Hi, I'm Ron T.. I live in Ohio. Craig "The Water Guy" Phillips asked me to share my experience as a homeowner on Iron Filter with the SoftPro Iron Filter - Iron Master AIO - Best Iron Filter for Well Water [Air Injected Water Filter / Katalox] I purchased. This is how my adventures played out. I hope this helps you in your decision.
Did you know that high iron content in well water can turn a simple home improvement project into a $10,000 nightmare?
That's exactly what I discovered when I started researching iron filtration systems for my Ohio well. What began as a quest to eliminate rusty stains and metallic taste turned into an eye-opening journey through the complex world of water treatment. After six months of using the SoftPro Iron Master AIO system, I'm sharing my complete experience – the good, the challenging, and everything in between.When I first contacted water treatment companies about my iron problem, two separate contractors told me my iron levels were "too high" for their systems to handle effectively. They quoted me prices exceeding $10,000 with no guarantee their equipment would work for more than a year. That's when I discovered SoftPro Water Systems and their Iron Master technology.
The Iron Problem That Started It All
Living with well water in Ohio, I thought orange stains on my fixtures were just part of rural life. My water had a distinct metallic taste, and within weeks of moving in, every white surface in my bathroom looked like it hadn't been cleaned in years. The iron content in my well tested at 8.2 parts per million (ppm) – significantly higher than the EPA's recommended maximum of 0.3 ppm for aesthetic purposes.
The problems went beyond cosmetics.
My coffee maker developed internal scaling within three months. The dishwasher left orange spots on glassware that required hand-scrubbing with CLR. Most frustrating was watching my brand-new washing machine struggle with iron deposits that turned white clothes into dingy, rust-stained laundry.
Iron in well water occurs naturally when groundwater passes through iron-bearing rocks and soil. In Ohio's geology, ferrous iron (dissolved iron) is particularly common. This clear, dissolved iron becomes ferric iron (rust) when exposed to oxygen, creating the visible orange staining and metallic taste I experienced daily.
Before discovering the Iron Master, I tried several DIY solutions. Water softener salt additives provided minimal improvement. A basic sediment filter captured some visible rust but did nothing for dissolved iron. Bottled water for drinking became expensive quickly, and it didn't solve the household fixture problems.
Research Phase: Why I Chose the Iron Master Technology
After those discouraging $10,000 quotes, I dove deep into iron filtration research. I learned that effective iron removal requires oxidation – converting dissolved ferrous iron into filterable ferric iron particles. The Iron Master AIO (All-In-One) system uses air injection oxidation combined with Katalox media filtration.
Here's what convinced me this technology was right for my situation:
Air Injection Oxidation: Instead of chemicals, the system injects air into the water stream. Oxygen naturally oxidizes ferrous iron into ferric iron particles that can be filtered out. This process handles iron levels up to 30 ppm – far exceeding my 8.2 ppm problem.
Katalox Light Media: This German-engineered filtration media combines mechanical and catalytic filtration. Unlike traditional media that just traps particles, Katalox actually catalyzes the oxidation process, making iron removal more efficient and extending media life.
Single Tank Design: The AIO configuration eliminates the need for separate oxidation and filtration tanks. This saved space in my utility room and reduced the complexity of installation and maintenance.
I compared this to other technologies like chemical oxidation (requires ongoing chlorine or potassium permanganate), greensand filtration (needs frequent regeneration), and traditional aeration systems (multiple tanks, more complexity). The Iron Master's simplicity and chemical-free operation aligned with my preferences for low-maintenance, environmentally conscious solutions.
Unboxing and First Impressions
The Iron Master arrived on a standard freight truck in professional packaging. The main tank measured 10 inches in diameter and 54 inches tall – smaller than I expected based on the system's capacity. Build quality immediately impressed me: the fiberglass tank felt substantial, and the Fleck 5600SXT control valve had the mechanical precision of industrial equipment.
Inside the box, I found:
- Pre-loaded Katalox media tank
- Digital control head with clear LCD display
- Installation manual with detailed diagrams
- Bypass valve assembly
- Air injection venturi and check valve
- All necessary fittings and connections
The documentation quality stood out. Unlike generic manuals, SoftPro's installation guide included specific instructions for the Iron Master configuration, troubleshooting charts, and maintenance schedules. The Fleck valve programming instructions were particularly detailed – important since this controls the entire filtration and backwash cycle.
One pleasant surprise: the system arrived with media pre-loaded and the control valve pre-programmed for typical iron filtration applications. This eliminated the messy process of loading filtration media and reduced setup complexity.
Installation Experience and Setup Process
I chose professional installation through SoftPro's network, and I'm glad I did. The technician arrived with specialized tools and immediately assessed my plumbing configuration. My well pump delivers water at 55 PSI through 1-inch copper lines – adequate pressure and flow for the Iron Master's requirements.
The installation process took approximately four hours:
Hour 1: Plumbing assessment and bypass valve installation. The technician installed a three-valve bypass system that allows complete system isolation for maintenance while maintaining household water supply.
Hour 2-3: Main system installation and air injection setup. The air injection venturi mounts before the control valve, drawing atmospheric air into the water stream. A check valve prevents backflow, and the air release valve eliminates excess air after oxidation.
Hour 4: Programming, startup, and testing. The Fleck 5600SXT required programming for my specific water conditions: 8.2 ppm iron, 15 grains per gallon hardness, and household water usage patterns. Initial backwash cycles removed any installation debris.
The technician explained the backwash process: every three days (adjustable based on iron levels), the system automatically reverses water flow, lifting trapped iron particles from the Katalox media and flushing them to drain. This regeneration cycle consumes approximately 80 gallons and takes 45 minutes.
Installation challenges were minimal but worth noting. My utility room required a floor drain for backwash discharge – something to consider if your setup lacks adequate drainage. The system also needs a standard 110V electrical outlet for the control valve operation.
Performance Testing and Real-World Results
Within 24 hours of installation, I noticed the first improvements. The metallic taste disappeared completely from drinking water. Within a week, new staining stopped appearing on fixtures, though existing stains required manual cleaning to remove.
I conducted formal testing at one week, one month, and six months post-installation:
Week 1 Results:
- Incoming iron: 8.2 ppm
- Filtered iron: 0.1 ppm
- Reduction: 98.8%
One Month Results:
- Incoming iron: 8.1 ppm (seasonal variation)
- Filtered iron: 0.1 ppm
- Reduction: 98.8%
Six Month Results:
- Incoming iron: 8.4 ppm
- Filtered iron: 0.2 ppm
- Reduction: 97.6%
The slight decrease in efficiency at six months falls within normal parameters for Katalox media. Annual media replacement is recommended for iron levels above 5 ppm, so this performance trajectory aligns with expectations.
Beyond iron removal, I discovered unexpected benefits. The system also reduced hydrogen sulfide (rotten egg smell) that occasionally affected my water. Turbidity (cloudiness) improved significantly, and overall water clarity became crystal clear.
Appliance Impact: My coffee maker operates without scaling issues. The dishwasher produces spot-free glassware without rinse aids. Most importantly, white laundry stays white, and my washing machine shows no signs of iron accumulation after six iron water filter whole house months of use.
Daily Living Impact and Household Benefits
The transformation in daily routines surprised me more than the technical performance numbers. Bathroom cleaning became dramatically easier – no more scrubbing orange stains from toilets, sinks, and shower surfaces. My wife noticed her hair felt softer and less dry after removing the iron content.
Kitchen Improvements: Cooking with iron-free water enhanced food flavors, particularly in tea and coffee preparation. Ice cubes became crystal clear instead of cloudy, and pasta water no longer had the metallic taste that subtly affected food flavors.
Cleaning Product Savings: Before the Iron Master, I purchased CLR, Iron-Out, and specialized rust removers monthly. Six months post-installation, I haven't needed any iron-specific cleaning products. Soap and detergent effectiveness improved because they no longer react with dissolved iron.
Seasonal Performance: Ohio's seasonal water table changes affect iron content. Spring runoff typically increases iron levels to 9 ppm, while summer stabilizes around 7-8 ppm. The Iron Master handled these variations without performance degradation or required adjustments.
Unexpected visitor validation: My neighbor, who had been considering water treatment, immediately noticed the difference in water taste and clarity. A plumber servicing my water heater commented on the lack of iron deposits – unusual for wells in our area.
Operational Costs and Long-Term Ownership
Monthly Operating Costs:
- Electricity: $3-4 (control valve operation)
- Water usage: $8-10 (backwash consumption)
- Total monthly: $11-14
Annual Maintenance Costs:
- Katalox media replacement: $180
- Control valve service (recommended): $85
- Total annual: $265
Cost Analysis vs. Alternatives: Compared to bottled water consumption ($60/month for drinking only), the Iron Master pays for itself within 18 months when considering total household water treatment. The system prevented estimated $1,200 in appliance damage and replacement costs over the first year.
Energy Efficiency: The control valve draws minimal power – approximately 15 watts during operation, zero during standby. Backwash cycles occur automatically during low-usage hours (typically 2 AM), minimizing impact on household water availability.
Water Usage: Each backwash consumes 80 gallons over 45 minutes. With backwash every three days, monthly water usage for regeneration totals approximately 800 gallons – significant for well owners monitoring pump runtime and electrical costs.
Hidden savings emerged over time: reduced soap usage (soap works better in iron-free water), eliminated rust stain removal products, and extended appliance lifecycles. My water heater efficiency improved as iron deposits no longer insulate heating elements.
The system offers excellent value compared to whole-house reverse osmosis (higher maintenance, water waste) or ongoing chemical treatment (monthly chemical costs, environmental concerns). For iron-specific problems, the Iron Master provides targeted, efficient treatment without over-processing water for contaminants that don't exist.