The 5 most common reasons to switch to the Watter system

Microbiological contamination is a structural problem in many industries. Companies use chemical disinfection methods such as sodium hypochlorite (NaOCl), hydrogen peroxide (H₂O₂) or chlorine dioxide (ClO₂) to control biofilm and germ pressure. Yet they often run into the same bottlenecks: high costs, inefficiency and unwanted residuals in their production process.

More and more companies are therefore making the switch to in situ produced hypochlorous acid (HOCl) with the Watter system. Based on practical experiences, we have listed the five most common reasons why companies choose a more sustainable and effective alternative.

1. Biofilm formation and persistent microbial contamination

Biofilm in process water and production lines is one of the biggest hygiene challenges in various industries. Once biofilm forms, it provides a protective layer for bacteria, often rendering standard disinfectants ineffective.

Common problems:

• High germ counts in waterborne systems and piping.
• Microbial contamination that keeps recurring despite cleaning protocols.
• Insufficient effectiveness of standard disinfection methods.

2. High cost and inefficiency of current disinfection methods

Companies invest large amounts of money in chemical disinfectants such as NaOCl and ClO₂. This leads not only to high material costs, but also to indirect costs such as production downtime and labor-intensive cleaning.

Common problems:

• High costs due to the monthly use of large quantities of chemical disinfectants.
• Disinfection processes are labor intensive and require regular production stops.
• Regular replacement of damaged equipment due to corrosive effects of disinfectants.

3. Process water quality problems

Clean process water is essential to prevent contamination of finished products or equipment. If water quality is inadequate, microorganisms can spread through piping, flushing systems or cooling systems.

Common problems:

• UV disinfection proves insufficiently effective in some applications.
• Microbial growth in cooling water systems and nozzles leads to blockages and reduced efficiency.
• High germicidal pressure in rinse or process water affects product quality and shelf life.

4. Need for a safer and more sustainable alternative

Many companies want to move away from traditional disinfection methods such as ethanol, alcohol and NaOCl. Not only because of the impact on humans and the environment, but also because of the limitations in effectiveness.

Common problems:

• Current chemical disinfectants leave unwanted residues.
• Stricter laws and regulations require more sustainable and safer methods.
• Occupational safety and chemical exposure are becoming increasingly important concerns.

5. Stricter microbiological controls and quality standards

Microbiological controls are becoming stricter due to tighter regulations and increased quality standards. At the same time, companies are finding that germ counts in their processes are increasing, possibly due to changed production methods, biofilm formation or process water quality issues. This can lead to rejects, claims and production downtime.

Common problems:

• Suddenly significantly elevated cfu/ml values in water and product samples.
• Product rejections and risk of high-cost claims.
• Increased focus on microbiological safety by growing quality departments.

A structural solution for microbiological control

The Watter system offers a sustainable alternative to traditional disinfection. By producing hypochlorous acid (HOCl) in situ, an effective disinfectant is generated without storage of hazardous chemicals. This not only reduces costs, but also ensures continuous disinfection of process water and production lines.