In-line, real-time, automated bacterial, micro-particles detection in water and other liquids by VBact

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Case Study: Detecting Carbon Filter Failure in Beverage Production with the Water Scanner

Background

A leading beverage producer implemented the VBact Water Scanner system to ensure the highest quality of water in their production process. The system was strategically installed near the source of the water, after the carbon filtration unit, to continuously monitor for both bacterial and particle content in real time.

Under normal operation, the VBact system reported stable readings with only minor variations, confirming steady water quality.

The Customer’s Challenge

One day, the beverage producer observed a sudden, sharp increase in the number of particles in the water supply, while the bacterial count remained stable. This unusual pattern suggested that the issue was not related to biological contamination, but rather a physical contamination event.

Traditional laboratory testing methods, which are primarily designed to analyze microbiological or chemical parameters, would likely have missed this specific type of problem.

Root Cause: Carbon Powder in the Water

Upon investigation, the particles were identified as carbon powder, pointing directly to the carbon filtration system as the source of contamination. Further inspection revealed a hole in the filter housing combined with frequent operational pressure spikes, which caused the carbon media to break down and escape into the water stream. This malfunction was the direct cause of the sudden particle spike detected by the VBact system.

The Role of the Water Scanner

The VBact Water Scanner played a critical role in early detection:

Continuous, real-time monitoring revealed the sudden surge in particle count.
The stable bacterial readings helped differentiate the issue as mechanical rather than biological.
The early warning prevented potential downstream consequences, such as:
- Reduced efficiency of the carbon filter.
- Changes in water taste and odor.
- Visible black carbon particles appearing in the finished beverage product.
- Potential equipment damage in the production line.

Without the VBact system, the issue could have gone unnoticed until significant quality or operational problems arose.

Outcome & Customer Benefit

Thanks to the VBact system, the beverage producer was able to:

Rapidly identify and isolate the source of the problem (damaged filter housing).
Prevent contamination of the final product before it reached consumers.
Maintain consistent product quality and safeguard brand reputation.
Avoid costly downtime or recalls that might have occurred without early detection

Conclusion

This case demonstrates how the VBact Water Scanner goes beyond traditional microbiological and chemical testing. By providing continuous monitoring of both bacteria and particles, it enables beverage producers to quickly detect, diagnose, and resolve issues that could otherwise threaten product quality, safety, and operational efficiency.