Monitoring indicators continuously is essential to prevent major problems from going unnoticed and to seek performance optimization. This practice applies to any area of a company. Taking this into account, the objective of this article is to specifically address the creation and analysis of a characteristic parameter of the use of water resources within an industry. Although the focus is on the beverage business, the approach can be applied to any type of production environment.
In a beverage industry, one of the main indicators of water use optimization is liter per liter (L/L):
Efficiency=〖Liters 〗_(water collected)/〖Liters 〗_(final product)
As the formula implies the amount of water used per liter of beverage produced, it allows you to evaluate the efficiency of the production process, identify opportunities for optimization and savings, and facilitate the comparison between batches and products.
However, calculating this indicator is not always an easy task, especially when you want daily monitoring. Factors such as water tanks, treatment plants, and production peaks usually bring complexity to the calculation process, requiring a detailed technical survey. This is necessary to avoid generating incorrect information that can lead to wrong decisions. In addition, according to the CNI (National Council of Industry), in the material “Water use in the Brazilian industrial sector“, another factor that highlights this difficulty is the limited availability of data on water use in the industrial sector, which constitutes an obstacle to the effective characterization of industries in terms of consumption of this resource (FERES et al., 2005).
Strategies for Evaluating Water Use Indicators in Industry
To survey the water trajectory in the industry, the first step is to assemble a complete map indicating where the water can pass through the plant. This is done with the aim of establishing the optimal measurement points for a quality indicator. Next, it will be explored how this process happens in a factory with five production lines, three of which are for soft drinks and two for water.
Step 1 – Mapping the Water Path:
Before implementing a measurement system, it is necessary to map the complete path of water through the factory systems. This is important as there may be recirculation points, where the same water passes multiple times. This step requires an on-site assessment, with a complete picture.
Step 2 – Setting the Measurement Locations:
After making the complete map of the plant, it is necessary to define the level of detail of the indicators to be calculated. It is possible, for example, to divide a floor plan into four levels:
- Plant
- Area (e.g. Utilities, Process, Packaging)
- Functional Area (Boilers, Filler, Chiller)
- Machine (Filler 1, Boiler 1, Boiler 2)
Expressing this division of levels graphically and using some example data, we have the following arrangement:
Step 3 – Defining the Calculation System:
The higher the level of detail, the more necessary it becomes to deploy an automatic data collection system and install digital meters. This is explained because, when performing this type of collection manually, in addition to being susceptible to errors and having little resolution, it may not offer the necessary precision to define, for example, which recipe or SKU has the best performance.
How to Manage Water Consumption Indicators in Industry
To generate good results and save water, it is ideal to create a routine to monitor the indicators found. After identifying the main consumption points, the stages and the equipment involved in the production process, it is necessary to define savings goals and key indicators, such as the liter per liter.
The next step is to define the procedures well, describing how the monitoring of this resource will be done. In addition, it is necessary to establish the frequency of measurements and who will be responsible for checking the dashboards.
With a certain frequency of monitoring, it is possible to carry out an assertive analysis of water use in industries and implement corrective actions. Using the data collected, it is possible to identify trends, recognize consumption peaks, and find areas of opportunity with potential for development.
It is essential, after surveying the indicators and implementing the measurement routine, to strategically manage the numbers discovered. In this way, it is possible to establish a rational use of water resources, reduce costs and identify points of attention for waste reduction.
Redefining Water Use: Innovations and Sustainability
Recently, the redefinition of water use strategies has been occupying a prominent place in industries. According to the CNI (National Confederation of Industry), in the article “Better use of natural resources and value generation“, 76.4% of Brazilian industries already use some sustainable economy strategy. These actions are essential to increase the useful life of natural resources, promote innovation and competitiveness in the private sector, and stimulate awareness in society.
This awareness arose from the fact that the water used for consumption and production, although essential for the development of various economic activities, is not infinite. In this scenario, the use of disruptive technologies and solutions ensures greater longevity of resources and causes a positive impact on society.
Finally, it is necessary to reinforce the importance of these and other actions aimed at more sustainability in the production process. Although the routine monitoring of water resources plays an indispensable role, there is still room for the industry to advance another level in productivity.