Improving Water Treatment Efficiency and Compliance

A leading manufacturing facility of a multinational conglomerate was strategically focused on reducing water consumption, increasing water reuse, and minimising COD discharge and product losses. This facility specialised in large-scale instant coffee production with a capacity of more than 14,000 tonnes annually. This water intensive production process consisted of wet processing and fermentation. Wastewater monitoring was critical to both their sustainability and profitability goals.

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PROBLEM

Despite having monitoring systems in place, the plant lacked effective control over wastewater quality. They faced significant operational and measurement challenges that resulted in reactive decision-making and business impact.

Operational Gaps: Low analyser uptime, frequent breakdowns, high manual intervention, and maintenance dependency.
Measurement Limitations: Inconsistent COD monitoring, frequent need for calibration and validation, and lack of real-time process visibility.
Impact on OpEx and Productivity: High operating and maintenance costs, invisible product losses through COD, limited ability to improve water reuse, and a risk of non-compliance.

SOLUTION

The plant installed the Forbes Marshall deployed the CX2000-based Online Continuous Effluent Monitoring System (OCEMS) integrated with the WaterVU digital platform.

This solution transformed monitoring into continuous process intelligence by providing:

Continuous monitoring of key water parameters: COD, BOD, TSS, and pH.
Automated features, including cleaning, calibration, and drift correction, to ensure high uptime.
Real-time data visibility, trend insights, and alarms.
A robust field installation with an integrated sampling system.

BENEFITS

The implementation of the Forbes Marshall solution led to a shift from reactive troubleshooting to proactive, data-driven decision making, delivering measurable impact across several key areas.

Operational Efficiency: Increased system uptime with stable, reliable performance, and reduced maintenance effort through automation.
Improved Water Management: Achieved significant reduction in water consumption and gain in water reuse.
Process Control and Cost Savings: Enabled real-time alerts for faster corrective action, leading to early detection of losses and optimized costs.
Compliance and Sustainability: Ensured consistent compliance with accurate, continuous monitoring, aligning strongly with water reduction and sustainability goals.

By combining reliable instrumentation with digital intelligence, CX2000 OCEMS transforms wastewater monitoring into a powerful driver of efficiency, cost savings, and sustainability