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.
Frequent breaks of the paper strips at the paper machine lead to losses of material, water and energy and to reduced productivity. Solution is to improve quality of white water by reducing biological deposits.This will be achieved through replacing biocides by new chemicals and small amendments of the existing technology.
A carbonated drinks facility used diesel fuel to operate its boiler despite it was connected to the natural gas grid. Replacing the boiler's burner with one that can fire natural gas, and increasing the contracted capacity for natural gas was found as a feasible measure to maintain economic benefits and reduce the pollution load.
A milk and beverage company suffered from repeated power outages, thus relied on diesel generators to maintain production availability. The triggers for the generators were not optimized to recharge after short power outages, leading to occasional cuts, forcing CIP to start. Adjusting the triggers of the generators shall eliminate untimely shutdown of equipment.
This practice provides insights on the benefits of adopting an information system revealing deficiencies that are otherwise unnoticed by the plant staff and therefor benefiting the company with immediate resource savings.
This practice illustrates a complete upgrade for steam and electricity generation systems within a company, based on energy efficient design concepts. Through this upgrade, smaller electricity generators are to replace the existing ones. In turn their waste heat can be utilized in generating a portion of steam demand, which allows to replace the old low efficient boiler with smaller ones.
This practice is an example illustrating the energy efficient design practices for load distribution and wasteheat recovery. The plant electricity supply needs to rely on the inhouse generators. It is therefor recommended to upgrade the generators to increase their efficiency, and utilize their waste heat to operate other heat needing users. Detailed approach to calculate the benefits are illustrated in this practice.
This practice highlights common issues that lead to inefficiency of a chiller system, and shows the importance of installing an information system to benchmarking use of resources and manage them effectively.
In this practice, the design of the cooling water system of the vacuum pumps and extruders was reviewed. The modifications needed to convert the system from open to closed loop, including the installation of cooling towers and backup chillers, are illustrated. Through this intervention, savings in both water and energy reach over 90% of the baseline.
The injection molding machines in this company were of an old technology, using fixed speed motors with cold runners. This lead to generation of waste in the form of plastic carrot. Replacing the machines with modern technology, supported in reducing the specific energy consumption, through increasing the machine throughput, and improved motor efficiency. The hot runner technology eliminates the generation of plastic carrot.
This practice tackles the issues that reduces the performance of cold stores. In this company having three cold stores, issues were related to insultation of coils, location of outdoor units, and proper maintenance of the system.