Wastage Control & Auditing

The audit work would typically involve two consultants on site during which we would measure losses from as many of the targeted cleaning and processing operations as possible. 

For the product loss quantification, we collect a series of effluent samples throughout the duration of each CIP/cleaning process (i.e. pre-rinse, flush etc) which we would test for key water quality parameters. In conjunction with flow rates, we would then equate losses back into a product equivalent to enable a detailed assessment of each clean or process to determine whether there is scope for optimisation.

Where measured wastage levels are deemed as high, MSA would make a series of high-level recommendations to improve efficiencies and reduce effluent loadings to drain (e.g. extending flush sequences, modifying CIP set points, reviewing segregation options, recalibrating instrumentation etc).

The deliverables from the audit work will be:

1. Spreadsheet containing:
   • All cleaning profiles
   • Notes on each clean
   • Summary table of cleans measured
   • Projections for the future
2. Concise Word report containing:
   • Areas for saving
   • Scope of savings (m3/day, kgCOD/day & product saving)
3. Recommendations on implementation

Data collected during our onsite audit work is compiled to produce a concise report with the accompanying wastage loss summary spreadsheet (CIP-PROP©) to give the following:

• Examination of major areas for effluent loading and volume, and product wastage
• Recommendations for achieving a reduction in water usage, effluent loadings and product loss
• Identification of the potential savings in terms of product, raw material and water and effluent costs
• A copy of our CIP Prop software along with basic training on how to use it

We are highly experienced in conducting water and waste minimisation audits in food and drink production sites. We have completed numerous audits for a wide variety of clients worldwide including Arla, Dairy Crest, Kerry Group, Volac, Mars, Refresco, Mondelez, Greggs, Bakkavor, Greene King and many more.

The average revenue saving identified in water, effluent and product from recent MSA wastage audits is around £150,000 pa. As well as this revenue benefit, the saving also has knock on implications for capital in terms of future water and effluent requirements.