- Pair with absolute-rated prefilters (1.0 µm or 0.6 µm) to protect membranes and extend filter life.
- .Conduct a filterability study to select the optimal filter cartridge and prefilter combination.
How can producers avoid this issue in the future?
- Define clear quality and performance standards.
- Align procurement and quality teams on TCO and filtration goals.
- Implement a filter management system with stock planning and scheduled changeouts.
- Partner with Donaldson for on-site filtration services and process audits.
