Water is the lifeblood of the process industry – so how can we protect it?

It goes without saying that without water, there would be no process industry.

Not only is it the main ingredient in many beverages, it’s also used in heating, cooling, cleaning and the transportation of some materials (dissolved in water). Then there’s the huge problem of waste water, which reduces the amount available for human and animal consumption, and potentially contaminates our rivers and oceans. Any issue with either the supply or quality of water could have severe consequences for critical sectors like food and drink, pharmaceuticals and energy – both from a human and commercial perspective.

Around the world, some four billion people experience water scarcity for at least one month per year, and an estimated 700 million could be displaced by it by 2030. The ethical imperative to safeguard our water supplies is clear but what exactly can process manufacturers do, given that the work is, by its nature, water-intensive?

What’s happening today?

Since the process industry incorporates so many different types of products, there’s no single solution to the problem of over-consumption and waste water.

Different producers have already taken steps to reduce their water usage over the years, including treating and repurposing waste water on-site to reduce reliance on fresh water supplies. And while the steps they take to get there can be complex (sometimes involving the transformation or construction of an entire facility), the 4Rs – reduce, reuse, recycle and rethink – provide a strategic framework.

Take dairies, for instance. They are often located close to farms and have their own water supply, which already reduces the impact on public utilities. But some have gone a step further by optimizing their Cleaning in Place (CIP) water to minimise waste, and reusing their COW (Condensate of Whey Water).

Water is, of course, the most important raw ingredient in industries like brewing and soft drinks production, and the sector is also a major producer of waste water. Both of these can be detrimental to the communities where facilities are located, particularly in warmer climates.

In recent years, we’ve seen some of the biggest manufacturers set themselves ambitious targets to minimise the impact and meet their ESG goals. Carlsberg, for instance, has committed to ZERO Water Waste, which includes using technology to increase efficiency, cleaning and reusing waste water, and sharing best practices.

The life sciences industry is starting to prioritise water stewardship too – with companies often mindful that the urban location of their facilities means a heavy reliance on public utilities. And while the biggest corporations are factoring waste water into their sustainability strategies, they’re also facing regulatory pressures around the requirements for wastewater discharge.

An innovative approach

Simple measures to make your processes more efficient can significantly reduce water consumption. Treating and reusing water is not only more sustainable, it can also bring down costs too, for both water management and energy (heating/cooling).

But, as our report Water stewardship | Download the report here! - NIRAS highlights, there are also a number of advanced treatment technologies now being deployed – including ultra-filtration, reverse osmosis and ultraviolet disinfection, all of which promote water quality and safety, and could even enable manufacturers to achieve Zero Liquid Discharge (ZLD) at their facilities.

The digitisation of manufacturing has also paved the way for smarter water management methods, using sensors and real-time monitoring to optimise both the use and quality of water. Other innovations include integrating Cleaning In Place (CIP) with closed-loop cooling and heating systems in order to recirculate water and minimise loss.

Why now?

Across the world, we’re seeing terrifying glimpses of what could happen if water supplies come under threat. Back in 2018, the South African city of Cape Town suffered a drought so severe that its municipal water supplies were shut down. And while a ‘Day Zero’ was narrowly averted, the event was a catalyst for better water management across different industries, including the process industry.

With net zero goals edging ever-closer, and the impact of climate change and polluted waterways becoming more visible, governments and regulators are tightening the rules around industrial water usage and discharge.

It’s important to factor in the reputational cost too. The public is becoming increasingly aware, and angry, about the state of waterways. Sewage is already a major problem in the UK – and any additional waste water from the process industries will only make it worse.

Consumers might not always know or question how much water is used in their products, especially in pharmaceuticals, but that could change as every manufacturer, not just consumer-facing ones, become more transparent in their reporting. Events like the extreme heatwaves and droughts that struck large parts of Europe in the summers of 2022-24 were another reminder of how fragile our water supplies are due to climate change.

While it’s certainly a challenge, good water stewardship is critical to both the future of the process industries and humanity.

Download our free guide, Water Stewardship: Trends and perspectives within the global process industry Water stewardship | Download the report here! - NIRAS, for expert insights and practical tips on how to get started.