Introduction

A major manufacturer of steel pipes operates a heavy industrial site in the UK, where large amounts of water are required in the production process. The company has been working with a water management partner since 2010, initially to identify and address inefficiencies in their water usage. Over the years, they have benefited from monitoring services and leak reduction expertise, which have driven substantial reductions in water consumption, costs, and associated carbon output.

Through systematic water audits, the identification and repair of underground leaks, and the introduction of comprehensive monitoring systems, the company has been able to optimise water usage, contributing to both financial savings and sustainability in their operations.

Before Active Monitoring: Where They Were

When the partnership began in 2010, the average daily water consumption at the site was 596 m³ per day, with 493 m³ of this being constant and unnecessary usage. Early surveys and audits revealed significant inefficiencies, particularly caused by underground leaks, which led to substantial water loss. The need for a more systematic water management approach became clear.

Key Interventions by the Water Management Partner

Initially, the focus was on identifying and repairing underground leaks, which led to significant early savings. This was followed by a larger-scale intervention in which a comprehensive water network management system was introduced at the site. This included the installation of valves and sub-meters, allowing the company to easily identify problem areas, monitor specific sections of the site, and take swift action when issues arose. With 13 meters now monitored across the site, the ability to manage water usage has become much more streamlined and efficient.

The partner also helped develop a detailed site plan for better water management, enhancing the long-term strategy for optimising water usage.

The 2019 Issue: A Complicated Underground Leak

After the early successes, water usage crept up again in 2019. This increase was due to an underground leak under one of the buildings, which was difficult to access and repair. The slip lining method, a trenchless repair technique, was employed to resolve the issue. This intervention resolved the leak and helped stabilise usage once again.

After Active Monitoring: Where They Are Now

Thanks to continued monitoring, proactive leak detection, and the installation of advanced monitoring systems, the company’s water consumption has decreased significantly. In 2024, the average daily usage was 221 m³, reflecting a 63% reduction from the initial levels. The comprehensive monitoring approach, along with improvements in water systems, has contributed to a sustained reduction in both water consumption and associated costs.

Outcome and Impact

The impact of the interventions is clear:

Before Active Monitoring (2010): 596 m³ per day

After Active Monitoring (2024): 221 m³ per day (63% reduction)

Annual Water Savings: 137,000 m³ per year

Cumulative Cost Savings: £5,750,000

Cumulative Carbon Savings: 740 tonnes

The company has seen a direct revenue and sustainability impact from these water management interventions. By reducing water consumption and improving system efficiency, they have not only cut costs but also reduced their environmental footprint.

Conclusion

The ongoing success with water audit, survey, and monitoring services demonstrates the strong revenue impact that can be achieved through effective water management in heavy industries. The 63% reduction in water usage, coupled with £5,750,000 in cumulative cost savings and 740 tonnes of carbon savings, highlights the importance and benefits of proactive water management in large industrial operations.

This case study serves as a prime example of how strategic water management not only drives cost savings but also supports sustainability goals, offering both environmental and financial benefits.