The Challenge
A nationwide packaging manufacturer with 100+ facilities sought to implement a proactive cross-connection control program that would protect their piping systems, ensure safe drinking water for staff, and keep them compliant. “We had conducted a number of surveys both internally and externally,” explains an environmental engineer at the company. “We noticed an inconsistent level of detail and quality within those surveys.”
The facilities owned by the manufacturer vary widely, too: “Some of our buildings are rented, some we own, some range from 50+ years old to being a new build.” And with that much variation, experience and expertise are a must. “We knew we lacked the desired technical knowledge needed to conduct cross-connection surveys.”
With uncertainty regarding the quality of information they had gathered, a lack of technical knowledge internally, and facilities ranging in age and infrastructure, they sought outside expertise to support OSHA compliance and reduce contamination risk. They needed a scalable approach that could be applied across locations.
“We knew we lacked the desired technical knowledge needed to conduct cross-connection surveys.”
– Environmental Engineer
Packaging Manufacturer
The Solution
“We needed a comprehensive understanding of our potable and non-potable systems, and we wanted consistency,” the environmental engineer explains. “Someone with experience and technical knowledge.”
The manufacturer turned to HydroCorp: “HydroCorp was able to understand what we were looking for and lay out a clear plan.” The HydroCorp team conducted a pilot survey of one facility, providing a comprehensive report outlining areas of concern and recommendations. “We wanted to replicate that in our other facilities; we went from one survey to doing multiple across the year.” Since then, HydroCorp has conducted surveys in seven plants for the manufacturer, ranging from 500,000-1 million square feet.
While on-site, the manufacturer’s staff would shadow HydroCorp’s surveyors to gain a better understanding of the system they work in every day. “Having that knowledge has been valuable–some employees have acknowledged the presence of particular findings in multiple facilities.” This improved troubleshooting and oversight, giving teams more confidence in daily operations.
“We’re saving time, and our employees feel more confident navigating their own systems.”
– Environmental Engineer
Packaging Manufacturer
The Result
Over the course of the year, HydroCorp provided more than 225 recommendations across the seven facilities. The manufacturer even had some redundant backflow preventers in place: “The annual maintenance associated with such devices is costly. We can remove that equipment, and that’s reducing our maintenance costs.”
HydroCorp delivered consistent documentation and reporting across all sites, providing a unified view of the piping systems, something internal teams couldn’t achieve at scale. The project has already paid dividends in safety, peace of mind, and efficiency. “We’re saving time and our employees feel more confident navigating their own systems.”
Not to mention the benefits of detailed system knowledge for regulatory audits: “When we’re finding these issues and fixing them, we’re reducing that cost [from a non-compliant inspection].” This system-wide consistency has reduced uncertainty, improved decision-making, and strengthened long-term infrastructure planning.
Ultimately, the partnership with HydroCorp has helped the manufacturer stay proactive without sacrificing in other operational areas. The environmental engineer explains, “We’re able to focus more on other initiatives, whether that’s environmental, safety related, or operational.”
