Dilution Control 101: The Risks of Under-Dilution and Over-Dilution

May 11, 2023

A large part of facility maintenance and commercial cleaning is the everyday use of hazardous chemicals.

Many people may be unaware of how dangerous working with chemicals can be because they use them daily to complete a range of mundane tasks. However, the reality of the situation is that each year, there are 50,000 workplace deaths related to chemical exposures.

Aside from workplace deaths, there are several risks associated with the improper use of chemicals, such as eye injury, respiratory damage, and severe burns. Part of the issue is that there isn’t enough industry-wide emphasis on the safe handling of ready-to-use chemicals and proper chemical dilution for chemicals that require it.

Ensuring proper guidelines are followed when diluting chemical solutions can ensure a clean, sanitary, and safe workplace for your workers and other building occupants.

If you’re eager to learn more about the importance of dilution control and the risks surrounding improper dilution control, continue reading!

What is Dilution Control?

Dilution control is the process of taking highly concentrated chemical products and diluting them with water to create a ready-to-use solution.

Whether disinfectants or cleaners, all concentrated chemicals require proper dilution to function as intended.

What is an Under-Diluted Chemical Solution?

An under-diluted chemical solution is a solution that has a lower ratio of water than the manufacturer recommends. In other words, an under-diluted chemical solution is actually too strong.

What is an Over-Diluted Chemical Solution?

An over-diluted chemical solution is a solution that has a higher ratio of water than the manufacturer recommends. Seemingly contradictory, an over-diluted chemical solution is actually too weak.

Methods for Chemical Dilution

There are two methods used for dilution: manual dilution and automated dilution.

Manual dilution is when solutions are diluted by hand, whereas automated dilution involves using an automated dilution control system to perform the task of dilution without the need for manual interference.

How to Properly Dilute Chemicals

The proper way to dilute chemicals is to follow the manufacturer’s recommended instructions for dilution. Manufacturers provide detailed guidelines on the ideal dilution ratio, application methods, and safety precautions.

Adhering to these instructions ensures optimal cleaning results while maintaining safety standards.

You can also choose to invest in an automated dilution control system. These systems virtually eliminate the risk of improper chemical dilution and many of the safety concerns associated with chemical mixing.

One of the main reasons you’d want to use an automated dilution control system is to prevent staff from improperly diluting solutions. When improper chemical dilution occurs, it’s either over or under-diluted. Either of these options can lead to poor cleaning results, wasted time and resources, and most importantly unsafe working conditions.

Now, let’s take a closer look at some of the risks involved with under-dilution and over-dilution.

Risks of Under-Dilution

Under-diluted chemical solutions have high concentrations of a chemical’s active ingredient, which can be a problem.

Here are five risks of under-dilution:

Ineffective Product Outcomes
Increased Time and Effort
Lackluster Appearances
Increased Likelihood of Surface Damage
Increased Health Risks

Let’s break each one down.

1. Ineffective Product Outcomes

Solutions that contain a high amount of the chemical’s active ingredient are likely to negatively affect the solution’s effectiveness.

With cleaning chemicals, for example, oftentimes, a residue is left behind if the solution is under-diluted. When this happens, the surface with chemical residue will attract more dirt, soil, and grime. That means the surface can appear even dirtier after cleaning it than it did before.

A higher concentration of active chemicals and additional dwell time can even damage the surface.

As a result, the cleaning solution cannot effectively clean any surfaces without risking making those surfaces damaged or dirtier in the long run.

With disinfectant chemicals, it’s more serious.

Under-diluted chemical solutions in this scenario are not more effective. If a disinfectant has a set dwell time, you cannot shorten it by mixing a stronger solution. Also, keep in mind that doing so is a violation of federal law. Additionally, disinfectant residue can cause skin injuries and irritation issues for people who come in contact with overtreated surfaces.

As a result, the disinfectant creates a degree of risk to cleaning staff who come in contact with the surface.

2. Increased Time and Effort

Staff will have to spend more time and effort recleaning the same surfaces.

This is a result of residue left behind after cleaning. It will quickly attract dirt and grime, leading cleaning staff to clean more frequently.

This is especially true if staff don’t realize that the problem is with the under-diluted chemical solution. They will continue to use the same solution to reclean the same surfaces, wasting time and effort without seeing better results. Additionally, the chemical products will run out faster than if diluted properly, wasting money.

3. Lackluster Appearances

Lackluster appearances, even with the increased investment in cleaning time, have the potential to affect how customers and staff view your facility.

The appearance of a facility is one of the first things that leaves an impression on customers. Poor appearances can lead to customer dissatisfaction, jeopardizing your company’s reputation. Additionally, staff like to work in a clean and presentable environment. Without that, it can affect their attitudes about working for your business.

Falling short of maintaining a clean appearance not only adversely impacts the staff and customer experience but also can influence your standing within the industry.

4. Increased Likelihood of Surface Damage

As mentioned previously, beyond poor appearances, an under-diluted chemical solution can cause damage to the surface it’s meant to clean.

This happens when the active ingredients of harsh chemicals come into contact with the surface. An under-diluted chemical solution can cause corrosion, discoloration, or structural damage depending on the surface.

This emphasizes the importance of selecting the right dilution ratio for the job and choosing the right chemical solutions for the right surface material.

5. Increased Health Risks

An under-diluted chemical solution can also pose serious health risks to the staff who use it and other building occupants.

Remember that under-diluted chemical solutions have a higher concentration of the chemical’s active ingredients. When diluted properly, chemical solutions that don’t require personal protective equipment (PPE) may require PPE in their highly concentrated forms.

Depending on how the solution is used, it can also adversely impact the indoor air quality of the area and/or facility. Even if using the chemical doesn’t require PPE, the room or environment may.

Employees will have no way of knowing that they should have PPE equipment because they’re assuming that the solution is properly diluted. As a result, they unknowingly risk skin irritation or respiratory problems, among other health issues.

Risks of Over-Dilution

You may be wondering, “If using an under-diluted chemical solution is so bad, would it be better to use an over-diluted chemical solution?” The answer is no; both are bad and come with their own set of risks.

Here are three major risks of over-dilution:

Reduced Effectiveness
Wasted Time and Resources
Increased Safety Risks

Let’s break each of them down.

1. Reduced Effectiveness

It should come as no surprise that over-dilution leads to weak chemical solutions.

Weak solutions are bad because they compromise the quality of the cleaning, disinfection, or other purpose behind the chemical solution. This happens because there isn’t a high enough concentration of the chemicals and active ingredient, which is meant to do most of the heavy lifting in a solution.

Lower quality cleaning means surfaces aren’t getting effectively cleaned, meanwhile, lower quality disinfection means that the solution may be incapable of targeting the microorganism it’s designed to eliminate. It also means the chemical and its associated cost are wasted.

2. Wasted Time and Resources

Due to the reduced effectiveness of an over-diluted chemical solution, the first attempt at cleaning or disinfection will prove ineffective.

When this happens, cleaning staff must re-clean or disinfect the same surface again. They could clean it several times before realizing the chemical solution is the issue.

Cleaning staff then find themselves compelled to invest more time and resources to achieve the desired level of cleanliness. This not only increases the associated labor costs but also consumes more cleaning supplies in the process.

3. Increased Safety Risks

Over-diluted chemical solutions tend to lead to increased safety risks.

Cleaning solutions, for example, will leave slippery residue behind on the surface they clean.

This has the potential to pose serious safety risks, such as leaving behind slippery surfaces that increase the likelihood of slips and falls. Alongside safety concerns, this also creates undue exposure to legal liabilities for your business.

Disinfectant solutions, on the other hand, may no longer provide their stated efficacy. Without proper disinfection, high touch points will grow and cross-contamination will go unchecked, leading to an increase in the spread of workplace illnesses. Without proper, responsible disinfection, the health of your facility and all who enter it may be in jeopardy.

Final Thoughts

Understanding dilution control is critical for safe and effective chemical management.

Whether you choose manual dilution or to install in an automated system, the goal is to ensure precise dilution for optimal cleaning results and the well-being of staff and building occupants.

If you’re interested in an automated dilution control system or want more insights into dilution control, reach out to an Imperial Dade facility near you. Schedule a free consultation with one of our Chemical Specialists, who is available to perform a comprehensive evaluation of your facility in order to best address your chemical management needs.