Cleancooling waterwithout chemicals
Case: Gerresheimerx H2O Shift
Clean cooling water at
Gerresheimer – completely
without chemicals
After a severe misdosing, Gerresheimer chose to abandon chemicals. With H2O Shift, the cooling water became completely clear in less than a week.
Background
Closed cooling system with constant chemical demand
Gerresheimer produces packaging for the pharmaceutical and healthcare industry and operates a factory in Værløse with a closed cooling water system. The water circulates from 12°C to up to 140°C in production and back again.
To keep the system clean, it required continuous chemical treatment against biofilm and algae growth. Eight years ago, something went wrong: 20 liters of concentrated chemicals were incorrectly dosed directly into the circuit.
After 27 years at Gerresheimer, operations manager Ali Ismaili decided to find a solution that removed chemicals from the equation – and sought out H2O Shift.
UNDERSTAND THE TECHNOLOGY
Testimonial from Ali Ismaili, Operations Manager at Gerresheimer
"To this day, I still don't fully understand how it works, but the results speak for themselves. All my colleagues are impressed by the effect, and we are now looking to expand the technology to other areas of our production."
– Ali Ismaili, Operations Manager, Gerresheimer
The problem, the solution and the impact
27 years of chemicals replaced in one day
Gerresheimer's cooling water system was dependent on continuous chemical treatment against biofilm and algae growth. The risk associated with handling and dosing was real – and had already manifested in practice.
To solve the problem, a Power2H2O unit was installed directly in the cooling water tank. The unit keeps the water quality stable and clean without the addition of chemicals. The existing chemical treatment was disconnected already during installation.
After three days, the water was significantly cleaner, and after a week, it was so clear that the bottom of the tank was visible. Gerresheimer has since operated chemical-free – without operational disruptions.
SOLUTIONS FOR WATER TREATMENT
The results
Power2H2O vs. chemical treatment
Two cooling systems – W4 and W8 – both ran with a Power2H2O unit installed. During a renovation in 2021, the unit on W8 was mistakenly removed, and the system has since been running with chemical treatment. This provides a direct basis for comparison of the two methods in practice – measured by pH, zinc, conductivity, biofilm, and iron.
| Parameter | W8 With chemicals | W4 With H2O Shift |
|---|---|---|
| pH-niveau | Mere stabilt og neutralt/let alkalisk (6,9–8,0) | Let surt (5,99–6,94) – påvirket af et gammelt, funktionsløst rør |
| Zinkindhold | Lavere, men holdt nede af løbende kemisk behandling | Forhøjet pga. det gamle galvaniserede rør, der afmonteres |
| Jernindhold | Stiger over tid – tydeligt tegn på begyndende korrosion | Relativt lavt – få tegn på aktiv korrosion |
| Ledningsevne | Store udsving med høje toppe | Stabil med lave udsving |
| Mikrobiologisk vækst | Øget vækst i 2024 trods biocidbehandling | Generelt lavere vækst – enkelte toppe i 2024 |
| Visuel vandkvalitet | Grønlig farvetone – tegn på organismer og mikrobiologisk vækst trods biocider | Klart og gennemsigtigt – god, stabil vandkvalitet |
Corrosion
W8 shows clear signs of active corrosion: Iron content is increasing, and biological growth is escalating despite chemical treatment. In W4, the elevated zinc levels and lower pH originate from an old, defunct pipe that is rusting. That pipe will be removed.
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