20TPH RO System + 40TPH Water Softener for Instant Corn Processing Plant

Project Overview

         

Item	Details
Raw Water Source	High-hardness surface water
Core Process	Automatic Water Softening + Reverse Osmosis (RO)
RO Permeate Capacity	20 TPH (tons per hour)
Softener Capacity	40 TPH
Service Scope	Engineering design, manufacturing, on-site installation, commissioning, final acceptance
Supplier	Shandong Yufeng Water Treatment Equipment Co., Ltd.

　Raw Water&Operational Challenges

　　The plant’s surface water supply presented critical risks to production stability and equipment lifecycle:

　　Excessively high water hardness with elevated calcium(Ca²⁺)and magnesium(Mg²⁺)content

　　Severe scaling risk in heat exchangers,pipelines and processing equipment,which reduces heat transfer efficiency and causes blockages

　　Fluctuating raw water quality fails to meet consistent food-grade production standards,leading to unstable product texture and quality

　　Rising maintenance costs and unplanned downtime without targeted water treatment

　　A combined softening+reverse osmosis solution was required to fully address these issues.

　　Customized Water Treatment Solution

　　To match the instant corn processing line’s production demand,we designed a two-stage industrial water treatment system with multi-stage pretreatment protection:

　　1.40 TPH Automatic Water Softener System

　　Deployed as pretreatment for the RO system to eliminate scaling risks at the source:

　　Efficiently removes calcium and magnesium ions to reduce raw water hardness

　　Equipped with fully automatic resin regeneration system,supporting 24/7 uninterrupted operation

　　Protects downstream RO membranes from scaling damage,extending membrane service life by over 30%

　　2.20 TPH Reverse Osmosis(RO)System

　　Core purification unit to produce stable food-grade pure water:

　　Three-stage pretreatment cascade:multimedia sand filter,activated carbon filter,and precision security filter

　　High-pressure RO membrane filtration with 98%+desalination rate

　　Removes dissolved salts,bacteria,microorganisms and fine impurities

　　All food-contact components comply with food safety standards for production use

　　Process Flow:

　　Surface Water→Raw Water Tank→Feed Pump→Sand Filter→Activated Carbon Filter→Water Softener→Precision Filter→High-Pressure Pump→RO Membrane System→Food-Grade Pure Water Tank→Production Workshop

　　This process chain ensures stable long-term operation,reliable anti-scaling protection,and consistent high-purity water for food production.

　　Turnkey Installation&Commissioning

　　Our on-site engineering team delivered full-cycle project execution step by step:

　　Engineering Design

　　Custom system layout based on the plant’s production capacity and site space,with optimized pipeline and equipment arrangement.

　　Equipment Installation

　　40 TPH softener tank assembly,20 TPH modular RO skid installation,and full pipeline&valve system connection.

　　Electrical&Control Setup

　　PLC automatic control system configuration,backwash and regeneration program setting,and pressure/flow monitoring system calibration.

　　Testing&Commissioning

　　Full system pressure test,RO permeate water quality verification,and 72-hour continuous stable operation test before final acceptance.

　　Project Performance Results

　　After commissioning,the system has run stably with excellent performance indicators:

　　Steady 20 TPH RO permeate output,matching peak production demand

　　Effluent hardness≤0.03 mmol/L,achieving complete scaling prevention for heat exchange equipment

　　RO permeate conductivity≤10μS/cm,consistently meeting food-grade production water standards

　　Fully automatic PLC operation with real-time monitoring,reducing on-site manual labor input

　　40%reduction in equipment maintenance frequency and downtime

　　Stable water quality directly improves finished product consistency and production efficiency

　　Applicable Industries&Scenarios

　　This high-hardness water treatment solution is widely suitable for:

　　Instant/ready-to-eat food production facilities

　　Corn deep processing and grain manufacturing plants

　　Food&beverage production lines

　　Agricultural product washing and processing systems

　　High-hardness groundwater/surface water purification for industrial use

　　Technical Highlights

　　Targeted design for high-hardness surface water,solving industrial scaling problems at the source

　　40 TPH automatic water softener with self-regenerating resin for uninterrupted water supply

　　20 TPH industrial RO system with multi-stage pretreatment for reliable food-grade water production

　　PLC fully automatic control system with real-time pressure and flow monitoring

　　Modular skid-mounted design for fast installation and easy daily maintenance

　　Full turnkey service from design to after-sales support

　　Conclusion

　　This project is a proven industrial water treatment solution combining water softening and reverse osmosis technology for the food processing industry.

　　By integrating a 40 TPH softener system with a 20 TPH RO system,we helped the client achieve stable,safe,high-quality process water for instant corn production.The system ensures long-term operational stability,reduces scaling risks,and supports consistent food product quality.

　　Get Your Custom Water Treatment Solution

　　Facing high-hardness water challenges or needing food-grade process water for your production line?Shandong Yufeng Water Treatment provides tailored turnkey industrial water treatment systems for global clients.

　　Contact our engineering team today to request a free project quotation and full specification sheet.

　　About Shandong Yufeng Water Treatment

　　Shandong Yufeng Water Treatment Equipment Co.,Ltd.is a professional manufacturer of industrial water purification systems.Our core capabilities include:

　　Industrial reverse osmosis systems(1–100 TPH)

　　Automatic water softening systems

　　UF and EDI ultrapure water systems

　　Customized solutions for food&beverage industry

　　OEM/ODM services for water treatment projects

　　We deliver one-stop turnkey water treatment solutions for industrial clients worldwide.‍