Rapid Response to Water Contamination at a Food Packaging Facility

The Challenge

A major food packaging facility faced a significant operational crisis when routine water testing revealed results that failed to meet Safe Drinking Water Act (SWDA) standards. This failure forced the facility to halt production for three days, posing substantial risks to both product safety and the company’s bottom line. Given the critical nature of food processing, where process water is integral to cleaning, preparation, and packaging, any contamination could have severe consequences. The facility urgently needed expert intervention to identify the source of the problem and restore compliance.

Many people think of an industrial facility as a fixed, permanent structure. The truth is, in most cases, they’re in a continual state of change. That’s why they call HydroCorp.
We don’t miss the details. It’s more than keeping water safe; we provide water system intelligence.

The Solution

HydroCorp’s Wisconsin-based team, led by backflow prevention expert Gary McLaren, quickly responded to the facility’s call for help. The team began by collaborating with the facility’s health and safety staff to devise a thorough cross-connection control survey strategy. This involved tracing every water line in the facility, from the input source to the output, including both process and potable water systems.

During this exhaustive survey, HydroCorp uncovered several critical issues. A previous internal modification to the process water lines had been poorly documented, resulting in water softener systems being directly plumbed into drainage pipes—a serious cross-connection risk. Additionally, a fire sprinkler line was found to be directly connected to the potable water supply, and several backflow preventers
were missing at key interconnection points.

Armed with these findings, HydroCorp developed comprehensive piping schematics of the facility’s water
system and created a fully documented report. This report included detailed recommendations for system corrections, a prioritized schedule for addressing the issues, and a cost analysis to help the facility plan its remediation efforts. HydroCorp’s systematic approach provided the facility with a clear, actionable plan to restore compliance and ensure the safety of its water supply.

HydroCorp’s intervention allowed the facility to safely resume production, ensuring product safety and regulatory compliance.

The Result

Thanks to HydroCorp’s swift and thorough intervention, the food packaging facility was able to address the critical issues identified in its water system. The comprehensive schematics and detailed management program equipped the facility with the tools and knowledge needed to prevent future contamination risks and maintain compliance with SWDA standards. Production was able to resume safely, with the facility fully confident in the integrity of its water supply.

HydroCorp’s Gary McLaren emphasized the importance of attention to detail in such complex environments: “Many people think of an industrial facility as a fixed, permanent structure. The truth is, in most cases, they’re in a continual state of change. That’s why they call HydroCorp. We don’t miss the details. It’s more than keeping water safe; we provide water system intelligence.”