Water is becoming a strategic issue for manufacturers. Rising costs, increasing pressure on supply, and growing operational risks mean that they can no longer afford to view water as simply another utility expense. 

In some areas, water scarcity has already disrupted industrial operations, with sites forced to delay production or limit expansion due to lack of water. As a result, manufacturers are beginning to take a closer look at how water is used, where it is wasted, and how efficiency improvements can strengthen their site's resilience. 

Why water efficiency matters now 

For many years, energy efficiency has been a major focus for manufacturing businesses. Water has often received less attention. 

That is changing. Hotter, drier conditions are increasing pressure on water resources, while suppliers are encouraging organisations to reduce consumption, reuse water where possible, and improve efficiency across their operations. 

At the same time, businesses are looking closely at operating costs. While water bills may appear relatively low compared to other utility costs, they rarely tell the full story. 

Understanding the true cost of water 

Water typically accounts for between 10% and 20% of a site's utility costs. And this figure doesn't include associated expenses such as: 

• Effluent treatment 

• Disposal costs 
• Chemical consumption 
• Water heating 
• Additional processing costs 

Taking these into account, the true cost of water can be up to five times greater than the figure shown on a utility bill. Fortunately, water efficiency opportunities give manufacturers a chance to save on all the hidden costs as well.  

Mapping water use across your site 

Before efficiency opportunities can be identified, manufacturers need a clear understanding of how water moves through their operations. 

A useful starting point is to review a site's processes and utility distribution systems, asking questions such as: 

• Where does water enter the site? 

• Where are the treatment points located? 
• How is water distributed? 
• What types of water are used in different processes? 
• Where does water ultimately leave the system? 

Taking a whole-system view helps organisations understand the complete journey of water across the site, from input through to discharge. 

Developing a utility distribution map at this stage can provide a valuable foundation for future efficiency work. Combined with process information and operational data, it allows manufacturers to identify where water is being consumed and where improvement opportunities may exist. 

Compiling and analysing reliable data 

Reliable data is critical for understanding water performance. 

Many sites already hold valuable information within process systems, cleaning procedures, and Clean in Place (CIP) protocols. By analysing consumption patterns alongside operational activities, organisations can begin to identify where water is used and where inefficiencies may occur. 

For example, comparing water consumption trends against cleaning schedules can help determine how much water is being used by cleaning processes, versus other site activities. 

The greater the visibility of water use, the easier it becomes to prioritise improvement opportunities. 

Finding water efficiency opportunities 

Because water efficiency has not traditionally been a primary focus for many manufacturers, there are often quick-win opportunities available.  

A practical approach is to begin with low-cost improvements that can deliver results fast, including behavioural and operational changes. These may involve reviewing: 

• Daily practices and behaviours 

• Cleaning procedures 
• Hygiene processes 
• Clean in Place (CIP) systems 

Once these opportunities have been addressed, organisations can move towards more substantial improvements, including water reuse and recycling initiatives. 

Exploring water reuse and recycling 

Water reuse and recycling can offer significant benefits when implemented appropriately. 

In many cases, the greatest value comes from recovering water before it reaches the effluent treatment stage. Doing so can help reduce treatment costs while simplifying some of the technical challenges associated with recycling and reuse. 

There are also opportunities around hygiene. In light of current legislation and guidance, recycling water to hygiene is often one of the preferred methods.     

While solutions are often site-specific, manufacturers that examine how water flows between processes frequently uncover opportunities to reduce both consumption and costs. 

Find out more about water efficiency: Join BIP.Verco's upcoming webinar 

Improving water efficiency begins with understanding where water is used, what it really costs, and where the greatest opportunities exist.  

As water scarcity and cost pressures continue to grow, organisations that act early will be better positioned to maintain reliable operations while delivering long-term efficiency gains.  

If you're interested in this topic, we recommend joining BIP.Verco's upcoming webinar:  

Turning water scarcity into opportunity 

Date: Tuesday 17th November  Time: 14:00 GMT 

During this webinar, BIP.Verco experts will explore how to: 

• understand your water use and make water projects pay back; 
• identify 'low-hanging fruit' water efficiency opportunities; 
• make sense of the water recycling/reuse conundrum; and 
• select the appropriate technology to help you use and monitor water more efficiently. 

Click here to register