Industrial water footprint: How to measure and reduce it effectively

Water is part of virtually all industrial processes, although its consumption often goes unnoticed until restrictions appear, costs increase, or new regulatory requirements arise. 

Knowing how much water a company actually uses and how it uses it is the first step to optimizing resources and ensuring operational continuity.

The industrial water footprint provides this comprehensive view . Beyond simply counting cubic meters consumed, it helps identify where the greatest losses occur, which processes can be optimized, and what opportunities exist to reuse water or improve its treatment.

What is the industrial water footprint and why is it important?

More and more companies are incorporating environmental indicators to assess the impact of their activities. Among these, the water footprint has become a useful tool for making data-driven decisions.

The industrial water footprint measures the total volume of freshwater used directly and indirectly during a production process . It includes not only the water used for manufacturing, cleaning, or cooling, but also the water needed to produce raw materials, generate energy, or treat wastewater.

This indicator allows us to know the real impact of water consumption and facilitates the comparison between different processes, plants or production lines.

Furthermore, having this information is especially useful for:

• Detect unnecessary consumption.
• Prioritize investments with the highest return.
• Reduce operating costs.
• Comply with environmental and sustainability requirements.
• Anticipate potential supply restrictions.

How to calculate a company's water footprint

Before proposing improvement measures, it is advisable to know precisely how water is used within the facility. 

Define the scope of the study

The first step in calculating a company's water footprint is to define which processes will be analyzed.

Depending on the objective, the study can focus on a single production line, a complete plant, or the entire organization, including even the supply chain.

The greater the scope, the more complete the picture of consumption will be.

Collect consumption data

Once the scope has been defined, it is necessary to gather information from:

• General and sector-specific accountants.
• Process equipment.
• Cooling towers.
• Boilers.
• CIP Systems.
• Cleaning processes.
• Water treatment.
• Historical operating records.

Digitalization greatly facilitates this work. In fact, monitoring tools such as those used in smart plant management allow for continuous data collection and the detection of deviations in near real time.

Analyze the fate of the water

Not all water consumed behaves the same way.

Part of it is incorporated into the final product, another part evaporates, another part is reused internally , and another part ends up as wastewater that requires treatment before being discharged.

Understanding this water balance allows us to identify which processes have the greatest potential for improvement.

Factors that influence the industrial water footprint

The amount of water needed to manufacture the same product can vary considerably between similar companies.

The difference is usually found in aspects related to the design of the facilities and the way they operate.

Technology used

More efficient equipment reduces both water and energy consumption.

The incorporation of recirculation systems, advanced filtration or membranes allows for a significant reduction in the intake of new water.

Condition of the facilities

Leaks, damaged valves, or poorly calibrated equipment can represent thousands of cubic meters of wasted water each year.

For this reason, proper operation and maintenance of treatment plants is essential to maintain the efficiency of the entire system.

industry type

Sectors such as food, chemical, pharmaceutical, paper or textile have very different water needs.

Each activity requires a specific strategy to improve its industrial water efficiency, taking into account the necessary water quality and the possibilities for reuse.

Strategies to reduce the water footprint

Once the areas where consumption is concentrated have been identified, it's time to act.

Large investments are not always necessary. Often, small operational improvements generate immediate results.

Optimize production processes

Reviewing washing times, automating cleanings, or adjusting flow rates are relatively simple measures that allow for a reduction in water footprint without affecting production.

It is also advisable to periodically review specific consumption per ton produced to detect deviations.

Reuse treated water

Wastewater treatment opens up new possibilities for reducing the demand for water supply.

Depending on the required quality, reclaimed water can be used for:

• Cooling towers.
• Industrial cleaning.
• auxiliary services.
• Irrigation of green areas.
• Certain production processes.

Reuse reduces the extraction of natural resources and improves sustainable water management within the company.

You may be interested in → How to implement water-saving measures in industry and agriculture without affecting productivity

Improve water treatment

A well-sized treatment system allows for better use of every cubic meter of water.

Technologies such as ultrafiltration, reverse osmosis , ion exchange or advanced biological treatments make it easier to obtain water suitable for new industrial uses.

In processes that require high purity, such as the pharmaceutical, energy or electronics sectors, the production of demineralized water is especially relevant.

We recommend this article → Production of demineralized water in industry.

Implement monitoring systems

Digitization allows us to know in real time what is happening at each point in the process.

Thanks to specific industrial water management tools , it is possible to detect leaks, control abnormal consumption, and automatically optimize certain operational processes.

Benefits of sustainable water management in industry

Reducing water consumption not only has an impact on economic savings.

A strategy based on sustainable water management generates advantages that affect the entire organization.

Lower operating costs

Optimizing water use directly impacts other associated consumption, such as the energy needed to pump, treat or heat it, as well as reducing the use of chemicals.

Greater resilience to scarcity

Water availability has become a strategic factor for many industries. Having reuse and optimization systems helps maintain production even in scenarios of restrictions or drought.

Normative compliance

The demands related to efficient water use and reuse continue to evolve.

Having reliable indicators makes it easier to demonstrate compliance with environmental requirements and prepare for future audits or certifications.

Improved environmental performance

A smaller industrial water footprint usually also translates into a reduction in energy consumption, wastewater generation and the impact associated with the entire water cycle.

The role of technology in industrial water efficiency

Continuous improvement requires reliable information.

Today it is possible to know precisely how an installation behaves thanks to the integration of sensors, automation systems and data analysis tools.

These tools allow for anticipating incidents , optimizing the operation of treatment plants, and evaluating the real impact of each implemented measure.

In complex industrial projects, this analytical capability makes it easier to prioritize investments and maximize the return on investment for actions aimed at industrial water efficiency.

Turning the water footprint into an opportunity for improvement

The industrial water footprint should not be understood solely as an environmental indicator. When used properly, it provides valuable information for optimizing processes, reducing costs, and making better use of a resource that is increasingly strategic for industry.

Performing a rigorous calculation of the company's water footprint , relying on monitoring technologies, and opting for reuse and treatment solutions allows for a progressive reduction of the water footprint without compromising production.

At SITRA we develop comprehensive solutions for the treatment, reuse and digitization of the industrial water cycle, helping companies to move towards sustainable water management with higher levels of industrial water efficiency.