For dairy processors discharging utility water to the environment, system stability isn’t optional – it’s the difference between compliant operation and recurring fines. One dairy processor in the northwestern United States experienced this firsthand while operating a reverse osmosis (RO) system to treat seal water from pumps prior to discharge. With conventional RO membranes in place, maintaining stable performance became increasingly difficult, and operational challenges mounted over time.
When Conventional RO Membranes Create Instability
Before switching membranes, the plant struggled to keep its system under control. Discharge quality issues led to recurring fines, while biofilm formation became a persistent operational headache. Membrane life was short, cleaning demands were high, and overall system stability was poor.
To keep the system running, operators relied on a daily cleaning program that included enzyme washes in an attempt to restore membrane performance. Despite these efforts, biofilm formation continued to create downstream complications. The permeate collection tank and pH probe required frequent manual cleaning – time-consuming work that pulled operators away from other responsibilities.
Fouling also introduced ammonia-related issues, directly affecting the plant’s ability to meet legal discharge limits. As a result, the operation fell into a constant cycle of cleaning, biofilm removal, and troubleshooting. Manpower demands increased, chemical usage rose, and the system remained unstable. Over time, these challenges reinforced the limitations of conventional RO membranes in this application.
A Shift to ZwitterCo Evolution RO
In 2025, the dairy processor replaced its existing elements with ZwitterCo Evolution RO membranes. Following installation, the system’s performance changed immediately – and dramatically.
Since the transition, the RO system has operated flawlessly. Polished water has consistently met specifications for direct discharge to the river, eliminating previous compliance concerns. Just as importantly, the permeate collection system has not required a single manual wash since the new membranes were installed.
Cleaning frequency dropped sharply as well. Over a five-month operating period, only two enzyme washes were required. In both cases, full membrane performance was restored, demonstrating reliable and repeatable performance recovery through cleaning. The ongoing instability that defined operation with conventional RO membranes was no longer present.
Measurable Operational Benefits
The switch to Evolution RO delivered clear and immediate benefits for the dairy processor:
- Greatly reduced fines since installing ZwitterCo elements
- Reduced chemical use and cost through the elimination of daily enzyme washes
- Reduced flush water by removing a daily cleaning step
- Operator time saved because the permeate collection system no longer requires regular cleanings
- More stable system operation and significantly longer membrane life expected
A Simpler, More Stable Approach to Seal Water Treatment
This installation highlights how Evolution RO can simplify utility water treatment at dairy plants. By reducing cleaning frequency, minimizing operator intervention, and delivering consistent discharge-quality water, the system now operates with fewer steps and fewer demands on plant personnel.
Most importantly, Evolution RO provided the level of system stability that wasn’t achievable with conventional RO membranes – turning a problem application into a reliable part of daily plant operations.