Why ozone for bottled water?
Bottled-water producers can't use chlorine — it leaves a residual chemical taste that destroys the product. UV alone provides no residual protection in the storage and filling stages, leaving the bottle vulnerable to post-UV contamination. Ozone solves both problems: it is the most powerful practical disinfectant available, provides a short-lived residual (15–30 minutes) that protects the water through the fill stage, and then completely reverts to oxygen leaving the product genuinely pure. Ozone also oxidises iron, manganese, hydrogen sulphide and taste-and-odour compounds — common issues with deep-bore source waters. For natural mineral and spring water producers, ozone is the only disinfection method that meets the global regulatory definition of preserving the natural character of the water.
The bromate challenge
Bromate (BrO₃⁻) is a regulated by-product formed when ozone oxidises bromide ions naturally present in some source waters. International limits — including the WHO, EU, US EPA and New Zealand limits — set the maximum bromate concentration in bottled water at 10 µg/L. Some markets (notably Germany) enforce even tighter limits. The challenge: bromate forms more readily at higher pH, higher ozone concentration and longer contact times — exactly the conditions you want for effective disinfection. Our proprietary process design philosophy minimises bromate formation by using lower applied ozone doses, very short and well-controlled contact times in dedicated process-control contactors, and (where source water bromide is high) pre-treatment options including pH depression and dissolved-organic-carbon optimisation. The Coca-Cola Amatil PUMP plant achieves bromate below 4 µg/L — well under the regulatory limit and below the detection limit of most laboratory methods.
The complete bore-to-bottle process
A bottled-water treatment train designed by us typically includes: source-water assessment and aquifer characterisation; pre-filtration (multimedia or ultrafiltration depending on raw water); ozone disinfection in a process-controlled contactor with precision ozone-to-water ratio; CT-value-monitored contact tank with dissolved-ozone measurement at multiple points; ozone destruct (thermal or catalytic) on residual gas and any off-gas; final polishing (typically GAC or UV) to remove the last traces of residual ozone before fill; CIP (clean-in-place) system using ozonated water at 2–10 ppm for tanks, lines and fillers; full microbiological monitoring loop; and SCADA-integrated data logging for traceability and audit. Every element is designed as a single integrated system — not bolted together from separate vendors.
Compliance, audit and quality assurance
Bottled-water producers face audits from multiple bodies: Ministry for Primary Industries (MPI) under the Animal Products Act and the Food Act, customer-led BRC / SQF / FSSC 22000 audits, and (for major brands like Coca-Cola Amatil) the brand-owner's own globally-aligned quality programme. Every system we deliver includes complete documentation — process flow diagram, P&ID, ozone-demand calculation, CT-value report, validation testing protocol, microbial challenge testing where required, calibration certificates for every analyser, and a full O&M manual mapped to HACCP critical control points. We're regularly invited to brand-owner audits and have a 100% record of our installed plants passing audit on first inspection.
The Coca-Cola Amatil PUMP project
Our reference installation is the Coca-Cola Amatil bottled-water plant manufacturing the PUMP brand — one of the highest-uptime bottling facilities in New Zealand. Our scope included the complete ozone treatment train, the ozone destruct unit, all process instrumentation, the control system and ongoing service. The plant achieves bromate concentration over 40% below the regulatory limit, delivers in-spec water within 30 seconds of start-up, and has run for years with minimal scheduled downtime. The project demonstrates what's possible when a bottled-water producer chooses an ozone supplier who understands the full lifecycle — from aquifer to brand audit — rather than just selling boxes.
