Optimising Water Consumption- Dosing System and Water Control at Fullers level

Due to lack of measurement of water consumption within a tannery, the company has uncontrolled water use, and consequently excessive consumption. Installing a monitoring system for water consumption on company level, and at the level of main water consumers, in addition to setting internal KPIs/OPIs for water consumption increase the level of awareness for the optimum consumption, and result in continous reduction of its use.

Optimization of CIP

A soft drinks production company suffered excess water consumption within their semi-automatic open CIP process. Automation of the product push from the pipelines and tanks, enhanced with advanced product push techniques utilizing compressed air to purge the pipes will save on water, electricity, and material.

Optimization of operating parameters for solid state polycondensation

A plastic recylcing company practices setting the temperature of the contamination removal steps at limits exceeding the optimum setting. Resetting the set points to the supplier's recommended setting saved 5% of the energy, and improved the product quality.

Optimization of the gluten drier operating parameters

A maize processing company had the set points for the gluten drier exceeding the common practice of simillar industries. Reducing the drying temperature to match the common practice resulted in 4% savings in natural gas consumption, and improved product quality.

Optimize operating time of rotary ovens

Due to poor production planning, and absence of Standard Operation Procedures (SOP), the rotary ovens of this bakery can be operating idle for long times. Setting production plan one day ahead, and following predefined SOPs saves around 15% of the operating time of the ovens, resulting in 4% saving in their energy consumption.

Organic waste valorization

Rejected product, off speficication, or returns from market from dairy products has to be incenerated to gurantee it is not consumed as human food. This dairy company practiced landfilling the incenerated residues. The proposed alternative is to utilize those products as animal feed, which shall benefits from the high protein content, keeps them away from human use, and mitigate the environmental impact of inceneration and landfilling.

Ozone-based continuous washing machine for denim

Through purchasing and installing of an Ozone-based washing technology, the jeans washing facility tremendously decreased the water and energy consumption, and eliminated the use of hazardous chemicals.

Phosphorus pentoxide Loss Tracking

Although the company monitors their overall loss of phosphorus pentoxide, lack of distribution of the loss at main leak points hinders the structured corrective actions. The company was recommended to practice the qualitative and quantitative monitoring of losses, following the structure of cost centers defined within the MFCA, so as to define the focus areas of option generation, and develop structured saving measures.

Pigging system for product recovery

Pipes of a paste manufacturing company need to be cleaned from products after each batch. Residues of product that remain in the pipes are sent to drain. Introducing the eco-innovative product push technique (pigging) will recover those product residues, reducing the organic loading on the drains, and decreasing the cost associated with conventional CIP process.

Powder Products Filling Optimisation