Integrating an ozone generator into any water-using machine: a flexible solution for industrial processes

Can an ozone generator be integrated into an existing installation?

This is one of the most common questions in industry.

Many companies still believe that ozonation requires a completely dedicated installation or a specific treatment line. In reality, it is often possible to integrate an ozone generator into almost any type of machine or process using water.

At OXYTRADING, we regularly develop solutions allowing ozone systems to be “plugged into” existing installations in order to improve:

• microbiological water quality,
• overall water quality,
• odour reduction,
• biofilm control,
• reduction of chemical consumption,
• water recycling and reuse.

Why ozone can easily be integrated into water-based processes

Ozone is a powerful oxidant that can be injected directly into:

• water loops,
• tanks,
• pipelines,
• recirculated circuits,
• reservoirs,
• washing systems,
• industrial process water networks.

The objective is not necessarily to replace an existing machine, but rather to enhance its performance through the integration of a properly designed ozone system. In most cases, integration can be achieved:

• without completely modifying the installation,
• without replacing the main equipment,
• with limited impact on the existing process.

What types of machines can integrate an ozone system?

In practice, almost any machine using water can potentially integrate an ozone solution.

Common examples:

Food washing machines

• fruits,
• vegetables,
• potatoes,
• salads,
• processed food products.

Crate and bin washing systems

Ozone may help:

• reduce cross-contamination,
• improve washing water quality,
• reduce certain chemical consumptions.

Industrial washing tunnels

• food industry,
• pharmaceutical industry,
• logistics industry,
• reusable packaging systems.

CIP / NEP systems

Ozone can be integrated into certain cleaning-in-place optimisation strategies.

Cooling towers

Potential applications include:

• biological control,
• biofilm reduction,
• improvement of water circuit quality.

Water recycling systems

• process water reuse,
• clarification,
• odour reduction,
• oxidation of certain organic compounds.

Irrigation and hydroponics

• water quality improvement,
• organic load reduction,
• management of recirculated networks.

Aquaculture and RAS systems

• water quality improvement,
• contaminant management,
• optimisation of recirculated water systems.

How is an ozone generator integrated?

Integration depends on:

• flow rate,
• water quality,
• volume,
• contact time,
• temperature,
• material compatibility,
• process objectives.

Several configurations are possible:

Venturi injection

One of the most common solutions for dissolving ozone into waterPressurised side-stream loop allows significantly higher mass transfer efficiency and ozone dissolution.

Contact tank

Used when increased contact time is required.

Injection into recirculated circuits

Widely used on:

• washing systems,
• tanks,
• cooling towers,
• continuous industrial processes.

The generator alone is not enough

The efficiency of an ozone solution mainly depends on:

• integration quality,
• mass transfer efficiency,
• contact time,
• process control,
• safety,
• adaptation to the real industrial process.

Two installations equipped with the same ozone generator can achieve completely different results depending on:

• hydraulics,
• injection system,
• flow rates,
• control strategy,
• overall system design.

This is why a technical feasibility study remains essential.

A technology that can be integrated without replacing existing equipment

One of the major advantages of ozonation is its ability to be progressively integrated into installations already in operation.

This approach allows companies to:

• modernise existing processes,
• avoid replacing complete production lines,
• reduce heavy capital investments,
• improve performance without rebuilding the entire installation.

In many cases, an external ozone skid can simply be connected to:

• an existing water loop,
• a tank,
• a pump,
• a washing circuit,
• a recirculated network.

A process-oriented industrial approach

At OXYTRADING, our approach is not limited to supplying an ozone generator. We support industrial companies in:

• engineering studies,
• sizing,
• integration,
• safety implementation,
• optimisation of ozone systems on existing machines and industrial processes.

As every application is different, the objective is always to design an integration adapted to the real operational needs of the site.

Ozone: a versatile technology for industrial water applications

Today, ozone can be integrated into many industrial water-based processes:

• washing,
• recycling,
• cooling,
• irrigation,
• cleaning,
• process water treatment,
• recirculation,
• post-harvest applications,
• aquaculture.

The real value does not lie solely in the ozone generator itself, but in the ability to successfully integrate this technology into the heart of the industrial process.