Increasing water accountability by 30% at a Disperse Dye plant using EverSense for WaterMAP

One of the largest producers of disperse dyes in India, catering to all commercially available dye variants in the segment utilises 4,300 m³ of water per day. Given their significant daily consumption, they found it challenging to estimate water consumption in the process and map its correlation with utilities consumed for manufacturing. Anomalies such as meter inaccuracies, unaccounted borewell water, and improper extraction were identified as key contributors to the inefficiency. Using EverSense for WaterMAP helped establish a comprehensive water balance for the plant. The EverSense interface and our monthly reports consisting of data-driven, actionable insights from our water specialists, the team was able to identify and isolate multiple anomalies affecting water accountability.

Problem

PROBLEM

The plant utilises 4,300 m³ of water per day but found it challenging to map this consumption in the process. Inaccurate water usage data resulted in unaccounted water.

They manufacture >20 dye products, all of which require process water and utility water for their heating and cooling processes.

Objective

OBJECTIVE

To know the consumption of water in the process and then map its correlation with utilities consumed for manufacturing. Reducing the amount of water required for manufacturing, given it relies heavily on water during the process.

Solution

THE SOLUTION

Through EverSense for WaterMAP we were able to validate meters, correct borewell water usage and fix extraction errors.

Our experts helped establish baselines for process and utility water consumption across the plant.

Benefit

BENEFITS

Increased water accountability initially from 60% to 87% by addressing anomalies in data.

Further increased water accountability to 90% by identifying and correcting an unmetered location.

Reduced overall water consumption by 4%

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Products

Ammonia Analyser

BM 26 A

BM 26 F

BM 26 BASIC ADVANCED

BM 26 W

DW 182

DW 181

OPTIFLEX 1100 C

OPTIFLEX 1300 C

OPTIFLEX 2200 C F

Associated Services

Process Optimization

Process Optimization

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Improving Uptime

Improving Uptime

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Forbes Marshal Digital

Forbes Marshal Digital

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