How to reduce water consumption in sensitive products filling?

All production combined, industry accounts for 20% of global water consumption, twice as much as domestic use. In a context of climate change and increasingly frequent water stress, each liter must be used wisely.

Serac is therefore developing solutions to significantly reduce water consumption, and supports customers from all sectors (dairy products, beverages, cosmetics, etc.) in their efforts with on-site audits, improvement plans and upgrade solutions for its filling machines.


3 ways to reduce water consumption in the filling of sensitive products:


Optimize the heating process of APA solutions:

It is possible to increase the heat exchange time and the contact surface to limit the degradation of the APA. The automatic leakage rate for solution renewal (200 to 300 liters per hour on average) can be reduced.


 Separate bottle rinsing in 2 steps:

The sterile water used for bottle rinsing is difficult to reuse because too loaded with APA. To help recycling it, it is possible to separate rinsing in 2 steps carried out on a single carousel. The water from the second step, having a very low content of APA, can be recovered and reused.


 Recycle cooling water in a closed loop system:

The cooling water used in the production of sterile water on the filling lines was until now very rarely recycled. Serac is now proposing to modify its machines to inject this cooling water into the plant’s closed loop circuit. This will reduce the consumption of tap water.


The implementation of dry and chemical-free treatments

To go even further in reducing water consumption, Serac integrates on its machines decontamination technologies that use intense light rays and electron beams: UV decontamination, pulsed light and the Serac BluStream® process. With these 3 technologies, it is possible to cover all applications, in clean, ultra-clean and aseptic levels.

Many manufacturers are replacing their liquid decontamination with dry treatments. Doing so, they also gain in productivity and reproducibility with technologies that are easier to control.


Personalized advice and feasibility studies

Serac’s customer service department intervenes on request to carry out on-site audits and propose improvement plans. These plans range from the simple optimization of cleaning cycles to complete upgrades, including the optimization of machine hydraulic pattern. Feasibility studies, evaluations of potential gains and costings are carried out on a case-by-case basis in order to take into account the particularities of each process.

It is possible to obtain very significant reductions in consumption with simple actions; this was the case for a major player in the cosmetics industry which was able to divide by 7 the water consumption of its cleaning cycles.

“ A new function which records all cleaning cycles installed on the control unit, enabled us to analyze each step of the cleaning process by comparing real and theoretical durations. The analysis revealed the key parameters to act on, in this case water temperature and mechanical action. “

Arnaud Rosier - Customer Manager @Serac France

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