Nancrede Engineering’s Three-Tank Zero Hardness™ Industrial Water Softener System

Nancrede Engineering’s Zero Hardness™ Failsafe Industrial Water Softener System in a Three Tank Setup.

Nancrede Engineering’s patent pending new three tank Zero Hardness failsafe industrial water softener system sends water through two water softeners in series while a third tank is in offline mode. This three tank setup greatly reduces the chance of failure and salt waste, reduces risk and increases your bottom line. This is ideal for critical systems that require very low hardness levels, and makes this the best possible boiler feed softener.

A traditional three tank water softener system differs in that it consists of one online tank and two offline tanks. This mode of operation creates an environment that fosters hardness leakage, increased operating and environmental costs, salt waste and a higher chance of nonperformance with no backup in place.

The Nancrede Engineering three tank Zero Hardness failsafe industrial water softener system always has one tank in a softening role and a second tank in a polisher role. This process minimizes damaging hardness to your processes, production, critical equipment, reverse osmosis and boiler by eliminating offline water softener tanks and resulting that result in water quality degradation. The offline tank in this setup alternates with the other two tanks when they switch roles. This results in the offline tank’s downtime being only a fraction of what it would be in a traditional setup. (If you want superior industrial water softening and boiler feed softening with just two tanks, see our two-tank Zero Hardness™ industrial water softener.)

Three Tank Zero Hardness™ Failsafe, High Efficiency Softener Systems Are Ideal for Critical Applications In:

  • Universities and Schools Water Softening
  • Pharmaceutical Water Softening
  • Food and Beverage Water Softening
  • Correctional Facilities Water Softening
  • Manufacturing Water Softening
  • Government Buildings Water Softening
  • Dairy Water Softening
  • Reverse Osmosis Pre-Treatment
  • Boiler Feed Water Softeners
  • Medical Building Water Softening
  • Hospital Water Softening
  • Prison & Jail Water Softening
  • Oil and Gas Water Softening
  • Surgery Centers & Healthcare Facilities Water Softening

Failsafe – 100% Redundancy Risk Reduction for Your Industrial Water Softener:

With the double pass, worker polisher design, two of the three industrial water softeners are online all the time, which reduces risk of poor water quality shutting down or limiting your process. If one softener tank were to fail, the other tanks would still soften and polish the water with no lack of soft water at any time. This effectively eliminates the largest single point of failure common in standard industrial water softener systems.

Two Tank Zero Hardness™ Industrial Water Softeners

Performance – Zero Hardness and High Water & Salt Efficiency:

Better performance, zero hardness and higher efficiency can be achieved by having two industrial water softener tanks online all the time passing through one softener then a second. Lower and more efficient brining rates can achieve water quality similar to that of higher brining rates by having the first softener remove most of the hardness and the second polish the water. Most large industrial and commercial water softeners are regenerated with 15 pounds of salt per cubic foot of resin. Higher water quality is obtained than with lower salting rates, but efficiency is lost. Using a lower brining rate but flowing in a worker polisher design can cut back salt consumption upwards of 40%, while still reducing hardness leakage and water consumption. The double pass, worker polisher design of this new patent pending softener system design offers the following performance advantages in regard to hardness removal and efficiency.

  • Continuous hardness leakage is close to zero.
  • Less salt is used to achieve better water quality.
  • Endpoint hardness leakage is vastly diminished.
  • Less water is used in regeneration steps reducing water waste.
  • Starting point hardness leakage is minimized.
  • The best option for a boiler feed softener and softening for critical processes and equipment.

High Peak Flow Rates in Your Industrial Water Softeners:

For high flow rate scenarios, the polishing softener can be pulled online so the system runs in parallel regardless of which unit is in lead or lag (worker or polisher) position to satisfy peak flow rates. When flows reduce back to normal levels, the system returns to a double pass configuration. The system is bi-directional, meaning either softener tank can be in the lead or lag position.

Zero Hardness™ Softener vs. Standard Alternating Softener:

Standard industrial water softener systems have the following disadvantages concerning hardness leakage and risk of poor water quality.

  • Water in the tank and piping of the standby industrial water softener has been sitting stagnant for several hours to several days causing poor water quality due to high starting point hardness leakage.
  • At the end of the industrial water softener service cycle, end point leakage occurs as the resin nears exhaustion and hardness makes its way to your process.
  • Piping design, materials of construction and industrial water softener control has not been optimized to minimize hardness leakage.

The Zero Hardness™ failsafe softener system doesn’t have these disadvantages. Hardness leakage from the lead softener is removed by the polishing softener. This, paired with special materials of construction and dead leg minimization piping design, results in minimal potential for hardness leakage and softener failure to ensure your production is never shut down or compromised by high hardness in your process water.

For more information on Nancrede Engineering’s three tank, double pass, high efficiency softener systems, consulting engineering or specialized sizing, contact us at or 888-569-2837.