Water Softener Systems

A water softener tank is essential in palm oil mill operations to remove hardness minerals such as calcium and magnesium from raw water. Hard water can cause scaling, reduce boiler efficiency, and shorten equipment lifespan.

Our water softener system ensures a continuous supply of soft water for boiler feed, steam generation, and cleaning processes. It helps prevent scale buildup, improve heat transfer, and reduce maintenance costs.

Each system is designed with durable ion-exchange resin, an automatic control valve, and an efficient regeneration process to deliver consistent water quality and reliable performance in demanding mill environments.

Understanding the Water Softening Cycle

Water softener works by removing hardness minerals — mainly calcium (Ca²⁺) and magnesium (Mg²⁺) — from your water supply through a process called ion exchange. During normal service mode, hard water enters the softener and passes through a bed of resin beads charged with sodium ions (Na⁺). As the water flows through, the resin captures the hardness ions and releases sodium in return, producing soft water that exits to your process line.

Over time, the resin becomes saturated with hardness minerals and needs to be cleaned. In the backwash mode, water flows upward through the resin bed to loosen and remove trapped sediments and impurities, which are flushed away to the drain. After that, the system enters regeneration mode, where a brine solution (a mixture of salt and water) is drawn from the brine tank and flows through the resin. The high concentration of sodium ions in the brine displaces the accumulated calcium and magnesium, restoring the resin’s softening capacity. Finally, the waste brine and hardness ions are rinsed out to the drain, and the softener is ready for the next service cycle.

Over 60+ units installed in Malaysia

Flexible Material Options

We can construct filters from mild steel, stainless steel, or FRP-laminated steel for added corrosion protection. This flexibility ensures long service life even under harsh, high-humidity palm oil mill environments.

Optimized Sand Bed Design

Our engineers can tailor the sand media grading and depth to achieve the right balance between filtration efficiency and backwash frequency — keeping your water clean without excessive downtime or water loss.

Automation Ready (PLC Integration)

We can equip your system with PLC-controlled backwash functions, allowing automatic cleaning cycles and minimizing operator error. This ensures consistent performance and reliable operation, even during shift changes.

Finishing Options for Durability

Choose from sandblasted surfaces, epoxy coatings, or industrial paint finishes, depending on your site condition and maintenance preference. Every unit is prepared for long-term operation under continuous mill use.

Customizing your water softener with CAD

We design and fabricate water softeners specifically for palm oil mill boiler operations, ranging from compact units of Ø800 mm diameter to large industrial vessels exceeding Ø2,500 mm in diameter. Whether you require a softener for a small process line or a complete boiler feed system, our in-house engineering team delivers solutions that ensure consistent water quality and extend boiler lifespan.

Using CAD-based design and 3D modeling, we ensure every unit is engineered to fit seamlessly into your site layout and piping configuration. This design approach allows us to optimize space utilization, flow direction, and maintenance accessibility for reliable long-term performance.

With a selection of ready-stock sizes — including Ø900 × 1524 mm, Ø1200 × 1820 mm, Ø1500 × 2000 mm, Ø1676 × 2438 mm, and Ø2500 × 1500 mm — as well as the capability to custom-build for larger capacities, we can tailor each system to meet your exact flowrate, hardness reduction, and installation requirements.

Complete System Integration and On-Site Expertise

Beyond manufacturing the softener vessel itself, our team provides full system integration — including brine tank setup, piping connections, and control system configuration. We ensure every component, from resin vessel to brine injector, operates in perfect balance to deliver consistent soft water quality.

Our scope covers installation, commissioning, and on-site calibration, giving you a turnkey system that’s ready for operation. The photos shown here are from actual installations carried out by our team, demonstrating our capability to handle industrial-scale systems with precision and attention to detail.