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.
Benchmarking the coating time of two chocolate coating machines in a company against each other highlighted that the time of one machine can be reduced by 37%, allowing higher productivity and less specific energy consumption. This can be achieved through only adjusting the opearting parameters of that machine.
The need for color correction in dyeing process necessitates decreasing the bath temperature to add the color correction, then gradually increasing the temperature. Therefore, reducing the number of color corrections, through assurance of the ingredients from the first time saves on energy and increases the productivity.
An aromatic production company has expanded overtime, with the water network being expanded to match with new installations. This expansion of water network was conducted in an "as needed" manner, ending up by having many connections and a complicated network with high losses. renovating the water network considering the energy efficient design shall save on water leaks, as well as energy demand.
The ingredients preparation process in a confectionary had excessive handling, being transferred between different pots up to four times. This overhandling resulted in remarkable loss of material. Reviewing the design of the preparation process allowed the elimination of one of the four stages, and water reuse accross different stages.
Although this pharmaceutical company had capacitor banks installed at the transformer to correct the power factor, those banks were noted not to function properly as the power factor was highly fluctuating. Installation of an automatic regulator, together with the installation of two fixed batteries supported in maintaining the power factor, and thus increased the bonus on the bill.
In a sardine processing facility, defrosting was achieved through placing the crates under water nozzles to accelerate the defrosting process, then placing the material in cold rooms set to 0-4 degrees for one day. Adopting and installation of Aerosol technology or ultrasonic humidification technology for defrosting provides faster defrosting process, eliminates the need for water, and improves the quality of the sardines.
Following a water mapping at this fruit processing company, it was possible to identify water saving measures that rely on water reuse. All washing stages at this company were utilizing fresh water, that is drained after use.
The drying tower of a detergent production company is running at 50% of its capacity, due to unoptimised operating parameters. Reviewing the operating parameters, particularly the air speed, and running a detailed mass/energy balance on the tower can provide a productivity gain of 20%, saving on material, energy and water.
Productivity loss was noted in a cement bags manufacturing facility due to unmonitored change over of dies between different product batches. Monitoring the changeover time, and adoptin a "Single Minute Exchange Dies" method elimiates the loss of production.
Mapping of compressed air users revealed that to assemble machines, that are far away from the compressor room demand high compressed air flow. Installing a dedicated air tank for each machine, reduce the sudden pressure drop within the network, and allow for reducing the compressors set point, saving on electricity consumption.