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Best practices

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.

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Biogas plant

A frozen chicken production company, has a sister company for protein production at a nearby location. The waste generated from both companies especially the portion generated during the slaughtering process is rich in organic matter. The purchase and installation of a modular biogas unit, shall treat the organic load generated from both companies, can generate ample quantity of energy as biogas. The unit is an eco-innovative unit including a technical container, fermenter, all sensors and biogas storage necessary for the operation of the plant and is delivered in prefabricated modular units.

Sector: Processing and preserving of meat and production of meat products
Subsector: Technology upgrade/Eco-innovation
Applicability: Utilities
Resource savings: EnergyMaterial
Tags: Processing and preserving of meat and production of meat products
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Boiler and Steam system Optimisation

In this practice, the company managed to improve the performance of steam boilers, reduced their energy consumption, and maximize their reliability through adoption of good housekeeping measures, and introduction of corrective actions to adjust the air/fuel ratios based on monitoring results.

Sector: Finishing of textiles
Subsector: Good Housekeeping
Applicability: Utilities
Resource savings: EnergyWater
Tags: Finishing of textiles preventive maintenance SOP
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Boiler CO2 recovery and treatment for use in beverages

Recovery and treatment of CO2 emitted from boiler flue gases, can act as an alternative to purchased CO2 for the production of carbonated drinks. This was the case of a beverage and juice company, in which case, the ROI was estimated to be less than 3 years.

Sector: Manufacture of beverages
Subsector: Process control or modification
Applicability: Process
Resource savings: Material
Tags: GHG reduction Manufacture of beverages Material sourcing
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Boiler tuning-up

Measurements of the boiler of a frozen chicken production company were conducted to benchmark its performance against the international norms. The boiler efficiency was found to be less than the benchmark value. The company was recommended to mitigate the causes of the low efficiency through setting Standard Operating Parameters for the boiler operation, as well as adopting a specific maintenance program. This action increased the boiler efficiency, and saved on fuel usage.

Sector: Processing and preserving of meat and production of meat products
Subsector: Good Housekeeping
Applicability: Utilities
Resource savings: Energy
Tags: Processing and preserving of meat and production of meat products
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Bypass homogenizer for clear juice

A juice production facility had a single setting for the homogenizer pressure disregarding the type of juice being processed. As some juice, for clear juice, dont need the homogenization stage, adjusting the line to bypass the homogenizer while producing clear juice saved on energy, water and spare parts.

Sector: Processing and preserving of fruit and vegetables
Subsector: Process control or modification
Applicability: Process
Resource savings: Energy
Tags: Processing and preserving of fruit and vegetables
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Changing from volumetric packaging to packaging by weight

This snack and beverage company packaged its final product by volume filling. Material balance showed that the packed weight is on average 20% higher than required which means an extra cost for the company. The company decided to replace the existing volumetric packaging technology with a new system based on weighting of the product.This resulted in a standardization of production, and increased productivity.

Sector: Processing and preserving of fruit and vegetables
Subsector: Process control or modification
Applicability: Process
Resource savings: Material
Tags: filling Mass flow Processing and preserving of fruit and vegetables
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Changing the configuration of the polymerization reactor

The company’s polymerization process is carried out in a reactor where additives are added from the top of the reactor. During the periodic cleaning some build-up material is difficult to remove, leading to product losses and increases in cleaning time. Investigations revealed that injection of the additives from the bottom instead of adding it from the top eliminated the build-up of material on the reactor walls and led to cost savings in terms of time and material as well as increasing worker’s safety.

Sector: Manufacture of other chemical products
Subsector: Process control or modification
Applicability: Process
Resource savings: Material
Tags: build-up Cleaning Manufacture of other chemical products
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Checking cooling unit insulation

The cooling system in a dairy suffered poor insulation resulting in overconsumption of electricity. Periodic check of the insulation, and adopting preventive maintenance technique saves 10% of the consumption.

Sector: Manufacture of dairy products
Subsector: Process control or modification
Applicability: Utilities
Resource savings: Energy
Tags: insulation Manufacture of dairy products Measurement
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Cleaning of support brackets by pyrolysis

Hooks, overwhich parts to be painted are hung, used to be cleaned (paint removal) using chemical methods that generate hazardous waste. Shifting to a pyrolysis process for paint removal reduced the chemical consumption, and associated hazardous waste. It also enhanced the productivity of the company, as the cleaning time was reduced.

Sector: Manufacture of parts and accessories for motor vehicles
Subsector: Technology upgrade/Eco-innovation
Applicability: Process
Resource savings: Material
Tags: Manufacture of parts and accessories for motor vehicles Productivity enhancement waste management
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Closed circuit for homogenizer cooling water

Water mapping at a fruit pulp and concentrates production company revealed that the cooling water from the homogenizer and the vacuum pump has an open loop and is actually drained. Collection and transfering the used cooling water to the existing cooling tower, enables the reuse the whole quantity in a closed loop, saving on water demand.

Sector: Processing and preserving of fruit and vegetables
Subsector: Process control or modification
Applicability: Process
Resource savings: Water
Tags: Processing and preserving of fruit and vegetables Vaccuum pump Water Mapping
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