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Industrial Microbiology – Real-time bacterial monitoring for industrial water processes

Microbiological contamination can cause significant operational problems in industrial water systems. Biofilms, bacterial growth and microbiologically induced corrosion (MIC) can reduce efficiency, increase maintenance costs and, in some applications, pose a health risk.

Traditional microbiological analyses often require laboratory testing and provide results several days after sampling. By then, the process may already have changed.

With online flow cytometry, bacterial levels can instead be monitored continuously, allowing operators to detect changes immediately and take action before problems develop.

Oleinitec supplies innovative solutions from bNovate for real-time bacterial monitoring in industrial applications.

Faster decisions with BactoSense

BactoSense uses automated flow cytometry to rapidly determine the concentration of bacteria in water without the delays associated with conventional cultivation methods.

The system automatically samples the process, stains the microorganisms and counts individual cells, providing continuous insight into microbiological activity.

Continuous monitoring enables operators to:

• Detect bacterial growth before it becomes a process problem
• Verify the effectiveness of biocide treatment
• Reduce the risk of biofilm formation and microbiologically induced corrosion
• Optimise chemical dosing
• Improve process reliability while reducing operating costs

Unlike periodic laboratory sampling, online monitoring reveals short-term microbial events that would otherwise remain unnoticed. This enables faster corrective actions and better process control. Recent industrial case studies have shown that continuous monitoring can detect microbial excursions within minutes instead of waiting for monthly laboratory testing, allowing operators to optimise chemical dosing and reduce operational risks.

Typical applications

BactoSense is suitable for a wide range of industrial water systems, including:

• Cooling towers
• Cooling water systems
• Boiler feedwater and condensate systems
• Process water
• Reverse osmosis (RO) systems
• Ultrapure water systems
• Beverage production
• Mineral water production
• Food processing
• Pharmaceutical utilities

Continuous microbiological monitoring has also proven valuable for identifying bacterial regrowth, locating contamination sources and understanding how operating conditions influence microbial activity in industrial water systems.

Industrial applications only

Oleinitec focuses on industrial applications, including process water, cooling water, food & beverage production and mineral water.

For drinking water applications, please contact our partner KZ Handels, who is responsible for this market.

Why choose Oleinitec?

Our specialists combine microbiological monitoring with expertise in industrial water treatment, process instrumentation and analytical technology. We help customers select the right monitoring solution and integrate it into existing control systems to improve process reliability and reduce operating costs.

Read more
Success Story – Food & Beverage
Success Story – Industry
Industrial Water Monitoring Report