Efficient hardness removal to protect boilers, cooling systems and process equipment
The Ozmist Food Calcium Reduction System uses ion-exchange resin technology to swap calcium and magnesium hardness ions in feed water for sodium ions, delivering softened water suitable for boiler feed, cooling tower makeup, RO pre-treatment, and food/pharma process water. Twin-alternating configuration provides 24×7 softened water availability during regeneration cycles. Automatic control valve with time or volume-based regeneration triggers, brine tank management, and remote monitoring. FRP or stainless steel resin vessels sized 100–3000 L depending on flow and hardness. Optional service-flow-controlled regeneration mode saves salt and water by regenerating only when actual water throughput reaches setpoint. Manufactured at Ozmist’s Greater Noida facility with BIS-compliant vessel construction and food-grade resins for pharma / food-processing variants.
| Parameter | Value |
|---|---|
| Service flow | 500 L/h to 30 m³/h across models |
| Resin volume | 100 to 3000 L per vessel |
| Configuration | Single (simple) / Twin-alternating (24×7) |
| Vessel material | FRP (standard) / AISI 304 (industrial) / 316L (food/pharma) |
| Resin type | Food-grade Na-cation exchange resin |
| Outlet hardness | < 5 ppm as CaCO3 |
| Inlet hardness range | Up to 800 ppm (higher with acid pre-treatment) |
| Regeneration | Automatic; time or volume triggered |
| Salt consumption | 100–150 g NaCl per litre resin per regeneration |
| Working pressure | Up to 6 bar (10 bar industrial variant) |
| Working temperature | 5°C – 40°C (60°C high-temp variant) |
| Optional monitoring | Inline hardness monitor + remote SCADA reporting |
| Warranty | 24 months full unit; resin consumable |
The Calcium Reduction System is deployed across a diverse set of Indian industrial and commercial contexts. What follows is a set of expert application briefs prepared by our engineering team, each describing the operating problem, the applicable Indian and international standards, and how Ozmist's configuration is engineered to meet it.
Every application description references peer-reviewed research or a named regulatory standard so procurement teams, quality engineers, and plant managers can validate the claims against their own audit expectations. Sources are cited in the References section at the end of this page. If your application does not match one of the profiles below, contact our engineering team via the quote form — the majority of custom Ozmist installations begin with a spec conversation rather than a datasheet pick.
Steam and process heat · IBR; ASME PTC 4
Hardness in boiler feed water causes scale on tubes, reducing heat transfer and eventually causing tube failure. IBR (Indian Boiler Regulations) and ASME code recommend feed hardness below 2 ppm. Ion exchange softening is the industry-standard technology, deployed at every industrial steam generation site. Ozmist supplies softeners sized to boiler feed rate, with hot-water resin variants where feed is above 40°C.
HVAC / cooling · ASHRAE guidelines
Cooling tower makeup water concentrates hardness as it evaporates. Uncontrolled hardness leads to scale on condenser tubes, reducing HVAC efficiency and requiring aggressive acid cleaning. Softening the makeup water controls cycles of concentration and reduces overall chemical dosing. Ozmist supplies HVAC contractors, IT campuses, and industrial refrigeration operators with cooling-tower softeners.
Water treatment
RO membranes foul rapidly if fed hard water without pre-treatment. While antiscalant dosing is standard, high-hardness feed (> 300 ppm) usually requires upstream softening. Softening extends RO membrane life by 3–5× versus antiscalant-only pre-treatment at high hardness, and reduces overall chemical cost. Ozmist supplies water treatment plants and industrial RO operators with feed-softening skids.
Food and beverage · FSSAI; food industry water quality specs
Beverage bottling, dairy processing, and beer brewing use large volumes of hardness-adjusted water. Certain products (beer wort, dairy CIP) require specific hardness levels — too soft causes rinse-off issues; too hard causes scale on process equipment. Ozmist supplies food/beverage plants with food-grade resin variants and pharmaceutical-quality regeneration salt handling.
Textile / laundry
Textile bleaching, dyeing, and finishing use large volumes of soft water. Hardness ions interfere with dyes, cause spots on finished fabric, and precipitate soap in industrial washing. Textile dye houses, commercial laundries, and hotel-linen operations use large softeners on incoming water supply. Ozmist supplies textile clusters in Panipat, Meerut, Ludhiana with softener skids sized 5–30 m³/hour.
Research-backed data supporting product selection, sizing, and ROI planning. Every chart includes a "View data table" button for accessible screen-reader access to the underlying numbers, and a source citation.
| Classification | CaCO3 range (ppm) | Typical action |
|---|---|---|
| Soft | 0–60 | Generally no treatment |
| Moderate | 60–120 | Consider softening for boilers, high-purity uses |
| Hard | 120–180 | Softening recommended for most industrial |
| Very hard | > 180 | Softening required; often multi-stage treatment |
| Peak flow | Feed hardness | Resin volume | Regen frequency |
|---|---|---|---|
| 1 m³/h | 200 ppm | 100 L | ~ every 8 hours |
| 5 m³/h | 200 ppm | 500 L | ~ every 8 hours |
| 5 m³/h | 400 ppm | 1000 L | ~ every 8 hours |
| 15 m³/h | 250 ppm | 2000 L | ~ every 8 hours |
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