Nestlé USA’s Pizza Division factory in Little Chute, Wis., has reduced its water usage by 7.4 million gallons per year by increasing the performance and efficiency of its cooling towers using GE’s water-treatment chemical technology.

Industrial cooling water must meet tight specifications, but Little Chute’s city water is challenging because of its hardness and alkalinity, according GE Power and Water. Standard chemical treatments were unable to treat it adequately because high concentrations produced scaling in the cooling towers, which decreased cooling efficiency and required additional maintenance. An older control system made consistent control of the cooling operation difficult, and it could not be integrated with plant data systems.

GE Power and Water, Trevose, Pa., provided its advanced GenGard water-treatment chemistry with stress-tolerant polymer and TrueSense controls for the plant’s four main ammonia condensers. They provide precise control of cooling water and enable more cycles where the water-treatment chemicals are in the high concentrations needed for optimum results. As a result, the cooling water is reused to a much greater degree than before, saving 7.4 million gallons of water and reducing sewer discharges by the same amount. This translates into nearly $50,000 in cost savings from avoided water purchase costs and discharge fees.