Advanced Manufacturing: How Water Systems Can Impact Cost

Ultrapure Water Systems

Ultrapure water (UPW) is the heart of advanced manufacturing. In industries like solar cell manufacturing, every rinse, etch, and cleaning step relies on high-purity water to prevent contamination and defects. But how pure is pure enough (and at what cost)? The reality is that not all ultrapure water specs are created equal. Overdesigning a system can significantly inflate both capital and operational costs. By understanding the biggest cost drivers, you can strike the right balance between performance and efficiency, without breaking the bank.

Key Cost Drivers in UPW System Design:

• • Total Flow Rate: More water means higher costs. Oversizing a system leads to excessive capital & operational costs.

• • Resistivity: Ultra-high resistivity can add unnecessary polishing steps, increasing complexity and cost.

• • TOC, Bacteria & Particulate Limits: Stricter limits mean more advanced filtration, disinfection, and monitoring.
    
    
• • System Redundancy: Backup systems are necessary, but doubling equipment “just in case” can quickly drive-up expenses.

• • Integrate Wastewater Reuse: Some process wastewater only needs minor pH adjustments and filtration passes before it can be reused, reducing freshwater intake and wastewater discharge.
    
    
  • Challenge Quality Requirements: Not every process requires 18 MΩ-cm water. Properly specifying purity levels can significantly reduce polishing costs.
    
    
  • Optimize System Sizing & Vendor Selection: A system that is sized for actual demand ensures efficiency. Plus, engaging with your manufacturing equipment vendors early and asking the tough questions prevents unnecessary specification inflation.
    
    
  • Align Cost Expectations Upfront: Some suppliers push for specs that aren’t always needed. Setting clear expectations avoids unnecessary over-engineering.