This project aims to comprehensively transform water management in the food industry through the implementation of a technological solution that enables the safe recovery and reuse of water used in CIP (Cleaning in Place) processes. This cleaning method is essential for ensuring the highest hygiene standards in production lines without dismantling equipment. However, it involves intensive water consumption, especially during the final rinse stages, where the water—although carrying a low pollutant load—is usually discharged.
The proposed intervention represents an advanced water efficiency strategy. Its core objective is to significantly reduce dependence on freshwater from external sources—such as aquifers or municipal networks—by replacing it with regenerated water on-site. At the same time, it reduces the generation of industrial effluents, contributing to a more circular, resilient, and sustainable operation. Such solutions are particularly relevant in areas exposed to water stress, where industries face increasing regulatory restrictions, social pressure, and rising supply costs.
The issue addressed by this project lies in the structural inefficiency of conventional CIP processes. These operations, designed for automated cleaning without dismantling components, use chemical detergents, acids, or alkalis, followed by large volumes of rinse water to ensure system cleanliness. Under standard conditions, the final rinse water—typically low in organic and microbiological load—is discharged directly to wastewater treatment systems or sewers without any prior reuse.
This linear water use pattern creates multiple impacts: it unnecessarily increases the volume of water drawn from external sources, raises operational costs related to supply and treatment, and worsens the pollutant load discharged into the environment. This situation is especially critical in regions with limited water availability, where regulatory frameworks are increasingly demanding more sustainable practices. From an ESG and reputational perspective, maintaining water-intensive processes without efficiency measures can pose risks to companies’ social and regulatory license to operate.
The proposed technological solution involves the integration of a physical-chemical treatment system to stabilize the water from the final rinse phase of CIP processes, enabling its safe and efficient reintegration into the industrial cleaning circuit. The system is based on the integration of three complementary processes:
Once the chlorine has fulfilled its biocidal function, it is removed through an integrated dechlorination process using activated carbon filters tailored to each plant’s design. This step is essential to prevent any negative effects of chlorine on subsequent process stages or equipment materials. After treatment and dechlorination, the regenerated water reaches the required microbiological, physicochemical, and operational quality for reuse as technical water in new CIP cycles, specifically in initial stages such as pre-rinsing or intermediate rinsing.
This solution enables a structural and measurable reduction in freshwater intake while maintaining the highest food safety standards required by the industry.
The solution is modular and flexible, designed to fit both large-scale processing facilities and medium-sized installations. Implementation begins with a technical assessment of the existing CIP system, including average water volumes used, retention times, operating temperatures, and the physicochemical characteristics of the residual water generated. Based on this analysis, a tailored in-line treatment system is designed and integrated into the circuit without disrupting ongoing production.
The system captures final rinse water at a specific point in the CIP line and routes it to an autonomous treatment unit that operates continuously. This unit includes a modular electroporation chamber, an advanced oxidation reactor, and an electrolytic cell for chlorine generation. After treatment, the water passes through a dechlorination module using activated carbon filters or chemical neutralization, depending on plant design.
Treated water is stored in an intermediate technical tank and reinjected into the system for use in early stages of the next cleaning cycle. The system operates with real-time monitoring of parameters such as redox potential (ORP), turbidity, conductivity, temperature, and free chlorine concentration. This ensures that the reused water consistently meets quality standards defined by food industry health regulations.
The implementation plan includes a pilot phase under real operating conditions, followed by technical training for operational and maintenance staff, microbiological and physicochemical validation of results, and formal commissioning. An intensive monitoring protocol is established during the initial months to ensure operational stability and allow for parameter adjustments if needed.
The project is executed in close collaboration between the plant’s engineering team, the specialized water treatment technology provider, and an independent entity responsible for verifying the water benefits generated. All operational data and performance metrics are integrated into a digital monitoring platform and aligned with sustainability reporting systems based on international frameworks such as CDP, SBTi, or GRI.
The objective of this intervention is to redesign the water cycle within the CIP operations of food industry facilities by incorporating a technology that enables the capture, treatment, and reuse of water from final rinse phases. Operationally, the system can recover between 20% and 40% of the total CIP water volume, depending on the plant’s characteristics and the type of product being processed. Once treated to ensure microbiological and physicochemical stability, this recovered water is temporarily stored in an intermediate tank and reused in new cycles as pre-rinse water.
This approach displaces the need for new water intake from external sources, thus reducing net consumption and pressure on local supply systems. The technology stands out for its sanitary safety, scalability across different plant sizes, and adaptability to various industrial configurations. Its applicability has been validated across multiple food subsectors, including dairy plants, beverage factories, breweries, meat processing plants, and industrial bakeries.
As more companies adopt such solutions, they contribute to a circular water model where water is no longer a single-use input but a reusable resource within the production process. This paradigm shift yields positive impacts not only on water balance but also on efficiency, sustainability, and environmental compliance indicators across organizations.
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