The Background
Electrodialysis is a process used to separate ions from salt solutions through a series of ion exchange membranes. In this case, the customer uses the technology to desalinate seawater, supplying coastal hotels with drinking water.
The Challenge
While the existing electrodialysis system was functionally effective, the manufacturing costs of the filter modules were too high to support scalable, cost-efficient production. The customer sought a redesign of these modules to significantly reduce production costs without compromising system performance or reliability.
The Solution
The project was approached in two phases. As an immediate, cost-effective measure, we retained the core system design, but implemented alternative operating principles targeting key cost drivers. This optimization led to a 38% reduction in manufacturing costs, providing the client with quick relief and improved cost-efficiency in the short term.
In the second phase, a long-term solution was developed that involved a complete system redesign. By reevaluating the architecture and incorporating alternative manufacturing techniques and materials, we achieved a 74% reduction in production costs compared to the original design. This future-oriented solution positioned the client for sustainable growth and long-term competitiveness in the market.
