Natursteine Mulbach Improves Water Treatment with a Custom-Built Dal Prete System
In the natural stone processing industry, water management is a key factor in ensuring production continuity, the quality of finished products, and environmental sustainability. When the materials being processed change, production volumes increase, or new technologies are introduced, the water treatment system must also evolve to meet the workshop’s new requirements.
This is precisely the path taken by Natursteine Mulbach, a family-owned company founded in 1933 and now led by the fourth generation, which has chosen to completely overhaul its water clarification system to support the evolution of its production.
A Company in Constant Evolution
Throughout its history, Natursteine Mulbach has gradually transformed its business. From traditional sandstone processing and outdoor products, the company has shifted to high-value-added products for interior design, specializing in the production of kitchen countertops and accessories made of quartzite and other natural stones.
This evolution has been accompanied by significant technological investments, including the introduction of 5-axis bridge saws, waterjet systems, and edge-processing machines, which have significantly increased production capacity, precision, and flexibility.
However, the upgrade of the machinery fleet highlighted an increasingly evident limitation: the water treatment system was no longer able to keep pace with the new production rates.
As the company’s management explains:
“With the new machines and materials, the water treatment system was no longer able to keep up with the pace of production.”
When Water Treatment Becomes a Bottleneck in Production
The previous system initially relied on settling tanks and, later, on filter bag systems. These solutions had supported the company’s growth for years, but over time they began to reveal their limitations.
The time required for clarification was increasing, the volume of sludge produced was growing steadily, and managing its disposal had become complex from both an operational and economic standpoint. The situation threatened to slow down the entire production process.
Natursteine Mulbach therefore decided to evaluate various solutions available on the European market, with a specific goal in mind: to find a system capable of improving performance without requiring invasive changes to the workshop’s organization.
A solution designed to meet the laboratory’s actual needs
After analyzing various alternatives, the choice fell on a monoblock system with a filter press developed by Dal Prete.
What made the difference was not only the proposed technology, but above all the approach to the project. Before the design phase began, a thorough on-site inspection was conducted at the plant to analyze the production process, the available space, and the characteristics of the materials being processed.
This made it possible to develop a fully customized solution capable of integrating seamlessly into the existing layout.
A particularly important aspect concerned the installation of the system inside the production building, a choice made necessary by the significant seasonal temperature fluctuations. The compact design of the Dal Prete system was therefore a fundamental requirement.
“Dal Prete was the only partner that truly analyzed our production process and designed a solution tailored to our needs.”
Better Water Quality, Less Sludge Management
The benefits were immediately apparent. The quality of the clarified water became consistent across all production lines, improving process stability and increasing the laboratory’s overall efficiency.
At the same time, sludge management has also changed completely. The switch from traditional filter bags to a filter press has made it possible to produce dewatered sludge cakes, which are much easier to handle, store, and dispose of.
The entire process has become more organized, cleaner, and easier to control, reducing the time spent on ancillary tasks and improving working conditions for operators.
“The difference was evident right from the start: we went from a complex process to a clean, controlled, and efficient system.”
A 70% reduction in water consumption
One of the most significant achievements is the reduction in water consumption.
Thanks to the new system, Natursteine Mulbach has reduced its use of fresh water by 70%, supplementing the remaining demand with rainwater already collected on-site.
This result has strengthened the company’s sustainability strategy, demonstrating how proper water cycle management can generate tangible benefits from both an environmental and a production standpoint.
The system’s high level of automation has also simplified day-to-day plant management. Continuous monitoring of key operating parameters, supported by an automatic alarm system, allows for prompt intervention in the event of anomalies, reducing the need for constant checks by operators.
In the years following installation, further improvements were introduced, including automatic pH control systems and specific chemical treatments for corrosion protection of the machinery, helping to further increase the reliability of the entire plant.
Water Treatment as a Strategic Investment
The experience of Natursteine Mulbach demonstrates that a water treatment plant should not be viewed merely as a utility, but as a strategic component of the entire production process.
The benefits extend beyond mere cost savings to include the quality of workmanship, production continuity, operator management, and environmental sustainability.
As the company’s management concludes:
“The benefits aren’t immediately measurable in financial terms, but the improvement in water quality and production efficiency is evident from day one.”
The project carried out by Dal Prete has transformed an element that was previously an operational limitation into a reliable, automated system that is perfectly integrated with the company’s production needs. This is a concrete example of how a custom-designed solution can help improve the efficiency and competitiveness of a modern stone workshop.
