Saving water without slowing production
Water efficiency in manufacturing production can be improved in many ways. We can change the way we behave, modify operational process or upgrade equipment and technology. Just improving water efficiency can bring about a range of sustainability, operational and cost benefits.
The main areas of water use in manufacture focus on:
- plant and equipment cooling
- product cleaning and preparation
- the application of paint and dyes
- product cooling
- equipment and site wash down.
Ways to be water efficient
Getting started
- Appoint a water conservation team.
- Investigate how water is being used around the site.
- Install water meters.
- Establish goals for water conservation.
- Develop and implement water saving initiatives.
Operation processes
- Identify and eliminate wastage (such as leaks) and inefficient processes (such as continual spray devices on stop-start production lines). This may be the most low cost area for water savings, as it involves minimal capital outlay. Savings can be made through implementing procedural changes, such as cleaning plant areas with brooms rather than water.
- Make sure water sprayers and jets turn off when the production line halts or ceases. Use timers or motion sensors to do this.
- Clean plant areas and paths with brooms rather than water.
Modify or upgrade plant equipment
- Change processes and plant machinery. A retrofit of key plant equipment may increase efficiency. Alternatively, upgrades to more efficient models can be factored in to planned maintenance and replacement schedules.
Recycling
- Reuse wastewater. As well as saving on mains water, this option may improve the reliability of supply, whilst reducing trade waste charges and associated environmental risks.
- Identify and prioritise the major water using practices, and the opportunities for reusing wastewater.
- Identify processes where the discharged water can be reused. This includes water from equipment cleaning, filtered backwash water, final cooling and cleaning water, and water used for transport.
- Use rainwater, dam water or process water to supplement fresh makeup water for cooling towers.
Managing and monitoring
- Conduct a water audit of the site. This may involve a detailed inventory of existing plant, equipment and plumbing, and operational procedures. Advice on conducting water audits is provided in the texts listed in the resources section. Alternatively, many water retailers offer water audits as part of their business support services.
- Develop a standard reporting procedure for water issues. This should include: - Total water use over a defined period (week, month, quarter) - Water use performance of major plant and processes - A comparison to previous water use patterns and identified goals - Issues that need addressing (such as leaks), and responsibilities for action.
Behavioural practices
- Brainstorm possible solutions, using members of the water conservation team and experts on water conservation and cleaner production. The findings and recommendations from the water audit are a good place to start.
- Establish a water conservation education program that encourages all staff to use water sparingly.
- Use water meter data and reports to identify leaks early.
Case studies
Find out how other manufacturing businesses are saving water.