Limescale control slashes maintenance costs

Published:  24 July, 2005

The cost of installing equipment to control limescale in spray nozzles was recovered in just three months at Imperial Tobacco in Nottingham.

Maintenance costs and downtime of a rehydrating unit at the Nottingham plant of Imperial Tobacco have been reduced following the installation of a Kal-Guard+ scale inhibitor from Watermatic. A payback of less than four months was achieved.

Before installing the 35 mm Kal-Guard+ unit on the water supply, the company needed to spend around three hours a week to remove scale from the spray nozzles manually, at a cost of around £30 an hour. Plant downtime added to the costs.

The gradual scaling up of the nozzles changed the spray pattern, so regular descaling was necessary to maintain quality control.

Alan Whitelock of Imperial Tobacco explains, ‘Since installing the unit, there is now only an occasional slight residue of soft limescale that is easily wiped away during the routine cleaning of the machine.’

This scale inhibitor is based on a zinc anode electrolytic design with electronic controls to match zinc levels to the hardness of the water. Tests at Cranfield University have shown that Kal-Guard+ reduces limescale on heating surfaces by up to 80%.

A status monitor confirms that the electrolytic cell is working, so that maintenance staff can check operation.

comments powered by Disqus



Welcome to Modern Building Services Online, the web edition of Modern Building Services (MBS) journal and the UK's most popular Building Services engineering site. Modern Building Services covers the entire Building Services Engineering industry. This site contains archived content from the journal, plus web-specific content.

When you go to our digital edition, you can also access the archive of digital editions.

Modern Building services has a group
on Linkedin - join us!

Construction Week



  • Field Sales Executive

    Successful professional technical salesperson required to sell to consultants and contractors. Unique opportunity to sell ultra-low energy, patented technology, ventilation products from a UK manufacturer. ...

  • Property Surveyor

    Property Surveyor/ Building Service Surveyor needed to work within the Technical Services team for the management of water hygiene/ legionella risk within DCC's property portfolio. We are looking for an experienced and dynamic team member to join our T......

more jobs »


"Is the Building Services industry lagging behind in the implementation of BIM?"