Hi, I'm Terry O.. I live in California. 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 over 15 million American households rely on private wells for their water supply, and nearly 25% of them struggle with iron contamination?
I certainly didn't realize how common this problem was until I found myself dealing with rusty, metallic-tasting water that was staining everything in my home orange-brown. After months of research and a somewhat bumpy start with shipping damage, I finally got the Iron Master AIO installed and running. What I discovered over the past eight months of ownership has completely transformed my relationship with our well water.
The journey wasn't without its challenges—the first unit arrived cracked from what I assume was a fall during shipping, which delayed my installation by two weeks. But once the replacement arrived and I got it properly installed, the results have been remarkable. We now have noticeably softer water throughout our home, and those stubborn iron stains that plagued our sinks, toilets, and laundry are finally gone.
The Iron Problem That Drove Me to Find a Solution
Living in California's Central Valley with well water seemed like a dream until the reality of iron contamination hit home. Our water tested at 4.2 parts per million (ppm) of ferrous iron—well above the EPA's secondary standard of 0.3 ppm. The impact was everywhere: orange-brown stains coating our toilet bowls, rust-colored rings in the bathtub, and laundry that came out looking dingy despite using premium detergents.
The metallic taste was the final straw. Coffee tasted terrible, and my wife refused to drink water straight from the tap. We were spending $80 monthly on bottled water, which felt ridiculous given that we had our own well. The iron wasn't just an aesthetic problem—it was affecting our quality of life and our budget.
I initially tried a basic sediment filter thinking it might help, but iron filtration requires specialized treatment. Ferrous iron (dissolved iron) can't be filtered out with simple mechanical filtration. It needs to be oxidized first, converting it to ferric iron particles that can then be trapped and removed. This is where air injection systems like the Iron Master AIO come into play.
Our local water treatment dealer quoted me $3,200 for a similar system, which seemed excessive. After researching the technology and reading dozens of reviews, I decided to go direct with SoftPro's Iron Master AIO, which promised the same air injection oxidation process at a more reasonable price point.
Research Phase: Understanding Air Injection Technology
Before committing to any system, I spent considerable time understanding how iron filtration actually works. The Iron Master AIO uses air injection combined with Katalox Light media—a relatively new filtration technology that's gaining popularity in the industry.
Here's how it works: The system automatically injects compressed air into the water stream, which oxidizes dissolved ferrous iron into filterable ferric iron particles. These particles are then trapped by the Katalox Light media, which acts as both an oxidizing agent and a filter medium. The system backwashes automatically to flush out accumulated iron particles and regenerate the media.
What sold me on this particular approach was its ability to handle multiple contaminants simultaneously. Beyond iron removal, the Katalox Light media also addresses hydrogen sulfide (that rotten egg smell), manganese, and even some arsenic—all common well water issues in our area.
The Iron Master AIO is rated for flow rates up to 7 GPM and can handle iron levels up to 10 ppm, making it suitable for most residential applications. The system includes a Fleck 5600SXT control valve, which is considered the gold standard in water treatment controls, known for reliability and precise backwash timing.
Capacity-wise, the system can treat up to 500,000 gallons before media replacement is needed, which translates to roughly 5-7 years of service life for an average household. This long service interval was appealing compared to systems requiring frequent cartridge changes.
The Shipping Disaster and Replacement Experience
This is where my experience took an unexpected turn. The first Iron Master AIO arrived with a significant crack running down the side of the fiberglass tank. The damage was clearly visible through the packaging, and I suspect it occurred during shipping transit. These units weigh about 85 pounds when packaged, so rough handling can definitely cause problems.
I documented the damage with photos and contacted SoftPro's customer service immediately. To their credit, they didn't hassle me about the return or try to claim it was my fault. The representative was apologetic and arranged for a replacement to be shipped within three business days. They also provided a prepaid shipping label for the damaged unit return.
The replacement process took about two weeks total, which was frustrating since I'd already scheduled time off work for the installation. However, the second unit arrived in perfect condition with extra padding around the tank. SoftPro clearly learned from the first shipping experience.
One thing I appreciated was that all components were individually wrapped and protected. The control head, tank, media, and plumbing fittings each had their own protective packaging. The installation manual was comprehensive, though I did find myself referencing online videos for some of the more technical aspects.
Installation Process: Smoother Than Expected
With the replacement unit in hand, I tackled the installation on a Saturday morning. I'm reasonably handy with plumbing projects, though I did consider hiring a professional given the complexity. The Iron Master AIO requires several connections: incoming water line, treated water outlet, drain line for backwashing, and electrical for the control valve.
The most challenging aspect was creating space in our utility room and establishing the drain connection. The system backwashes automatically every 3-5 days, sending approximately 30 gallons of iron-laden water to drain. I had to run a new 3/4" drain line about 15 feet to reach our laundry sink.
Plumbing connections were straightforward with the included bypass valve assembly. The system comes with 1" NPT connections, which I adapted to our existing 3/4" copper lines using standard fittings available at any hardware store. Everything aligned properly, and I didn't encounter any fitment issues.
Programming the Fleck 5600SXT control head was initially intimidating—there are multiple settings for backwash frequency, duration, and flow rates. However, SoftPro includes a pre-programmed settings sheet specific to the Iron Master AIO, so I simply followed their recommended configuration. The entire process took about 4 hours, including time to pressure test all connections.
Initial startup involved a 30-minute backwash cycle to settle the Katalox Light media and remove any shipping dust. The water ran dark brown initially, which was expected, then gradually cleared. After the startup sequence, we had to wait about 2 hours before using the treated water to allow the system to stabilize.
Performance Results: Measured Improvements
The transformation was noticeable within 24 hours. Our water went from a metallic taste and slight discoloration filter for iron to clear, odorless water that actually tasted good. I conducted before-and-after testing using a TDS meter and iron test strips to quantify the improvements.
Pre-filtration measurements showed iron levels at 4.2 ppm, with total dissolved solids around 320 ppm. Post-installation testing revealed iron levels below 0.1 ppm—well within EPA guidelines. The TDS reading dropped to 295 ppm, indicating the system was removing more than just iron.
The most dramatic change was in our appliances and fixtures. Within a week, existing iron stains began loosening and washing away. Our toilet bowls, which had permanent-looking orange rings, gradually returned to their original white. The dishwasher started producing spot-free dishes without rinse aid, and our coffee maker stopped developing that brown mineral buildup.
Laundry results were equally impressive. Whites stayed white, and colored clothing maintained their vibrancy instead of taking on that dull, iron-stained appearance. We eliminated the need for iron-removing laundry additives, which were costing us about $15 monthly.
Water pressure remained consistent throughout the home, even during the system's backwash cycles. The Fleck control valve is designed to maintain service flow during regeneration by using the bypass temporarily, so we never experienced interruptions.
After six months of operation, I retested the water quality and found iron levels still below 0.1 ppm, confirming the system's continued effectiveness. The automatic backwash cycles have been running like clockwork every three days, indicating the system is processing a significant amount of iron.
Operating Costs and Maintenance Reality
One aspect I carefully tracked was the ongoing operational expenses. The Iron Master AIO uses minimal electricity—about $3-4 monthly based on our utility rates. The control valve operates on 120V AC and only draws power during backwash cycles and for the timer display.
Water consumption for backwashing averages 30 gallons every three days, totaling about 300 gallons monthly. At our local water rates (we're on municipal backup), this represents roughly $8 monthly in additional water costs. However, since we're primarily on well water, the actual cost is minimal.
The major expense will be media replacement, estimated at 5-7 years depending on iron loading and water usage. Katalox Light media replacement costs approximately $180-200, making the annual media cost around $30-35. This compares favorably to cartridge-based systems requiring $150-200 in annual filter replacements.
We eliminated our $80 monthly bottled water expense immediately, creating a net monthly savings of about $65. The system has essentially paid for itself in improved water quality and eliminated bottled water costs within the first year.
Maintenance requirements are minimal. I check the system monthly to ensure backwash cycles are running properly and occasionally test iron levels using inexpensive test strips. The Fleck control valve tracks cycle counts and can alert to any operational issues, though we haven't experienced any problems.
Salt or chemical additions aren't required—the air injection and Katalox media handle oxidation and filtration without consumable additives. This was a major advantage over some iron removal systems that require potassium permanganate or chlorine injection.
Real-World Daily Life Impact
Beyond the measurable improvements, the Iron Master AIO has transformed our daily experience with water. My wife no longer complains about the taste when making coffee or tea. Our guests have commented on the improved water quality, particularly those familiar with our previous iron issues.
Cleaning became significantly easier. Bathroom fixtures stay cleaner longer without constant iron stain removal. Our shower doors, which previously required weekly iron removal treatments, now stay clear with normal cleaning. The time saved on deep cleaning iron stains amounts to several hours monthly.
Our water heater is operating more efficiently without iron sediment accumulation. Iron particles were previously settling in the tank bottom and reducing heating efficiency. The annual water heater flush now produces clear water instead of rust-colored sediment.
Soap and detergent performance improved dramatically. We reduced laundry detergent usage by about 25% while achieving better cleaning results. Dish soap lathers properly now, and we eliminated the need for specialized iron-removing cleaning products.
Surprisingly, our skin and hair condition improved. Iron in water can cause dryness and irritation, though I hadn't connected these issues to our water quality. Both my wife and I noticed softer skin and more manageable hair within weeks of installation.
The automatic operation is seamless. We hear the backwash cycle running occasionally—a gentle humming sound lasting about 15 minutes—but it's not disruptive. The system handles everything automatically without any intervention required.
Honest Assessment: What Could Be Better
While overall satisfied, the Iron Master AIO isn't without limitations. The initial shipping damage, though handled professionally by SoftPro, highlighted potential concerns about packaging and freight handling. These units are heavy and require careful shipping practices.
Installation space requirements are significant. The 10" diameter tank stands about 54" tall, requiring substantial floor space and ceiling clearance. Our utility room could accommodate it, but smaller spaces might struggle. The drain line requirement also limits installation locations.
The backwash cycle consumes considerable water—about 30 gallons every three days. For households on expensive municipal water or those with well capacity concerns, this ongoing water usage might be problematic. The cycle timing isn't adjustable based on actual iron loading, so it runs on a fixed schedule regardless of demand.
Initial water waste during startup was substantial. The first few backwash cycles and media conditioning process consumed nearly 100 gallons before producing quality treated water. This isn't unique to this system, but it's worth considering for drought-prone areas.
The control valve programming, while ultimately straightforward, could be more user-friendly. The digital display requires cycling through multiple screens to access different functions, and the manual could be clearer about customization options. I found myself relying on online resources for some adjustments.
Katalox Light media replacement will eventually require professional service or significant DIY effort. The media weighs about 50 pounds and requires proper handling during replacement. This isn't a simple cartridge change that most homeowners can handle independently.
The system doesn't address water hardness, so we still deal with calcium and magnesium scale formation. A separate water softener would be needed for comprehensive water treatment, adding complexity and cost to the overall system.