Smart Monitoring and Optimising Water Use
50% reduction in consumption for cleaning
Project overview
Client: Delka
Location: Petit-Rechain, Belgium
Industry: Food industry - sauces and food preparations
Key results
50% reduction
A drastic drop in water used for cleaning through the optimization of cycles and parameters.
Smart monitoring
Installation of connected flow meters for real-time tracking across all production lines.
Leak detection
Implementation of AI-driven anomaly detection, securing the site against invisible losses.
The challenge
Huge supply costs and wastewater volumes driven by rapid company growth.
Delka which produces over 400 different sauce recipes, faced growing pressure to control its resources. Every recipe change requires thorough equipment cleaning to ensure food safety, an operation that accounted for 80% of the site's total water consumption.
As the factory expanded to over 11,600 m², Delka lacked the granular data needed to see exactly where water was going. Without this visibility, it was impossible to identify effective reduction strategies that wouldn't compromise their strict hygiene standards.
What Revalio delivered
Revalio designed a comprehensive approach combining data objectification with practical solution engineering.
1. Smart Monitoring & Flow Mapping
Installed flow meters at the inlet of every emulsifier and on main production lines.
Connected devices to the Shayp platform for real-time visualisation and tracking of the performance indicator (Litres of water/kg of sauce).
Analysed the local hydric context, including rainfall potential and compliance with discharge requirements.
2. Water Audit & Action Plan
Sinner Circle Optimisation: Analysed mechanical action, chemistry, temperature, and time.
On-site Trials: Transitioned to hot water for better residue removal and selected high-performing alkaline detergents.
Recirculation Engineering: Proposed an external CIP (Cleaning-In-Place) system with dedicated tanks to reuse intermediate rinse water for pre-rinsing.
How it works
The strategy is built on a simple principle: "You can only optimise what you measure."
Measure & prevent with Shayp: Using AI algorithms to monitor water consumption in real time and detect leaks immediately, with automated SMS alerts for rapid intervention.
Maximising every drop: Automating cleaning cycles to remove operator-related variability and ensuring spray ball pressure meets manufacturer recommendations.
Alternative sourcing: Evaluating the site’s 5,560 m² of roof space to recover rainwater for non-food contact uses (toilets and floor cleaning), potentially covering up to 30% of total site needs.
Facing similar challenges?
If your company is dealing with water consumption control issues, industrial cleaning optimization, or effluent reduction, Revalio designs and supports customized solutions, from audit to operational implementation.