Founded in 1986, Gaffey Technology has evolved from a regional service provider to a globally recognized OEM specializing in smart, sustainable water disinfection technologies. The British company designs, manufactures, and distributes on-site electrochemical systems that eliminate the need for dangerous chemicals. Their Hyprolyser® systems generate sodium hypochlorite on-demand from salt, water and electricity, while chloriDOS® units precisely blend and dose chlorine dioxide; unique fail-safe vacuum operation and exact volumetric reagent and dilution management render it particularly suitable for achieving high chemical efficiency whilst optimising efficacy of the water treatment biocidal process.

Gaffey Technology looked into the future and decided to take control.

Gaffey wanted full ownership of their software and system logic —Gaffey Technology’s water disinfection systems were originally developed using a combination of proprietary PCB hardware and outsourced programming, according to Gaffey’s requirements.

Their goals were clear:

• In-house software development under Gaffey’s complete control
• Self-regulating disinfection processes that adapt to challenging environmental conditions
• Continuous, autonomous operation to reduce manual intervention and downtime
• A control platform that could integrate easily into product lines—and be easily, remotely modified
• Remote accessibility for monitoring, diagnostics, and troubleshooting using:
  • VNC to access the systems’ HMI application
  • MQTT to communicate with their newly-developed proprietary IoT platform.
• A robust, standards-compliant PLC capable of handling high-speed I/O, analog processing, and secure connectivity

The ideal controller would need to deliver industrial-grade performance with flexibility for custom development—and be compact enough to retrofit existing equipment.

After reviewing Gaffey’s requirements, Ainsley Sawicz of LED Controls, Gaffey’s long-time supplier of electronic components, recommended Unitronics’ UniStream PLC+HMI, model US5-B5-RA28—an all-in-one controller combining powerful logic, high-speed I/O, a vibrant HMI, and comprehensive communication features.

Using UniStream and the UniLogic® development environment, Gaffey created its proprietary Adaptive Response Technology (ART), a next-generation control architecture now embedded across its Hyprolyser® and chloriDOS® product families.

System Architecture and Control

At the core of ART is the UniStream PLC, serving as the central nervous system of Gaffey’s solutions for monitoring and control.

Control Functions: Programmed in UniLogic

• Temperature regulation: The PLC collects data from PT100 sensors and adapts electrolyser power input and dilution flow to compensate for heat gain from the electrolysis process.
• Flowrate tracking: UniStream’s high-speed counters capture pulse signals at granular resolution—thousands of pulses per liter—to build pulse profiles that enable accurate system function.
• Pressure & level management: Integrated analog I/O ensures real-time control of system pressure and chemical tank levels.
• Dynamic power distribution: ART adjusts power input in response to hydraulic variables, water salinity, and ambient temperature.

HMI—Designed in UniLogic

• Process mimic screens: show current status or readings of flow meters, valves, sensors, cycle times, water pressure, softener capacity remaining and vessel level status.
• Graphical trend views: Live and historical data
• Guided warnings: Operator instructions for fault conditions

• Alarm and history logs: Built-in UniLogic screens for history, acknowledgements, de-rating occurrences, system status changes and basic settings changes—all logged to SD card for compliance and diagnostics
• Service interval calendar reminders.
• Secure user access: Tiered password protection with multilingual interface (6+ languages)

Remote Access & Communication

• UniStream’s built-in MQTT integration: Enables real-time data exchange including temperature, pressure, flow rates, and alarm conditions, facilitating comprehensive system integration and remote monitoring to/from Gaffey’s proprietary IoT platform
• Remote troubleshooting: VNC, Modbus TCP/RTU, and email alerts support distributed service operations
• Post-sale flexibility: OEM partners and technicians can access system diagnostics or implement updates remotely

Backed by UniStream controllers, and with LED Controls’ robust stock levels and fluid supply chain meeting growing demand, Gaffey’s Adaptive Response Technology redefines what's possible in water disinfection. It dynamically compensates for variable conditions—seasonal water temperature shifts, inconsistent supply pressure, and complex installation environments—ensuring consistent disinfection performance with minimal human intervention.

By replacing legacy hardware with smart, software-defined PLCs, Gaffey has delivered:

• Increased system uptime
• Improved disinfection safety and reliability
• Lower operational costs
• A future-proof platform

Gaffey’s integration of Unitronics’ UniStream platform is a prime example of how automation professionals can pair intelligent control systems with precision electrochemistry to solve today’s water quality challenges. ART demonstrates how advanced PLC technology doesn’t just automate processes—it transforms them.

Ainsley Sawicz, Sales Manager, LED Controls , said:

“At LED Controls, we pride ourselves on forming lasting connections – and not just electronically! It’s been a pleasure and a privilege to help a booming family business like Gaffey by partnering with Unitronics to provide the perfect equipment to realise their vision.”

Phil Gaffey, Managing Director, Gaffey Technical Services , reported:

“UniStream filled all of our requirements—PLC control, high-speed and analog I/O, HMI screens, and IoT communication—and enabled us to develop an industry first: autonomous Adaptive Response Technology for water disinfection.”