Small Industrial RO Systems Keep Breaking Down? 5 Common Failures + Solutions to Streamline Maintenance

That small industrial reverse osmosis unit in your workshop—one day it's churning out water like clockwork, the next it suddenly “goes on strike.” Either it can't keep up with demand, or the water quality is so bad it's unusable. Not only does production stall, but you're stuck waiting for a technician to show up, watching losses pile up!

Industrial RO failures aren't as complex as they seem. Today we'll dissect the 5 most common issues, explaining symptoms and troubleshooting steps clearly. After reading this, you'll troubleshoot confidently—no more panic!

1. Issue 1: Sudden Drop in Water Flow, Workshop Water Supply “Cut Off”
A uniquely industrial phenomenon: Production that used to yield 5 tons of water per hour suddenly drops below 2 tons. The workshop production line is waiting for water, leaving everyone frantic. Checking the pipes reveals the water flow is noticeably weaker than usual.

3 Core Causes + Industrial-Grade Solutions:
Clogged pretreatment system (most common in industrial settings)
Industrial reverse osmosis systems always include pretreatment (e.g., multimedia filters, security filters). Sediment, colloids, and suspended solids in the water can clog filter cartridges/media, obstructing inflow.

✅ Solution: First, disassemble the security filter to inspect the cartridge (industrial cartridges are typically large 40-inch filter bottles). If discolored or clumped, replace immediately. For the multimedia filter (quartz sand/activated carbon tank), perform backwashing—open the backwash valve and flush for 15-20 minutes until the drain water runs clear.

Insufficient Pressure in High-Pressure Pump
The industrial high-pressure pump serves as the “power source” for water production. Pump wear or improperly opened inlet/outlet valves can prevent pressure from building (normal industrial unit pressure ranges from 0.8-1.2MPa; pressure below 0.6MPa will cause water shortage).
✅ Solution: Measure inlet/outlet pressure with a gauge. If inlet pressure is low, check if the inlet valve is fully open and if the raw water tank level is sufficient. If outlet pressure is low, disassemble the pump to inspect bearings (replace if worn) or contact the manufacturer to replace the pump head with an identical model.

Membrane Element Clogging (Industrial Membranes Clog More Easily)
Industrial feedwater quality fluctuates significantly (e.g., high turbidity during rainy seasons), causing membrane elements to accumulate scale and block water flow channels.
✅ Solution: First perform membrane flushing (industrial units have a dedicated “flush mode”; press the button for automatic 30-minute flushing). If flushing fails, circulate a citric acid solution (1-2% concentration) for 2 hours (ensure temperature does not exceed 35°C). For heavy scaling, add an alkaline wash (sodium hydroxide solution).

II. Issue 2: Excessive Product Water Conductivity, “Non-Compliant” Water Quality
Industrial-specific phenomenon: Product water conductivity suddenly spikes from 10μS/cm to over 100μS/cm (industrial water typically requires <50μS/cm). This causes equipment scaling and product spoilage when used for cooling or cleaning.

2 Key Causes + Industrial-Grade Solutions:
Membrane Element Damage / Seal Ring Degradation
Industrial membranes operating under prolonged high pressure may develop membrane cracking or deformation of end seal rings (O-rings), allowing untreated raw water to “mix” into the product water.
✅ Solution: Inspect the membrane housing. If leakage traces are present, replace the membrane element's sealing rings (select industrial-grade, high-pressure resistant models). If the membrane is damaged, replace the entire membrane (common industrial models are 4040/8040; choose reputable brands and avoid low-quality membranes).

Failed pretreatment, deteriorated feedwater quality
Industrial feedwater often contains heavy metals and organic compounds. If the activated carbon tank becomes saturated or the softening resin fails, contaminants bypass into the membrane system, causing product water to exceed standards.
✅ Solution: Test feedwater quality (focus on turbidity and residual chlorine). Replace carbon if the activated carbon tank fails; regenerate softening resin (Soak in industrial salt for 8 hours). For significant water quality fluctuations, add a pre-installed precision filter (1μm filtration precision).

III. Issue 3: System Noise is Deafening, Workshop is “Unbearably Loud”

An industrial phenomenon: Equipment emits a “rumbling” sound during operation, 3-5 times louder than normal. Vibrations from pipes can be felt up close, potentially affecting the stability of nearby equipment.

2 Hidden Causes + Industrial-Grade Solutions:
High-pressure pump failure (more severe in industrial pumps)
Long-term full-load operation of industrial high-pressure pumps causes bearing wear and impeller blockage, leading to noise. In severe cases, the pump body may overheat.
✅ Solution: Shut off power, remove pump cover to inspect impeller (clean if contaminated), measure bearing clearance (replace bearings if exceeding 0.1mm) If the pump body leaks, replace the mechanical seal (select high-pressure-resistant fluororubber material).

Pipe Resonance / Valve Noise
Industrial pipes are thick and operate under high pressure. If mounting brackets loosen, water flow can cause pipes to collide with the frame. Sticking check valves or control valves can also produce a “clicking” sound.
✅ Solution: Reinforce loose pipe brackets with angle iron. Insert rubber pads between pipes and brackets to reduce vibration. Disassemble valves to clear internal debris, or directly replace with industrial-grade stainless steel valves (greater durability).

4. Issue 4: Abnormal Concentrate Drainage – Either Wasting Water or Blocking
A common industrial phenomenon: Concentrate pipes either drain excessively (several tons per hour, wasting water costs) or barely drain at all, causing a drop in product water flow and increasing membrane system pressure buildup.

2 Primary Causes + Industrial-Grade Solutions:
- Faulty concentrate control valve (industrial valves prone to jamming)
Long-term exposure to high-concentration wastewater causes internal scaling and debris buildup, preventing the valve from sealing tightly (excessive wastewater) or opening fully (insufficient wastewater).
✅ Solution: Remove the valve, soak in hydrochloric acid solution (5% concentration) for 30 minutes (to descale), then rinse with clean water. If the valve core is worn, replace with an industrial-grade electric control valve (automatically regulates flow, more reliable than manual valves).

System Pressure Imbalance
Mismatched openings of the product water valve and concentrate valve in industrial reverse osmosis systems can cause excessively high or low system pressure, affecting concentrate discharge.
✅ Solution: Measure inlet/outlet pressure at the membrane housing using a pressure gauge. Adjust the concentrate valve opening (normal concentrate flow should be 1.5-2 times the product water flow) while ensuring the product water valve is fully open to prevent pressure buildup.

5. Failure 5: Membrane Element Fouling and Blockage—Premonition of System “Paralysis”
Industrial-specific phenomenon: Sudden increase in membrane system pressure differential (inlet > 0.3MPa higher than outlet), with product water flow halved. Persistent failure to resolve after multiple flushes indicates an impending major failure in industrial reverse osmosis.

3 Common Contamination Types + Targeted Solutions:

Contamination Type 1: Inorganic Scale (Calcium/Magnesium Deposits)
Identification: White crystalline deposits on membrane housing walls, removable after acid cleaning
Solution: Circulate 1-2% citric acid solution for 2 hours at 25-30°C


Contamination Type 2: Colloidal Contamination (Silt/Clay)
Identification: Brown sticky deposits on membrane surface that resist rinsing
Solution: Circulate a 0.1% sodium hydroxide + 0.05% sodium hypochlorite mixture for 1.5 hours

Contamination Type 3: Biological Contamination (Bacteria/Algal Biofilm)
Foul odor from membrane, viscous discharge
Soak membrane elements in 0.2% sodium hypochlorite solution for 4 hours, then rinse thoroughly

Industrial Reverse Osmosis Maintenance Guide: Follow These 3 Steps to Reduce Failures by 80%!
Daily Operation Logging: Record raw water turbidity, membrane inlet/outlet pressure, and product water conductivity. Abnormal readings enable rapid issue identification (e.g., sudden conductivity spikes likely indicate membrane rupture).

Scheduled Chemical Cleaning: Avoid waiting for clogs—perform acid/alkaline cleaning every 1-2 months (adjust based on feedwater quality).

Stock spare parts in advance: Keep 2-3 extra sets of high-pressure pump bearings, membrane seals, and security filter cartridges to avoid production delays caused by waiting for replacement parts during failures.

If your factory's reverse osmosis system faces more complex issues—such as system startup failures, PLC error codes, or uncertainty about selecting replacement membranes—feel free to leave a comment below!