Case Study A Smooth Transition:
Enabling Vertik-Al's Chromium-Free Future

Water Treatment Solutions to Overcome New REACH Prohibition of Hexavalent Chromium, Negotiate Space Constraints and Maintain Production Output

Case Study Overview

Vertik-Al, a leading provider of vertical and horizontal Aluminium powder coating for the architectural Aluminium industry, faced a critical challenge when European regulations (REACH) prohibited the use of Hexavalent Chromium in their pre-treatment process. To comply with regulations while maintaining consistent production efficiency, Vertik-Al needed a reliable water supply with stringent quality requirements.

  • INDUSTRY: Multi-industry Powder Coating Manufacturing
  • PROBLEM: Transition from Hexavalent Chromium to Chromium-Free Pre-Treatment
  • IMPLEMENTED SOLUTION: Water Supply with <30 μS/cm Quality

The Problem

The transition from a Hexavalent Chromium to a Chromium-free process required a large volume of water with a quality level below 30 μS/cm to ensure effective pre-treatment. Restrictive space at VertikAl’s facility posed significant hurdles for installing the required water treatment systems. Additionally, maintaining uninterrupted production during the transition was crucial for Vertik-Al to meet customer demands and ensure operational continuity.

The Result

The integrated water treatment system provided by AllWater enabled Vertik-Al to meet stringent purity standards for Chromium-free processes, ensuring compliance with REACH regulatory requirements whilst enhancing operational efficiency. Despite space constraints and existing infrastructure limitations, the seamless integration of the new water treatment system allowed Vertik-Al to maintain uninterrupted production, eliminating downtime and sustaining productivity. By leveraging AllWater’s expertise and innovative solutions, Vertik-Al successfully navigated the transition to Chromium-free manufacturing processes, demonstrating a commitment to regulatory compliance and operational excellence. 

The Solution

  • Space Optimisation: AllWater Technologies Ltd and Vertik-Al devised a solution to optimise space utilisation. Existing bulk chemical storage tanks, including redundant units, were removed and replaced with chemical day tanks, which in turn were fed by gravity from IBCs

  • Customised Water Treatment System: AllWater coordinated with Vertik-Al to keep the existing DI plant operational whilst space was cleared for a new Duplex DI plant. Once the new plant was successfully commissioned the old plant was removed from service, refurbished, and once more recommissioned , utilising a new PLC/HMI driven control system which now encompasses all 4 ion exchange DI streams.

  • Monitoring System: Implementation of advanced monitoring technologies, including realtime monitoring of chemical usage and system performance, provided Vertik-Al with enhanced visibility and control over their water treatment processes, facilitating proactive maintenance and optimisation.

"We have been very happy with AllWater’s professionalism and response times when we have needed help with the plant. The staff are all very helpful and knowledgeable and we are very satisfied with the service provided."

Jamie Davies

Turnspeed

"We needed a DI plant that is capable of producing the processing water to serve our Chemical Process lines twelve rinse tanks, 24 hrs a day, 7 days a week at a max of 20.00 μS/cm. The water plant is now consistently cleaning the water to 1.00 μS/cm."

Steve Silk MBE

Marshall Aerospace

"We have built a good relationship with AllWater and continue to enjoy service contracts with them. They know what they’re doing and we’re always happy with their service"

Andy Best

Production Director - Vertik-Al

"We needed a DI plant that is capable of producing the processing water to serve our Chemical Process lines twelve rinse tanks, 24 hrs a day, 7 days a week at a max of 20.00 μS/cm. The water plant is now consistently cleaning the water to 1.00 μS/cm’"

Amelia

Production Manager

"AllWater Technologies installed their pure water system in our premises to replace our old system which went into retirement. The level of service and maintenance that AllWater are giving us will ensure that we get the quality of product and the length of service we are looking for out of our plant. Their level of service is excellent."

John Malone

excel gs ltd

"Thank you for all your support. I have to say that I am really impressed with All Water approach to provide a really good service. Thank you again."

Radu Vitanescu

Liberty Engineering

"AllWater have provided great service, specialist advice and an effective waste water treatment solution for our site."

Paul Pearcy

Warburtons

"AllWater have always delivered us a great service and are equally competent maintaining existing kit or installing new. They’re friendly and reliable and, perhaps most importantly, trustworthy."

Phil Parkinson

Joseph Holt

"AWT professional service allows our site to run with minimal downtime when unplanned breakdowns happen. AWT service is invaluable in maintaining our production lines throughout."

Adam Cook

Qsil

"The person was very polite and explained everything in detail. Report was typed and easy to understand."

Richard Fox

London and Brighton Plating

"We are more than satisfied with the level of service we receive from everyone at AWT. Excellent work, Thank you!"

Daniel Holden

Karas Plating

"AllWater Technologies provide an exceptional level of knowledge and support, and we cannot fault their service and commitment. The team consistently exceed expectations and although others may offer a cheaper alternative, we have every confidence that they could not offer better!"

Eric Allen

Albumedix LTD

"By using AWT we know that our plant and equipment is being maintained to the highest standard using the expertise and knowledge that we find second to none. When issues arise it is paramount that we can resolve these issues promptly; AWT are always there to support us."

Allen Staunton

Creganna Medical

"Using All Water Technologies has been a breath of fresh air. Their attentive service from the first call through to delivery completion, has made the management of our water treatment plant very easy indeed. We wash over 2.5 million items of tableware for the event industry every year, working at some of the UK’s most prestigious events, so having peace of mind over our washing operation is essential. I would recommend AWT to anyone’"

Joe Nisbet

Jongor Hire

"AWT offered Rimex a bespoke solution to our water softening and storage requirements. They took charge and managed the project efficiently and effectively from the very beginning. I am delighted with the outcome and I will continue to use AWT for preventative maintenance and any other future projects."

Daniel Meakin

Rimex Metals

"All went very well with the plant being well finished, installation being of a high standard and all works being completed on time and to specification."

Dom Oughton

Optimum

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