This section compiles a database of more than 200 resource efficiency measures that were identified using the TEST methodology and successfully implemented within several industries across many sectors. The measures are classified by sector and subsector, type (good housekeeping, process control/modification, technology change, etc.), category of resource savings (water, energy and/or materials), scope and applicability (process or utilities). The database enables the use of predefined filters including the possibility to use keywords for an advanced search.
Each measure in the database includes a description of the problem, a technical description of the solution, the economic and environmental benefits quantified for the specific company case, the costs and the expected return on investment, suppliers of equipment as well as other aspects related to safety, maintenance, productivity and technical implementation.
A bakery has a process water treatment station consisting of one Single stage Reverse Osmosis (RO) unit. In depth water mapping revealed that the RO rejects 25% of the input water, which is being drained. This represented 20% of the overall water used in the company. Adding a second stage RO unit tremendously decreased the share of drained water, increasing the efficiency of treatment, and reducing the water demand by the company.
This seafood company had siginficant loss of material in the form of non-complying shrimps and shrimp shells. With the support of the development department of the company, the company is testing the production of breaded shrimps to utilize the non-complying shirimps in a value added product.
This seafood company generates quantities of material loss in the form of shrimp shells, that are currently disposed off. The company is testing a measure to convert those shells into bisques for human consumption. That measure would valorize over 200 tons of waste annually.
A Maize processing company generates ample volume of wastewater, rich in organic residues. Analysis of that wastewater showed "non-compliance" of the pollution level to the applicable environmental laws for discharge, resulting from high levels of COD and BOD. Installing an Upflow Anaerobic Sludge Blanket treatment unit shall handle the wastewater load, while generating methane gas, which partially replaces the conventional boiler fuel.
A pastry having a comressed air system which represents the focus area for energy flow. It consisted of four compressors with rated power of 110 kW each. Investigations and measurement revealed that leakage within the network is the main cause of loss in the compressed air consumption. Adopting a maintenance plan, to assure that leakage points are identified and fixed in timely manner, served in reducing the electricity bill of the company.
For jam production, product BRIX indicates complete cooking of the product. In a jam manufacturing facility, BRIX is measured manually by operator, who moves from one cooking bowl to another. This manual operation results in overcooking of products, and consequently excessive energy consumption. Automating the measurement of BRIX in real time shall support reduce the energy, and allow for better utilization of the installed cooking capacity.
Ink used in a printing company is prepared through manual mixing using a vigorous stirring system in a trough. This led to spillage of 4% of the prepared ink. Switching to an automatic stirring system, with programmed stirring speed and time eliminated that loss.
A beverage and juice manufacturing company had manual procedures for transfer of syrup to the blender. Those manual procedures led to disturbance in operations, loss of syrup, and added pollution load on the wastewater. Through installation of sensors and motorized valves, syrup transfer process was automated, eliminating those losses.
Sugar handling is done manually, by operators and forklifts to transfer sugar bags from the storage to the production hall. Installing a storage silo, with pneumatic transfer shall reduce the spillage of sugar from handling operations.
A company producing soft drinks with different flavors has to clean the production line whenever there is a change in product. Production plan imposed 3-4 changeovers per day, which was the cause of high consumption of water and chemicals associated with each CIP cycle. Changing the production plan to reduce the frequency of product change, saving on chemical use, energy and water consumption.