Photos by Billy DelfsAvon Lake Regional Water is in the midst of a $32 million overhaul of its water filtration plant, which includes replacing aging infrastructure and modernizing its chemical treatment operations.
The multi-phase project, supported through two low-interest loans from the Ohio Water Development Authority (OWDA), is slated for completion within the next year.
The most visible change: replacing 12 filters with four high-capacity units capable of restoring full treatment capacity while simplifying maintenance.
“These being attached to the current filters puts them right next to where everything else is,” said Greg Yuronich, Chief of Utility Operations. “It makes it kind of a smaller environment that they have to cover, maintaining everything.”
The upgrade also includes a complete overhaul of chemical feed systems, most of which were installed during a 1980 plant expansion.
These systems are being replaced with modern, peristaltic feed systems for improved metering precision.
Key to the renovation is the transition from chlorine gas disinfection to liquid sodium hypochlorite, a move driven by operator safety.
“[Chlorine systems], with proper maintenance, are very safe, but there is an inherent risk that something could go wrong,” said Plant Manager Jason Gibboney.
Since sodium hypochlorite bleach works equally as well for treating the water, it was an easy decision to make the switch from a safety perspective.
As they transition, there will be some trial and error with the calibration of pumps.
“There will definitely be a timeframe where we’re actively still using gas and also starting to use the bleach on limited timeframes just to make sure the system works as it should,” Gibboney said.
Yuronich noted that initially, during this trial period, they fill the tanks with drinking water rather than chemicals.
“Just in case there was some sort of error with the setup, [like] it was pumping at a much higher dosage than you were expecting — with an inner stand-in of drinking water, you’re not going to affect the water quality in any way, but you get a good idea of how that equipment’s going to react under different flows, different dosages, and it’s the much safer way to test those new systems out,” he said.
“Once we get that ironed out, then we’ll transition more on a permanent basis over to the bleach, and then pick a time to use all of our remaining gas,” Gibboney added.
To support the new chemical systems, the plant is constructing a dedicated storage building that will triple on-site capacity for critical inputs like aluminum sulfate (their most frequently used chemical) and powder activated carbon (PAC).
Bringing storage closer to application points will improve operational reliability and reduce the risk of disruptions from delivery delays.
“Currently, that system and many others sit nearly a football field or more away from where they’re actually dosed,” Gibboney noted. “Now it’ll be about 100 feet.”
Not to mention, there’s been more of a demand for certain chemicals in recent years, so being able to keep a bigger stock on site will relieve supply chain stress.
Yuronich cites carbon as a good example of this. “In 1980, carbon was used mostly for taste and odor removal on an as-needed basis,” he said.
Now, with harmful algal blooms and the possibility of algal toxins being introduced, the demand for carbon has sharply increased.
“The capacity that we had to store [carbon] on site was barely sufficient for one truckload. So the timing of those chemical deliveries was very stressful at times,” Yuronich said.
“Having additional storage for those chemicals, specifically carbon, is just going to be a huge improvement as far as preparedness,” he added, “as it allows us to hold a much larger chemical reserve between deliveries.”
The vast majority of chemicals will be stored in the newly constructed building. However, a portion of the old storage building will be repurposed for a lime slurry system to be installed.
Demolition of older plant buildings will begin once the new systems are completely ready.
While the water tower built in 1964 and the mixing and chemical building original to 1926 will be razed, Avon Lake hopes to repurpose the historic administrative and filter building into a brick-and-mortar training center for water and wastewater operators.
“With the original structure approaching 100 years next year, we wanted to preserve it,” said Chief Utilities Executive Robert Munro. Not only is it a community focal point for its yearly Christmas decorations, “it’s where we started,” he said.
“It would be kind of a first of its kind, at least in our area,” said Munro. “Having an actual classroom setting dedicated to water and wastewater, but also having an active working water filtration plant right next door, and just down the road, a water reclamation facility.”
“That’s a need in our sector, finding qualified licensed operators. So that’s kind of the hope,” he said, cautiously optimistic that the state will provide some funding toward workforce development.
Munro has already spoken with the executive director of OTCO (the Operator Training Committee of Ohio), a nonprofit dedicated to recruiting and training the next generation of professionals in the water sector, and “they’re very much on board with trying to establish something,” he said.
Although Northeast Ohio has some certificate programs at local colleges, Munro views the specialized, on-the-job type training they could offer in this space as a massive opportunity for professional advancement.
As plans for future training take shape, the utility remains focused on completing the plant improvements on time and on budget.
The project is being delivered by Great Lakes Construction, selected through a competitive bidding process. Although initially delayed by more than a year as they worked through nuances with the Ohio EPA, construction is now advancing on schedule.
Most of the new chemical systems are expected to come online within six to nine months, with final grading and seeding extending into late 2026.
From a financial perspective, the utility structured the OWDA loans with deferred payments until project completion and secured a quarter-percent rate discount thanks to its strong borrower history, resulting in a rate comparable to what they could get on a bond.
“The way things lined up, the timing was pretty good on this project. We are retiring some debt, so with that debt service coming off our books, there will be minimal impact to customer rates,” Munro said.
He added that Avon Lake’s reserve funds exceed state and national benchmarks, and the utility has not raised consumption rates in years.
Munro has explored alternative financing options like WIFIA (the Water Infrastructure Financing Investment Act) for future projects, but said, “For now, OWDA is working real well for us.”
Long-term, the filtration upgrades position the utility for greater regional collaboration and future system expansion.
Avon Lake provides wholesale water to multiple surrounding communities and is planning an additional 10 to 15 million-gallon capacity expansion.
Although a large portion of a $67 million grant from the All Ohio Future Fund will go toward the sewer side of operations, some will go toward the design of that capacity expansion.
“It’s going to be easement acquisition, maybe property acquisition design at the water filtration plant, design at our bulk customer, Rural Lorain County Water Authority — their pump station, their transmission main to get the water to the megasite, our transmission main to get it from the plant to their pump station,” Munro said. “All of those designs, preliminary designs and detailed designs.”
Another project on deck is the 2-year, $17 million 2025 Water Bundle Project, which includes installing new water mains across 23,000 linear feet, enhancing stormwater infrastructure, and upgrading and restoring roads.
Yuronich said they do a water bundle project every couple of years, analyzing the infrastructure within Avon Lake.
“Where are we seeing increases in water breaks? Where is there a need for additional pressure capacity? Planning ahead and staying current with all those things, even though you’re still spending money, it helps keep the cost of those improvements down by being able to plan them out,” he said.
Avon Lake has also been in talks with its bulk customers to identify improvements to the ETLs (eastern transmission lines).
“I think we have a great group of bulk partners. They’re customers, but quite frankly, they’re partners in this with us. We’re all benefitting from this consortium that we have,” Munro said.
Munro predicts that eventually neighboring water facilities will outgrow their current footprints. When this happens, collaboration will be crucial.
Smaller plants will likely face regulatory requirements and upgrades they can’t afford, and find Avon Lake’s model of providing bulk water to be mutually beneficial.
“We see that all of our bulk customers benefit from a low water rate, availability, and providing [bulk water] with a high level of service,” Munro said.
“Let’s leverage those economies of scale for everyone’s benefit. I think that’s where you’ll see a lot of future collaboration,” he added.
Still, Munro emphasized the importance of internal decision-making when it comes to system investments.
Munro’s advice to other utilities is straightforward: “Don’t defer. Do not defer.”
Understanding it’s unpopular to raise rates, “One way or another, the infrastructure is going to have to be upgraded, improved,” he said.
He pointed to Prichard, Alabama, a suburb of Mobile, as an example of what can happen if systems aren’t upgraded over time. In 2023, Prichard Water was placed in a receivership with a judge ordering improvements to be made.
Gibboney also stressed the value of being proactive, particularly with social media being so prevalent now.
“There’s really no patience for failure and outages, especially with power and water. People take to [social media] the moment the tap isn’t running. So replacing ahead of failure is the key,” he said.
These aren’t just local lessons. Avon Lake’s experience underscores what it takes for utilities to stay ahead of aging infrastructure: planning early, investing consistently, and prioritizing safety and service reliability.
By combining smart asset management, proactive safety planning, and long-term vision, Avon Lake Regional Water serves as a model for mid-sized utilities modernizing their aging systems while holding the line on rates.
