By André Opperman, Managing Director, Rolfes Water
Industrial operators often recognise the immediate cost of water treatment chemicals but overlook a far greater burden: the hidden cost of poor water treatment. These are indirect financial, operational and compliance risks that remain latent until they materialise in asset failures, unplanned outages or reputational damage.
Untreated or inadequately treated process water contributes to equipment corrosion, scaling, fouling and microbiological ingress which reduces boiler and cooling system efficiency. Understanding the impact of inadequate water treatment is essential to protect continuity, profitability and compliance.
Water Risk and Business Continuity
Water is integral to industrial productivity. The World Economic Forum 2025 Global Risks Report ranks environmental dangers, including extreme weather, biodiversity loss and resource shortages, as “the most pressing global risks over the next decade… closely linked to water”.
What is particularly striking about the WEF research is that water is not just a supply issue. It is also a governance and resilience challenge. This includes water treatment failure risks in industrial systems where small deviations in chemistry, or the lack of chemical dosing can lead to large-scale failures, inefficiency and rising maintenance budgets.
Financial and Operational Toll of Neglect
Now, let me share what I have observed in the field. Hidden costs accumulate in ways that are not always obvious. Scaled up heat exchangers can lose up to 30 percent efficiency, forcing higher energy use and eventual system shutdown. Corrosion in cooling pipework or boiler systems may result in ruptures, product contamination or unscheduled outages. Furthermore, scale on boiler tube surfaces leads to a significant increase in fuel usage.
At a typical plant, downtime can cost hundreds of thousands of rands per day. At the same time, long-term maintenance costs continue to rise as equipment degrades faster than expected. Water inefficiency and increased consumption further erode margins. This illustrates the water treatment return on investment many management teams fail to quantify.
At Rolfes Water, we assist clients in identifying these hidden risks. We do so not just by analysing chemical usage but by modelling how poor water chemistry affects uptime and asset value. To learn more, please visit our Water Treatment Services.
Compliance and Environmental Risk
Most South African operators reference SANS 241 standards for potable water. While elements of this framework are sometimes adopted for industrial process water, effluent discharge is usually subject to specific municipal limits, which are often less stringent than SANS 241 for obvious reasons. Failure to maintain microbial, chemical or physical parameters during compliance testing can result in fines, production shutdowns and reputational damage.
Here is what concerns me most about compliance risks. Industries discharging wastewater or operating in areas where water quality is under public or regulatory scrutiny face heightened exposure. Untreated effluent or chemical mismanagement may lead to regulatory action and public backlash. More information on SANS 241 testing is available in our FAQs.
Industry Perspective
From my perspective, I have seen how process water treatment is frequently under-resourced. This is often not due to negligence but to an underestimation of its critical role.
Well-managed chemical programmes, supported by consistent monitoring and field expertise, deliver significant gains in system reliability. The benefit is not limited to chemical efficiency. It includes fewer production disruptions, longer equipment lifespan and a reduced risk profile.
Our approach extends beyond supply. We deliver integrated programmes that include staff training, diagnostics and continual optimisation. These services ensure that water treatment supports plant performance, compliance and business continuity.
Recommendations to Avoid Hidden Costs
Based on what I have seen across different industries, industrial operators should consider the following actions:
Conduct regular water quality assessments that focus on the relevant standards or limits for the specific water source. Your Rolfes Water representative can advise on the most appropriate testing protocol and, more importantly, how to ensure compliance with these standards and limits.
Partner with experienced service providers who offer diagnostics and technical support, not just chemical supply.
Implement system monitoring tools to track conductivity, flow rates, biological indicators, scale, fouling and corrosion risk.
Train internal teams to recognise early warning signs such as scaling, fouling and bacterial growth.
Include water system performance as part of operational reviews and capital planning.
Looking Ahead: Water as a Strategic Asset
Water has become a priority issue for business continuity and sustainability. As Reuters recently reported, “water has to be the most salient nature-related risk” for companies exposed to climate impacts and resource volatility.
Firms are beginning to integrate water risk into environmental reporting, financial planning and operational resilience strategies. The evidence is clear. Businesses that treat water as a strategic asset, rather than a background utility, are better positioned to manage costs, meet compliance expectations and maintain productivity.
Final Reflection
The impact of inadequate water treatment does not always appear suddenly. It builds over time. This results in higher maintenance costs, declining efficiency and increasing risk.
At Rolfes Water, we work with industrial operators across the continent to deliver practical, cost-effective and compliant total water treatment solutions. These programmes protect assets, reduce downtime and support long-term growth.
To explore how we can help your operation, visit our Water Treatment Services page.
