FMCG plant utility monitoring, measured per business unit across the campus
FMCG plant utility monitoring measures water, electricity, steam and compressed air for each business unit on a campus, from milling and beverages to edible oils and personal care. Aqueduct puts every unit on one live view, ranks them by use per tonne or per litre of output, finds leaks, idle load and drift, routes the fix to your CMMS and verifies the result at the meter.
Where utilities go on a multi-unit FMCG campus
| Business unit | Heaviest utilities | What Aqueduct measures first |
|---|---|---|
| Grain milling | Electricity for mills, conveying and dust extraction | Feeder kW per tonne milled, idle running between batches |
| Beverages and juices | Process water, CIP, rinsing, RO polishing, boilers and cooling | Water balance per line, CIP per cycle, RO recovery |
| Dairy and ghee | Steam, refrigeration, CIP water | Steam per batch, refrigeration efficiency, CIP water |
| Edible oil refining | Steam, vacuum systems, cooling loads | Steam and power per tonne refined, cooling tower make-up |
Why a campus of plants is hard to run as one
Units that cannot be compared
A large unit and a small, intense unit show up as two totals. Intensity per tonne or litre is never worked out.
Shared utilities, no allocation
Steam, compressed air and treated water come from a central utilities block, and every unit disputes its share.
Losses between the meters
Water and power lost between the main incomer and the units sits in nobody's budget.
Disclosure from spreadsheets
BRSR and other water and energy disclosures are compiled by hand from bills and logbooks.
What the numbers say.
lost by US discrete manufacturers to preventable maintenance problems in 2016.
Source: NISTaverage recovery time after a stop in 2024, up from 49.
Source: Siemens, 2024Sources2 references cited on this page
Related
Common questions
Meter steam, compressed air, chilled water and treated water at each unit boundary, then allocate the central utilities block's cost on measured use. Aqueduct does this from live data, so allocation reflects what each unit actually drew that month.
With one self-contained, high intensity unit, often beverages or dairy, where process water, CIP, boilers and cooling all sit under one roof. Aqueduct proves the approach there, then repeats it unit by unit.
Yes, with the measured inputs. Aqueduct supplies the water withdrawal, consumption, discharge, reuse and energy data that BRSR disclosures draw on, per unit and per site. Your sustainability team prepares and files the report. See BRSR Core.
By intensity, not totals. Aqueduct divides each unit's water, power and steam by its own output, per tonne milled or per kiloliter bottled, so a small intense unit and a large efficient one are judged fairly. Units are then ranked by distance from their own baseline.
See Aqueduct on your own facility.
Bring a site, a utility bill or a question. We will show you where the loss is.