Eliminating Salt-Type Water Softeners In Car Wash Applications

Salt-based water softeners in a car wash can consume salt at the rate of 500 lbs/Month and as much as 500 lbs/Day in an active truck wash. With the electronic technology of Soo-Soft® water treatment, it is now possible to replace antiquated salt systems in most auto, truck and other vehicle washing operations. This greatly reduces the maintenance, operational costs, and environmental impact issues for a washing operation. In order to replace an existing salt system and install a Soo-Soft® system into a wash facility, it is necessary to understand the differences between the two technologies and how they affect the minerals in the water and the minerals that are deposited on the components of the wash system.

Ion Exchange

Salt-based ion exchange systems operate by removing a portion of calcium from the water. Water passes through a tank filled with zeolite beads. These beads collect calcium on their surfaces as water passes through the tank. When the beads become loaded, they are cleansed of calcium deposits. This is accomplished by washing them in a salt brine solution, a process referred to as regeneration.

These beads can also be contaminated by other elements in the water such as ferric iron, which is a bacterium. The ferric iron creates a bio-slime preventing the calcium from sticking to the resin beads. In time, the resin beads must be replaced in order to maintain their effectiveness.

A salt-based system can remove up to 75% of calcium from the water when new. As the beads age and become contaminated, their ability to remove calcium from water is reduced. This is a natural effect of time and contamination for ion exchange systems. The end result is that as little as 25% of the calcium is removed from the water. The remainder is released into the plumbing system to form scale on pipes and wash equipment.

Physical Softening

The Soo-Soft system varies a complex group of electrical signals millions of times a second that alters the physical chemistry of water. A cascading chain reaction reduces the long chains of hard calcium into a fine calcium aragonite powder. With a particle size of only 2-4 microns, the soft calcium groups itself into soft snowflake-like shapes. Spaces appear between these groups and allow the water to become an improved carrier for the formation of suds. This calcium powder is so fine that it becomes six times more dissolvable into the water itself. The extremely small size of the calcium particle creates another advantage. Heat, pressure changes, and evaporation will not cause the particle to revert, and form hard lime scale. The temperature required for re-conversion to a hard crystal state is 700 degrees. Since the Soo-Soft® system is always processing the water, new lime scale formation is always being prevented from forming.

The surface tension of the water is also reduced by this conversion to a soft form. This increases the solubility of the water making it an even better solvent. In addition, the electrical charge of the water and minerals suspended in it are altered so calcium will not adhere to surfaces.

The end result of all these physical water modifications is that all pipes, filters, pumps, wash equipment, etc. will discharge their existing calcium deposits after 90 days of soaking in the treated water.

A “Soup” Analogy

Imagine for a moment that you have a bowl of soup loaded with large croutons that are old, dry, and hard. If you try to get them to dissolve into the liquid soup it is very difficult. Stirring the soup does little good, as does removing a portion of them. It makes it easier to get at the liquid, but great portions of the hard croutons are still there.

If you however crush the hard croutons into the soup, they become powder. The soup dissolves the breadcrumbs quickly and now has an even consistency as the breadcrumbs are dissolved into it. The soup is now more liquid, smooth, and has a uniform consistency.

What the Soo-Soft system does for water is very similar. The large hardened forms of calcium are electronically broken down into a fine powder. This powder is so fine that the calcium particles dissolve into the water, making the water “Wetter and a better solvent, which makes more suds from less detergent. The wetness of the water (reduced surface tension) is what makes it possible for the Soo-Soft® System to dissolve the existing calcium deposits in the plumbing system and keep them from returning.  It has the added benefit of improving the solvency of wash and rinse water.

Installation

Salt systems have been eliminated in wash facilities with water hardness in excess of 28 grains per gallon. Salt systems using 500 lbs. per day have been eliminated.  In applications where ferrous iron exists in water supplied from a well, (i.e. “rust”) the salt-system cannot be eliminated unless the well is chlorinated.  This is because the iron is actually a bacterium and the caustic salt kills the bacteria. In municipal water this is never a problem as the water is chlorinated by the municipality.

New Wash Facility

In a new installation, where plumbing and wash equipment have not yet built up scale deposits, no de-scaling will occur. The Soo-Soft system can simply be installed in lieu of a salt-type water softener.

Existing Wash Facility

Existing wash facilities, even those which have had a salt-type softener installed will have mineral scale built up on the interior of plumbing pipes, water heaters, wash and rain arch plumbing, hoses, etc. The increased solvency of the treated water created by the Soo-Soft system will dissolve mineral deposits. In a facility that uses an R.O. system for a spot-free rinse, the rinse will remove deposits that are coming out of the system. However, parts of the system that are not soaking continuously in the treated water will take longer for these deposits to be removed. In these cases, it is often best to perform a chemical de-scale of these components or the entire system. Contact our technical line for further information.

RO Filters

RO filters will last longer, use less water and require less frequent membrane replacements. Calcium fouling of membrane filters is eliminated with water that dissolves calcium deposits. The small particle size passes through all but the finest of filters.

Detergent Usage

Water softened with the Soo-Soft System is a better absorbent of detergents. More space is created between particles so more suds can form. Additionally, the PH of the water is stabilized. The water becomes a better solvent, improving soak, wash and rinse cycles. Detergent amounts can be reduced, as the water is now a better washing agent. A better wash can be created with less effort and additives. The increased wetness of the water is also evident with tire cleaning and bleaching solutions. Whitewalls become whiter and brighter, creating greater customer satisfaction.

Reduced Chemicals

Water treated with the Soo-Soft system also influences the chemicals used for detailing and window cleaners. The increased solvency of the water makes cleaners more effective and rinsing easier. This helps to reduce labor requirements and costs.

Nozzle Life

High-pressure spray nozzles clog with calcium as well as prematurely wearing out from hard calcium that pushes through nozzles and wears them out. This causes thousands of gallons in wasted water. This is eliminated with water that has small particles. Water, energy, and nozzle replacement are saved.

Water Savings

Increased effectiveness of water for both washing and rinsing means less water is required. Water processed by the Soo-Soft system reduces membrane clogging in R.O. filters. Since these units use as much as 80% of their water consumption to keep membranes clear, water is conserved. Where water is recycled, cyclone and other filters last longer.

Towels & Wash Brushes

Calcium builds up in towels when washed in hard water. Hard calcium is abrasive and breaks down the fibers in the towels and scratches the car’s finish. The more they are washed in hard water, the faster they fall apart. Water treated by the Soo-Soft® system dissolves the existing calcium in the towels and makes them last longer. Softer, calcium-free towels are more absorbent, less likely to scratch the finish, and when combined with a cleaner rise will aid in reducing labor costs. Laundry detergents also become more effective so that less detergent is required for washing.
Hard calcium crystals also wear out wash brushes faster. The abrasive calcium crystals cut into the soft brush materials. The Soo-Soft® system softens this calcium and greatly extends the life of brushes.

Energy

Calcium is an excellent insulator, preventing equipment from heating efficiently. Hard calcium deposits cost countless dollars in annual energy costs.  Studies of water heaters indicate that ¼ inch of scale can increase fuel consumption by as much as 40%. In areas of very hard water it is not unusual for a water heater to accumulate one inch of calcium. This results in double the costs of operation. In addition, the calcium deposits cause the premature failure of the water heater itself. The Soo-Soft® system dissolves calcium deposits in the system, on heating elements, and water flows through the system easier requiring less energy consumption for both heating and pumping.

Maintenance

Calcium is an abrasive, which collects inside of high-pressure pumps, causing premature failure of delicate ceramic pistons. Electric solenoid valves also collect calcium deposits, causing them to seize. With an electrical heating element, calcium builds up on the outside of the element and traps heat. The element is then forced to work at much higher temperatures than its design parameters. It then fails long before its time. In some areas, heating elements build an inch of scale in just a few months.

Temperature sensors with calcium deposits add to the problem. The sensor becomes thermally insulated from the water, masking the actual water temperature. This causes the control system to demand more heat from the element. In addition many sensors have their own heating element built in. Calcium deposits cause elements to burn out prematurely. Calcium deposits are a major factor in corrosion. The corrosive contaminates become trapped by the hard scale causing them to dissolve pipes, tanks, valves and water heaters. Corrosion reduces the life expectancy of all components that use water.

Water filters of all types collect calcium deposits on their surface. This drives replacement long before the filters are fully utilized. The Soo-Soft® system reduces particles of calcium to 2-4 microns in size, which simply pass through, extending filter life. This becomes especially important in water reclamation systems.

Environmental Regulations

As populations increase, the issue of water conservation and the cost of water treatment loom larger on the horizon. Municipalities are becoming more aggressive in regulating water usage. Car washes become easy targets for over-regulation.

The use of salt-based softeners to soften water is fast becoming taboo in many parts of the country. These systems require regular flushing with salt and dump salt brine into sewage systems. The salt brine discharged from these units is dumped into rivers, lakes and streams. This brine cannot be treated or removed by municipal waste facilities without great cost.

Effectiveness

A 2-inch Soo-Soft® system can continually soften 150 gallons per minute through a 2-inch copper pipe. A 1-inch unit will soften 30 gallons per minute through a 1-inch pipe. Installation requires no plumbing or electrical modifications and can be completed in ½ hour or less. It saves money immediately and pays for itself instantly.

We are proud of our American manufactured products. For this reason they come with a complete 6-month money back guarantee and a full 5-year parts and labor warranty.

For further technical information call (800) 234-1810.

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