Check for a salt bridge first, then verify that regeneration is actually occurring and the brine draw stage works.
Salt bridge
A hard crust can form above an empty cavity in the brine tank, making the tank look full while no salt reaches the water below.
No brine draw
A clogged injector, restricted brine line or valve problem can prevent brine from being pulled through the resin during regeneration.
Regeneration settings
Demand-based systems may regenerate less often than an owner expects. Confirm hardness setting, reserve capacity, meter operation and actual water use.
When replacement makes sense
If the control valve is failing or resin is badly fouled, repair cost can approach the value of a newer high-efficiency system from RKIN, SpringWell or Kind Water.
Sizing and chemistry checks for Water Softener Not Using Salt: What Usually Causes It?
Water-softener decisions should be based on measured hardness, expected daily water use and peak service flow. “Grain capacity” is useful only when interpreted with the programmed salt dose and regeneration efficiency; the largest number on the product page is not automatically the most efficient operating point.
Iron changes the sizing problem. Some dissolved iron can be handled by ion exchange, but meaningful iron loading can foul resin and increase maintenance. When testing shows significant iron, manganese or sulfur, dedicated pretreatment is often more robust than asking the softener to solve every well-water problem.
Compare regeneration efficiency and long-term ownership
A well-sized unit should regenerate often enough to protect resin capacity without wasting salt and water. Compare usable capacity at the intended salt setting, estimated gallons between regenerations, service-flow rating and the amount of water used during regeneration. These operating details matter more over ten years than a small difference in purchase price.
Also consider valve support, replacement resin availability, bypass plumbing and local drain requirements. Salt-free conditioners belong in a separate category: they may reduce scale behavior in appropriate water but do not remove calcium and magnesium the way a true ion-exchange softener does.