AquaRevival Filters: Innovative, Compact, and Safe Solutions for Water Filtration
Established in 2018, AquaRevival focuses on AquaRevival filtration systems that utilise regenerative media, catering to the aquatics, food and beverage, agricultural, and industrial sectors. Their cutting-edge systems provide drinking-water quality while enhancing sustainability and operational efficiency.
The filtration solutions offered by the company are certified under NSF 50, 61, and 372, ensuring safety and performance across a variety of applications. Importantly, their technology has received NSF certification for Cryptosporidium reduction, representing a significant leap forward in recreational water safety.
Manufactured entirely in the US, AquaRevival’s products are constructed using ASME-certified materials, showcasing their dedication to quality and compliance. By incorporating advanced automation and energy-saving features, the company provides clients with a cost-effective alternative to traditional sand filtration systems, minimising water waste and chemical usage.
We spoke with Paul Nehlen, president of AquaRevival, about how the company, with its emphasis on innovation and sustainability, continues to set new standards in water filtration, offering solutions that adapt to the changing demands of modern industries.
A Passion for Invention
Nehlen’s career spans decades with a Fortune 500 company, followed by a stint with a private equity firm that owned a competitor in the water filtration sector. As the head of engineering and operations, he contributed to the business’s growth, improved manufacturing processes, and filed patents, including one for heat exchange, before departing when the company changed ownership.
An entrepreneur with a zeal for invention, Nehlen has been constructing filtration pressure vessels and similar systems since the 1980s: “I began in a factory building compressed air and gas purification equipment at 17. I’ve been immersed in welding and manufacturing heavy equipment for a long time.”
Upon founding AquaRevival, Nehlen started from the ground up, designing a filter housing and internal filtration system specifically for water-based fluids.
“The filters used by our competitors are based on regenerative filters that have been around for over a century. Initially designed for the automotive industry, they were later adapted for dry cleaning fluid, and decades later, someone decided to use them for pools. However, they were never intended for water.”
“The business literally started in my garage. I built the first filter, much like Harley and Davidson did with their first motorcycle, in a shed. The neighbours found it amusing; they never knew what I was building next. Their children would come over, and we’d have science class in the garage.”
“That’s how it all began.”
AquaRevival: Setting a New Standard
The technology is groundbreaking in numerous ways. It is not only the first system designed specifically for the industry but also the first and only firm to achieve certification from NSF International, the leading testing and certification organisation in the water industry, for a new standard in Cryptosporidium parvum reduction.
This parasite causes severe gastrointestinal disease and cannot be eradicated by chlorine alone, posing a long-standing risk in environments such as water parks, swimming pools, and resorts.
“A few years ago, the NSF 50 language was revised to allow for the capture of Cryptosporidium parvum, and the Model Aquatic Health Code also includes it,” explains Nehlen. “These are the two primary standards used in the US to determine whether a filtration system qualifies for commercial settings.”
NSF 50 specifically addresses water that humans will be in, regulating everything from filtration to UV treatment and chemical dosing.
“No one else had attempted a couple of things. One was that the filtration rate was increased by 50%. Previously, you could only run two gallons per minute per square foot, but they raised it to three. We tested and achieved that.
“We were the first and only company to reach three GPM per square foot for our filters. Our competitors limit their filters to 1.4 GPM per square foot. We outperform them by more than double.”
“This means our filters are significantly smaller for the performance you receive. They occupy less space in the pump room, which reduces construction costs as facilities can utilise a smaller filter.”
Safer Swimming
Moreover, the Cryptosporidium endorsement allows AquaRevival to demonstrate that not only is it filtering far more water per unit of time than its competitors, but it is also certified to filter Cryptosporidium, which can be as small as one to three microns in diameter.
“Cryptosporidium can survive for days in chlorinated water. Therefore, pools often add UV systems, which deactivate the organism’s DNA. However, if your UV system isn’t functioning optimally, the Crypto continues to circulate through the system and back into the pool.
“The difference with our filters is that we remove 67% of the Cryptosporidium on each pass. The testing for this is precise. Because we capture the Cryptosporidium, it never reaches a swimmer’s mouth, eyes, or mucous membranes. It is disposed of, making your water undeniably safer.”
“That’s why it was incorporated into NSF 50, and why the Model Aquatic Health Code anticipated that, eventually, someone would devise a method to capture it—and now we have.”
The Centers for Disease Control found that between 2009 and 2017, Cryptosporidium was the leading cause of water-related diarrhoea outbreaks in the US, accounting for 35% of these incidents, with over half (56%) of reported cases linked to contaminated water in pools or playgrounds.
While healthy individuals typically recover, infections can lead to severe malnutrition and wasting in immunocompromised patients.
“If you already have a compromised immune system, it can be lethal. It’s generally not fatal, but it can make you very, very ill.”
Thus, for operators, technology that effectively prevents Cryptosporidium outbreaks is revolutionary.
The Benefits of Choosing AquaRevival
AquaRevival’s filter systems are straightforward to install, whether for a new project or refurbishing an existing facility.
“All of our filters fit through standard doors. This means we save money on demolition because you typically don’t need to alter the building to accommodate our filters.
“For new constructions, they can build a smaller pump room, leading to direct capital expenditure savings. These savings often cover the cost of the filters and more. Customers have even informed us that by purchasing our filters, they constructed a smaller pump room, which more than paid for the filters, essentially making them free.”
Due to their smaller footprint, that space can also be monetised:
“You could add a food and beverage stand, a shop, or more slides, all of which enhance guest experience and generate revenue.”
Beyond public safety, there are additional operational and financial advantages, he adds:
“We’ve incorporated several features that no one else has into our filters. We have photo-driven maintenance screens customised to local facilities. If there are language barriers, we utilise images. For instance, the screen might display a specific valve and instruct, ‘Close this valve.’ Maintenance procedures are graphically illustrated in the controller, either attached to the filter or mounted on a nearby wall.”
This simplifies the operation of the system.
“We coordinate all the other systems, including chemical control, heaters, and UV, through our filter controller. This allows us to manage the system shutdown, media revival, and startup sequence in a manner that ensures chemicals aren’t added when water isn’t flowing, and heaters do not accumulate water in the pipes during a shutdown scenario. It’s a seamless, automated operation that requires minimal manual input.”
Reliability and Ease of Maintenance
AquaRevival also provides a 15-year warranty.
“Most warranties cap at 10 years, with some only lasting five. We utilise ASME Section VIII quality materials and have material test reports for all subcomponents. This incurs additional costs, but we do it for reliability. These filters operate overnight when no one is around, so safety is paramount.
“Because our filters are smaller, you don’t need scaffolding or large ladders to work on them; everything can be accessed from the ground, which is safer for the maintenance team. We’ve considered what happens post-installation, when staff are left to operate the system independently.”
After installation, there is no need to disassemble the filter for cleaning:
“We employ a patented Clean-in-Place (CIP) process, similar to that used in the food and beverage industry. Dairies don’t disassemble everything when switching between milk, kefir, or yoghurt. They clean in place. We’ve adapted that process for this industry.
“Our system meets the new, stringent NSF 50 standards for cleaning. It’s easier for operators, doesn’t require disassembly, and still achieves long filter runs with minimal maintenance time.”
Sustainability at AquaRevival
Sustainability is a significant aspect of the company’s philosophy:
“Because our filters are smaller and we don’t backwash like traditional sand bed filters, we conserve a substantial amount of water,” states Nehlen.
“In a sand bed filter, you reverse the flow to flush out the dirt, which can waste thousands, even tens of thousands, of gallons of water weekly. We don’t do that. Instead, we ‘revive’ the media. This means we stop the pumps and agitate the media to suspend it and the trapped dirt inside the tank. Then we restart the system, and it re-coats the filter elements.”
The key is that no water, chemicals, or heat (which the operator has already paid for) is wasted during this process. “This all contributes to a lower environmental impact. We can filter out particles as small as 1 micron, and in some cases, sub-micron, which includes Cryptosporidium. The water that emerges from our filter is crystal clear, approaching bottled water quality.
“It’s a testament to the technology.”
An Efficient Solution
As the AquaRevival system captures around 67% of Cryptosporidium in the first pass, it is exceptionally efficient. “Rather than running it repeatedly like some competitors, we achieve a higher capture rate each time.
“We design the system to accomplish 100% turnover of pool water in approximately 24 hours. So, if you have a 100,000-gallon pool and run 100,000 gallons through the filter every four hours, not every molecule passes through exactly once. Some go through multiple times. However, over 24 hours, it balances out.”
He adds another crucial sustainability point: “When we revive the media, we decrease the pressure inside the tank. These are surface filters, and as dirt accumulates, it reduces the available surface area, increasing the pressure differential, with higher pressure in and lower pressure out.”
“Once the pressure reaches a set threshold, the control automatically halts the system, revives the media, and re-coats the elements. This reduces the pressure again, so the pumps don’t have to work as hard. It’s all automated.
“Early in the cycle, pumps operate easily. As the filter loads up, they exert more effort to maintain flow. However, we reset the pressure before it becomes too high, so the pumps consume less energy overall.”
By minimising water waste, chemical use, and energy consumption, the technology promotes a much more sustainable approach to aquatic filtration.
“A Game Changer”
One satisfied AquaRevival customer is MountJoy Aquatics, a leader in commercial aquatic distribution.
“Our goal is to enhance the safety of public water through technology and innovation,” states Bart Mountjoy, president. “AquaRevival’s industry-leading filters have helped us achieve that goal.”
“AquaRevival’s willingness to challenge industry norms through technology and innovation has been a game changer for us. Additionally, their commitment to quality and support makes selling and supporting their products a straightforward decision.
“The AquaRevival filter represents a comprehensive rethink of the regenerative media filter. Industry standards for facility types, flow rates, maintenance, and care have been transformed with this filter. The NSF certifications, customer testimonials, and contractor loyalty speak for themselves.”
R&D and What’s Next
AquaRevival’s approach to research and development is informed by time spent in the field with customers, says Nehlen:
“That’s how we’ve developed a profound understanding of real-world challenges. I’m an engineer by training, and over the years I’ve designed a lot of equipment. However, I believe people return because they enjoy collaborating with us in the pump room. I listen. I may not always have the right answer immediately, but I’m relentlessly committed to finding it.”
The team collaborates closely with customers not only to resolve their issues but also to help them become experts themselves. “This way, they can provide the best possible experience to their customers.”
R&D at AquaRevival encompasses several areas. “We’ve developed concepts we haven’t yet introduced to the market. There are some exciting technologies in the pipeline, but our primary focus has been on regenerative media filters, as that’s where we see the most significant impact for water parks: filtration that reduces water usage, saves energy, lowers chemical costs, and enhances safety.
“Water is the single most crucial resource in this industry. If we can assist parks in using less water and fewer chemicals while improving water quality, we’re directly lowering their operating costs and environmental impact.”
The R&D process includes building physical prototypes, employing computational fluid dynamics, and 3D modelling. “And even though we’re a small company competing against global giants, we’re leading the way,” he adds.
“We now hold nine US patents and patents covering the UK, Australia, and Japan. We are, without a doubt, at the forefront of NSF 50 commercial aquatic filtration technology.”
As for what’s next: “I can’t reveal too much yet, but I can assure you it will be worth discussing. It’s a significant advancement that will greatly assist water parks in improving their uptime and overall operations.”
