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.
In this pastry company, the wafer production line recorded out of specification products due to over burning in the oven. Investigations revealed that the burner lacked maintenance and Standard Operating Procedures (SOP). Adopting a periodic maintenance program, together with setting SOPs for the oven shall enhance the product quality, reduce the out of specification products, and save in energy consumption.
MFCA assessment revealed considerable losses from returned products. In depth analysis highlighted that the returns originate from mismatching the product supply and the market demand. Remedial actions include a set of good housekeeping measures, including strengthening the communication between concerned departments within the company. Considerable savings in raw material, energy and water were achieved from those actions.
This dairy has two stages of pasteurization, each having the set point as a standalone process. Reviewing the whole pasteurization process, as a complete system revealed that the pasteurization temperature of the first stage can be reduced without any adverse impact on product quality. This served in cutting the energy consumption by 5.8%.
A bakery recorded a 10% losses of products mainly due to poor production practices. Reviewing the recipe and the procedures of cake production with the introduction of simple loss prevention techniques, cut down product losses by 50%.
Mapping the material losses in a cement bags manufacturing company revealed that losses of ink and solvents occur mainly at the end of each production batch due to ink leftovers in the machine that are removed by solvents. Reducing the feed tray size, the volume of feed tubes, and the dead volume in the ink trough significantly reduces the quantity of ink leftovers, and the required solvent quantity.
The energy efficiency measurements in this pastry show that the boiler’s stack temperature is relatively high and reflects inefficient transfer of heat inside the boiler. Some maintenance practices are recommended which will increase the boiler efficiency, reduce the stack temperature, and save energy consumption of the boiler.
Stoppage of wire drawing machines generates losses in raw material. Investigating the reasons for these stoppages in an automotive cable company revealed that lack of machine maintenance together with the low quality of used copper are main reasons. adopting preventive maintenance program, and contacting the copper suppliers to provide high quality material reduces those stoppages, and consequently saves on material and increases productivity.
End of line rejects are high in a pipe manufacturing company. Those rejects are due to the lack of technical skills for the workers, and rejects occuring due to misadjustment of equipment during change of set. Adopting a lean manufacturing methodology or KAIZEN technique together with a training campaign for labor and employees significantly reduces those rejects.
In this snacks production facility, frying oil had reduced lifetime. This was mainly due to the impurities from the fried products. Removal of those impurities from the oil between production batches, together with controlling the frying oil temperature shall save around 10% of the total oil used in frying.
Company is exploring opportunity to reduce offcuts of film edges in reforming which wre originally perceived as inherent to the laminating process and "irreducible".Negotiation with supliers and consumers reveals opprotunity to significantly reduce the offcuts and related loss of material and production of waste by bringing size of product closer to the standards of the laminating film supplier.