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 Chocolate pumping is only equipped with a single outlet filter, leading to many blockages and making it difficult to clean. In consequence chocolate is lost and production needs to be interrupted. The problem is solved through installing a new higher efficiency filter which removes impurities at the very beginning.
This pasta manufacturing company didn’t have any control over the quantity of steam injected to the couscous cooking stage, thus excessive quantities of steam were utilized to assure complete cooking. Installing a steam flow meter to monitor the steam consumption, and regulate it accordingly helps in reducing the specific steam consumption.
Analysis of the light fixtures used within the production hall revealed that the light intensity is not sufficient, and the light fixtures are of old technology, with high energy consumption. Replacement of the light fixtures with modern technology, reduce the energy cost, increase the light intensity, and increase the lifetime of the lamps.
Due to lack of control over the temperature setting, viscosity of cream that is used to fill the biscuits was improper and led to blockages in the filling machine, and consequntly loss of material. Installing double wall pipe ahead of the cream filling machine helps maintain the cream temperature and viscosity within the desired setting, and eliminate these losses.
For a pasta production company, monitoring equipment were installed, and the production line was fully automated, yet missing the analysis and feedback loop. So the production lines had fixed program not considering the variations in process parameters. closing the loop through an analysis software lead to saving of 5% of the resource use.
Lack of maintenance in a carbonated beverage production facility resulted in production interuptions, as well as deterioration in product quality resulting from poor performance of utilities. Adopting a preventive maintenance program associated with periodic measurment of main parameters eliminate those losses.
Mapping raw material losses in a biscuit production facility reveald that significant losses occurred from dough spillage at the conveyor transferring it to feed the equipment. Installing barriers around that conveyor prevent material overflow and eliminates the losses.
Reviewing the frequency of cleaning the production line highlighted excessive number of cleaning cycles from the common practice. Changing the program to match the nature of the products, quality of raw material, and operating conditions of the equipment can eliminate one cycle of cleaning, increasing the availability, and saving on product losses, water and energy consumption.
Benchmarking the yield of a cream separator at a dairy company against the yield from another nearby company revealed that the potential of increasing the productivity is high. Reviewing the operating parameters of the separator can lead to converting 50% of the current losses to products.
A beverage company practiced overcleaning within their CIP program, which was based on 7-step CIP. Common practice for simillar industry is to use only 5-step CIP, provided that the nature of the production, the temperature and concentration of the solutions, the laboratory controls and the preventative measures are taken into consideration. Changing to 5-step CIP reduced the chemicals used by the company, water and energy needed for a non-productive process.