This document discusses brine saturator systems from Flocktons. It outlines their experience providing these systems over 15 years across industries. Key benefits include reliable, easy to operate systems with long asset life and value. Systems can be customized in size, storage capacity, and accessories. Flocktons provides installation, training, maintenance and technical support. Their systems automatically produce brine from salt and have options for telemetry and adding other solutions. Storage tanks are expected to last over 15 years.

3. Brine Saturator Systems
Requirements:
• Reliable System
• Easy to Operate
• Value for Money
• Long Asset Life

4. Brine Saturator Systems
Options:
• Size
• Storage Capacity and Expansion
• Accessories
• Telemetry

5. Why Use Flocktons?
 Experience
 Across a wide range of industries – AND over 15 years of pre-wet systems
 Materials Choice
 Best materials for highly corrosive brine – GRP, Plastics, Stainless Steel, etc.
 Engineering Design
 Design Flexibility to suit local requirements / Site appropriate storage tank capacity / Full
instrumentation and control / Remote information and interrogation
 Installation Services
 Assistance with location design, plus full installation, commissioning, and TRAINING to the
appropriate level
 Full Service Aftercare
 Routine PPM, spares supplies, emergency callouts, technical assistance, training updates
 Currently providing service care to over 50 pre-wet systems for winter road applications
 Proven System Reliability
 Many systems, many years reliable operation
 Ongoing Innovation
 System evolution using latest technologies

6. Installed systems in the UK
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7. Flocktons Systems: Technical Benefits
Automatic brine production
• Loader filled or Bagged salt or Blown salt
• Regulated freshwater supply and/or recycled water
• Dilution to desired concentration
 Capacity Options for high volumes of salt – no further
operator intervention
 Options to add ‘other solutions’ and ABPs, accurately
 Interface with Spreaders to give auto-loading and status info
 Option to return unused Spreader brine to storage
 Remote telemetry monitoring and technical assistance

8. How to size Saturator Systems?
 Number of Spreaders operating from the depot
 Size of Spreader brine tanks
 Anticipated (or maximum?) number of runs per day
 Reserve storage capacity for extra vehicles or unforseen
events
 Any need for additives or special products
 Capacity of freshwater supply
 Availability of manpower to add more salt to Saturator
2500 Litres 5500 Litres

9. Saturator System Options
 Self-contained saturator with integral brine storage
 Two tank system for additional brine storage capacity
 Multiple brine storage tanks (Used in larger depots)
 Customised systems for special requirements
 Large capacity saturator for less frequent salt loading

10. Saturator System Options
 Self-contained saturator with integral brine storage

11. Saturator System Options
 Self-contained saturator with integral brine storage

12. Saturator System Options
 Two tank system for additional brine storage capacity
(Used in larger depots)

13. Saturator System Options
 Large capacity saturator for less frequent salt loading

14. Systems for special requirements
 Additional Rainwater storage / Washdown water recovery
Metered water areas / high rainfall / environmentally sensitive circumstances
 Additional brine storage
Large / busy depots
 Mixing of other additives
E.g. ABP’s, Calcium Chloride, etc.
 Telemetry / SMS messaging for alarms / salt levels etc
 Guidance on salt consumption / requirements
E.g.:

15. Sustainable solutions including the use of rainwater
/ washdown water for brine production
Rainwater from salt barns etc
Washdown water from yard
Mixed with mains freshwater as
required
Pumped Return to storage of
unused brine from Spreaders
Calibrated mixing of other
additives, e.g. ABP’s or low
temperature chemicals

16. Above ground rain water storage

17. Special systems – some options
Freshwater tank / Salt Saturator tank / 2 Brine storage tanks / Underground
rainwater and washwater collection tank / constant concentration mixing tank /
ABP storage and mixing facility
Features...

18. Special systems
Site specific colour schemes / multiple
loading points / large shallow bunds etc.
Lincolnshire: 2 x 50,000l brine stores
(GRP)

19. Special systems
Translucent GRP for easy
assessment of salt levels
-Refill in this case with blown salt
(fewer impurities, higher cost)

21. 25t Saturator,
Hopper loaded
white salt,
30,000l Brine
store,
Fully bunded

22. 25t Saturator, Hopper loaded white salt, 30,000l Brine store, Fully bunded
100,000 litres brine from 1 salt refill. 8 Spreaders, 2,500 l per fill
Equivalent to ‘5 days worth’

23. 25t Saturator,
30,000l Brine
store,
Bagged salt,
Fully bunded.

24. OCS (Operator Control
Station) Screen gives all
essential data for system
operation
This data can be
viewed remotely on
a PC screen via
EnvisionRV Software
This can be viewed
either as ‘live’ data
or as ‘recent
snapshot’ data

26. Requirements for site
communications
 Several possible solutions:
 Communication is possible via mobile phone network
 Vulnerable due to mobile network and signal issues
 Much better to have a static IP address dedicated to each
pre-wet system
 Better to avoid existing ‘office networks’ due to firewall
access issues
 Remote access via Envision RV software, to single or multiple
sites, and datalogs
 ‘Live’ information access is given, which allows control of
systems remotely, but this can be password protected!
 All fully customizable

27. Typical information from each site
 Current status
 Volume of stored brine available
 Strength of stored brine
 Low salt level in saturator
 Any parameter out of normal limits, e.g. water levels
 Alarms or Equipment failure, e.g. pump not working
 Volumes loaded to each Spreader
 Volume of brine made over time
 View multiple sites from a single location
 Information customised to suit needs

30. Capital Cost Estimates
 Depends on several factors:
 Size of saturator
 Volume of brine storage capacity
 Double skinned or single skinned vessels vs concrete
bund costs
 Ancillary items, e.g. recycled water, ABP or additives
 Telemetry requirements
 Number of systems ordered – bulk discounts apply!

31. £25-30,000

32. £30-35,000

33. £45-50,000
Additional
30,000l
store tank
£15,000

34. Ongoing maintenance
 Team of Engineers:
 Available on site ‘As rapidly as required’
 Nationwide coverage – over 50 systems currently
supported
 Guided by System Status Reports as to nature of problem
 Spare parts can be held locally or by Flocktons
 Training offered in O&M ‘Best Practices’

35. Ongoing maintenance
 Ideal Circumstances:
 Pre-season ‘Start-up’ Service
 No need for maintenance during operation
 Post season ‘Shut-down’ and check over
 Operating staff need to be trained and ‘On –side’ for
effective operation

36. • Dave Davies , Principal Maintenance Engineer, Lincolnshire
County Council.
• Dennis Vacher, Highways Supervisor, Cambridgeshire Highways.
• Paul Leaves, Transport Manager, Hampshire Transport Manager.
• Richard Hancox, Network Manager (Severe Weather Manager)
EM Highways, HA Area 9

37. Asset Life: What is the likely lifespan of
the units – Will they last 15 years?
 Emphatic YES!, and probably 20 years +
 From direct experience tanks, vessels and pipework will all easily last for well over
15 years
 But…….
 Electronics and pump motors may require replacement during this lifetime due to
salt damage and / or obsolescence
 Engineering Design
 As far as possible protect from corrosive environment / Use suitable materials etc.

38. 15 Year old Saturators and Storage

39. 15 Year old Saturators and Storage

40. 15 Year old Saturators and Storage

42. Flocktons aim to be the best provider of reliable
and precisely engineered solutions to guarantee
constant supplies of correct strength brine for
winter road maintenance