Factory focus Waste management & recycling Optimising water usage makes sense


With cost control of paramount importance to support operational efficiency objectives, focusing on how manufacturers can seek to reduce their water use can help the bottom line, as well as drive a sustainability agenda. Nigel Knight from Siemens Water Technologies says manufacturing businesses should take a fresh look at how they approach water management as part of their daily operations, and assess the benefit of technology investments with quick payback periods which can optimise usage of a costly, precious and heavily-used natural resource


Plants that are in control of their T


hough still relatively inexpensive to buy when compared to other European countries, UK water usage accounts for a significant


proportion of manufacturing costs. As a resource it forms a critical opera- tional element and is used in huge volumes on a daily basis across a wide spectrum of industrial sectors. With organisational efficiencies and sustainable best practice high on all business agendas, safely and effectively optimising water and its associated energy usage, can go a long way to helping meet operational and corporate demands. As manufacturing plants face continuing pressure to not only reduce costs but also meet stringent environ- mental targets and offset legislative scrutiny, water management strategies during industrial processes continue to attract attention. Obtained from various sources such as local water authorities or bore holes, water supply comes at a price. In the midst of other operational areas, it can also be a key cost area that does not receive the attention it deserves in terms of reduc- ing its impact on the financial well- being of a manufacturing operation. In this regard, assessing the worth of water recycling initiatives can make sound business sense.


First steps Before considering water recycling options, manufacturing plants should first look to reduce a site’s water usage. Plants should commence by simply undertaking a water usage audit. Check where water wastage may be occurring and analyse overuse in areas such as staff wastage. Checks should also be made for leakage through damaged or what can often turn out to be an ageing infrastructure. Every drop counts, so engaging the workforce in initiatives that reduce usage will prove valuable.


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water usage can then consider options for water recycling and begin the process of cutting volumes and associ- ated cost. The first stage of water recy- cling therefore is to look at what the end goal is and the site’s requirements for water. If there is a suitable use for recycled water – maybe diverting it to another process area of the plant, or even using it as an alternative water source to wash commercial fleets at the site – the next step is to assess which technologies will enable this usage and ensure the plant is as opera- tionally efficient as possible. For both stages of the process it is advisable to engage with a water treatment expert who can ensure the right solution is implemented to meet with the plant’s exact needs. It is important to select a reuse


system that is operationally efficient, both in terms of minimising energy use and engineering time. A water treatment system should not have a negative impact on overall plant oper- ations. In terms of energy use, there are highly efficient, intelligent systems available. For example, variable speed drives can be used in pump systems as they respond to water volumes so won’t run at high output unnecessar- ily. Smart technologies should also require minimum engineering time, as they are low maintenance and easy to operate on an ongoing basis. Today’s systems are also efficient in terms of cleaning cycles and careful assessment of the quality of water required in other areas can help influence invest- ment decisions. A prime example of a business that


has adopted a water recycling system for reuse of water in the cleaning process is a beverage manufacturer. Siemens Water Technologies has worked with the company to help recover a large volume of water that is now being reused in the process system, instead of discharging directly to their waste treatment plant. Further


Select a reuse system that is operationally efficient both in terms of minimising energy use and engineering time


treatment systems could involve the reuse of reject recovery water from RO systems and back wash water systems from filtration units. This investment has reduced the water volumes returned to the drains by approximately 50 per cent and is helping to optimise water use in an industrial sector where high water volumes are prevalent. In addition to high-purity treatment,


water can also be recycled for use in boilers, cooling towers and clean-in- place (CIP) systems. For ultimate efficiency, water treat-


Nigel Knight from Siemens Water Technologies


ment and recycling should be viewed as a part of a site’s integrated water system. While many manufacturing plants look at their requirements on a need-by-need basis, true operational and cost efficiencies are achieved with an integrated system that is carefully and intelligently designed. In today’s challenging industrial


marketplace optimising water usage is something plant managers cannot afford to overlook. Through available technol- ogy, which can have short payback periods, tackling leakage issues, cutting workplace wastage and recycling and reusing water in other areas of a plant’s operation can help industry achieve significant gains both in terms of sustainable operational efficiencies and a positive impact on the bottom line. It is vital to choose a system that


meets each plant’s specific operational needs and one that guarantees every drop of water is in compliance with legal, corporate and customer demands. Improving water management will


underpin overall system efficiencies by reducing energy and operating costs. It also lowers a manufacturer’s carbon footprint, maximises revenues and contributes to a cleaner global environ- ment – all positive factors that can flow from turning attention to how we use a vital resource we often take for granted Siemens Water Technologies T: 0113 385 3500 www.industry.siemens.co.uk Enter 305


SEPTEMBER 2013 Factory Equipment


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