Water Softener Plant – 500 LPH

Water Softener Plant – 500 LPH 

Product Overview

This 500 LPH Water Softener Plant is a compact, industrial-grade system designed to remove hardness-causing minerals such as Calcium (Ca²⁺) and Magnesium (Mg²⁺) from borewell, tube-well, and municipal water sources.
It is primarily intended for household or light commercial use to:

• Protect plumbing, boilers, geysers, washing machines, and other water-using appliances from scale formation 🏠🔧

• Improve soap and detergent efficiency in laundry and cleaning 🧼

• Ensure smooth operation of household water systems and reduce maintenance

Built around a 10×35 (1035) FRP pressure vessel, the system delivers a consistent flow of softened water suitable for appliance and piping protection, not for direct drinking or cooking. For potable water, an additional RO / UV / filtration system is recommended.

Key Technical Specifications (Standard Package)

• Rated Capacity: 500 Liters Per Hour (service flow at design hardness).

• FRP Vessel: 10×35 (1035) — sized for optimum resin bed depth for 500 LPH duty.

• Core Process: Ion-exchange softening (cation exchange resin).

• Resin Type: Strong-acid cation exchange resin (sodium form) for Ca²⁺ / Mg²⁺ removal.

• Control Valve: Manual or programmable automatic metered multiport valve (customer choice).

• Brine Tank: Sized for periodic regeneration (salt-based) — brine dosing arrangement included.

• Polishing: Optional 5–10 micron cartridge after softener for sediments.

• Piping & Fittings: Food-grade UPVC / CPVC or MS as per site.

• Power: Pump & control panel (if using automatic valves/booster pump) — site dependent.

How It Works (Simple, Accurate Explanation)

Service Cycle (Softening):

Hard water flows through the resin bed inside the 1035 FRP tank. Calcium (Ca²⁺) and magnesium (Mg²⁺) ions in the feed water are exchanged for sodium (Na⁺) ions attached to the resin beads — producing softened water downstream.

Exhaustion & Regeneration:

Over time, resin exchanges saturate with Ca/Mg and must be regenerated. Regeneration uses a concentrated salt (NaCl) brine to replace captured Ca/Mg with Na⁺ on the resin, restoring capacity. The exhausted brine is flushed out during the rinse steps.

Where & Who Uses It (Applications & Typical Users)

• Residential: Large single houses, multi-family homes, compound residences where hard water causes scale.

• Small Commercial / Service: Guest houses, small hotels, salons, laundries, and commercial kitchens that need scale-free water for equipment longevity.

• Pre-treatment: Before boilers, heat exchangers, and RO membranes (to prevent scaling and extend membrane life).

• Industrial Light Use: Small process lines, cooling feeds, and any application sensitive to hardness.

Using a water softener reduces maintenance, improves detergent performance in laundries, and prevents scale build-up in hot-water appliances.

Primary Benefits (What the Customer Gets)

• Scale Prevention: Stops calcium/magnesium scale on pipes, heaters, geysers, boilers, and fixtures — prolongs equipment life.

• Improved Efficiency: Appliances (heaters, boilers, and boilers’ fuel efficiency) perform better and use less energy over time.

• Lower Maintenance & Costs: Less cleaning, fewer chemical descalers, fewer service calls.

• Better Cleaning Results: Soaps and detergents lather more effectively — laundry and dishwashing quality improves.

• Protects Downstream Treatment: Softening protects RO membranes and other sensitive equipment from fouling.

Operation & Maintenance (Realistic Expectations)

• Regeneration Frequency: Depends on inlet hardness (ppm), household water usage, and resin volume — typical small installations regenerate every few days to weekly. We size the brine tank and program regeneration based on your hardness report.

• Salt Consumption: Regular top-up of common salt (NaCl) is required. Salt usage depends on resin capacity and regeneration schedule.

• Backwash & Rinse: Periodic backwash and rinse are required to remove trapped solids and the displaced brine. Automatic valves can schedule these; manual valves need operator action.

• Service: Resin life typically 8–15 years (site-dependent). Periodic resin health checks, valve servicing, and salt quality checks recommended.

Design / Selection Notes (to avoid customer confusion)

• Water Test Required: Final system sizing (resin volume, brine tank size, regeneration interval) must be based on an inlet water analysis (hardness as CaCO₃ mg/L, TDS, iron presence, chlorine, etc.). We strongly recommend a lab test before final quotation; otherwise quoted performance is indicative.

• Iron / Manganese: If raw water contains iron or manganese above trace levels, pre-treatment (oxidation / sediment filtration / iron removal) is needed before the softener to prevent resin fouling.

• Sodium in Product Water: Ion-exchange softeners add small amounts of sodium (from NaCl). For low-sodium requirements, potassium chloride can be used for regeneration, or consider alternative technologies.

Typical Bill of Materials (Standard 500 LPH Unit)

• FRP Pressure Vessel (10×35 / 1035) with distributor/underdrain

• Cation exchange resin (pre-loaded to design level)

• Brine tank with float and salt grid

• Multiport control valve (manual or automatic)

• Raw water pump (as required by the site head)

• Piping, fittings, valves, and base frame

• Instruction manual, commissioning & basic operator training

Performance Guarantee & Recommendation

We guarantee the system will reduce hardness to the target level agreed at the time of quotation, provided raw water characteristics match the lab report used for design and the customer follows recommended regeneration & maintenance.

For transparency and to prevent any customer confusion:

1. Request a recent water test (hardness, iron, TDS).

2. Supply a site-specific regeneration schedule and salt consumption estimate.

3. Provide commissioning and brief user training.