Project overview
Client: Delka
Location: Petit-Rechain, Belgium
Industry: Food industry - sauces and food preparations
Key results
Control of consumption
A detailed analysis linked water consumption to production (L/kg of sauce), providing a robust water performance indicator.
Identification of the main consumption area
Cleaning operations account for approximately 80% of the site's total water consumption, representing the priority optimization lever.
Operational optimization
Improvement opportunities were identified through optimization of cleaning cycles, volumes used, and CIP parameters (time, temperature, chemistry).
Reduction in operating costs
Targeted actions on cleaning operations enable simultaneous reduction of water, energy, and effluent treatment costs.
The challenge
Delka faces growing pressure to control its water consumption. Water and wastewater costs are rising, environmental regulations are becoming stricter and food safety requirements remain extremely high.
Industrial cleaning is essential to ensure product safety. Each recipe change requires thorough cleaning of equipment to prevent cross-contamination. With more than 400 different sauce recipes, these cleaning operations are frequent and water-intensive.
Before the study, Delka lacked detailed data on where and how water was being used. Without this visibility, it was difficult to identify the most effective actions to reduce consumption while maintaining strict hygiene standards.
Our solution
Revalio designed a comprehensive approach combining water measurement, analysis of existing practices and the identification of practical, site-specific solutions.
Improved visibility of water use
Water meters were installed on the main production lines, on the clean-in-place system and at the main site inlet. Connected to a Shayp monitoring platform, these meters provided detailed and continuous data.
The results showed an average monthly consumption of around 1,277 cubic metres, with significant variations depending on production and cleaning activities. Cleaning operations were confirmed as the main contributor to water use.
Optimising cleaning practices
Together with the equipment manufacturer, on-site trials were carried out to make cleaning more efficient while reducing water consumption.
Key improvements included:
using hot water to shorten cleaning times,
selecting more suitable cleaning chemicals,
better control of pressure and flow rates,
automating cleaning cycles to reduce operator-related variability.
These changes make it possible to clean faster, more consistently and with less water, without compromising food safety.
Project impact
As a result of this study, Delka now benefits from:
a clear and quantified view of its water consumption,
simple and reliable performance indicators,
a prioritised and realistic action plan.
This approach helps Delka reduce its environmental footprint, control operating costs and strengthen its resilience to future water-related challenges, while maintaining high hygiene standards.
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.