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EmailChris Nancrede, EIT, ASSE 12080, presented The Art and Science of Water Softener Design: The Definitive Masterclass for Plumbing Engineers at the ASPE Convention on Wednesday, October 14, 2026.
Water softeners are widely used in commercial, healthcare, and industrial plumbing systems, yet they are often oversized, under-specified, or improperly matched to the needs of the systems they serve. These design shortcomings can lead to hardness leakage, premature equipment failure, excessive salt consumption, increased operating costs, and even conditions that contribute to Legionella risk.
Drawing on patented water softener design innovations and hands-on experience with installations across multiple industries, Chris’s presentation explored how plumbing engineers could make more informed decisions when sizing, specifying, and configuring water softener systems.
The session covered the three critical parameters of softener sizing: gallons per day (gpd), flow rate in gallons per minute (gpm), and water hardness. Chris also examined key equipment and configuration decisions, including fiberglass-reinforced plastic (FRP) versus steel tanks, controller and valve selection, and the advantages of single, twin, and triple softener configurations.
Beyond system sizing and equipment selection, the presentation addressed strategies for improving long-term performance and reducing operating expenses. Topics included specialty resin selection, condensate polishers, and salt and brine management approaches that could reduce salt costs by 40 to 75 percent. Chris also discussed the important design differences between potable and healthcare water systems and process softener applications.
The presentation emphasized that water softener design involved more than selecting equipment to meet a specified capacity. Every decision from system configuration to component selection could affect water quality, operational reliability, capital expenditures, ongoing maintenance, and the longevity of the broader plumbing system.
By connecting engineering principles with real-world installation experience, Chris provided plumbing professionals with a practical framework for designing water softener systems that performed reliably from initial startup through long-term operation.