How a top Rubber Manufacturer saved 25% in Water Costs and $60,000 per factory annually

Our client wanted to monitor and optimize the water usage in their Rubber Manufacturing facility. To reuse and subsequently save water, they needed to assess the water quality in the treatment tank. Datakrew effectively addressed their need by setting up an IoT-powered Smart Water Monitoring Solution to monitor and assess the water quality in the treatment plant.

Our client is the world's leading rubber franchisee operating over 36 rubber factories in 5 countries. They produce Crumb Rubber and Latex in Southeast Asia, China, and Africa at their processing facilities. They act as a supply chain manager, specializing in the origination, production, and distribution of natural rubber.

Rubber manufacturing is an extremely water-intensive process. Our client regularly reused the water used for washing rubber pellets to minimize wastage. However water quality assessment solely relied on visual inspection and there was no data on crucial parameters like pH, turbidity, conductivity, and oxidation-reduction potential (ORP). This led to pumping in more water and untimely disposal of still usable water causing significant water wastage. And since electric motors were used to pump water every so often, substantial energy loss occurred. Our client wanted to optimize their water usage and reduce energy consumption.

Datakrew effectively addressed the client's requirement and installed water monitoring sensors to monitor and assess water quality in the treatment plant.

This IoT monitoring solution gathered instantaneous measurements of significant water quality parameters such as:

To achieve this, various water monitoring probe sensors, all of which are IP68-rated, submersible in water, and appropriate for use in industrial treatment facilities with CEP certification were utilized.

With the continuous monitoring of the water quality using the submersible water monitoring probe sensors, accurate data on water quality parameters were obtained. The pH, turbidity, conductivity levels, and oxidation-reduction potential (ORP) determined if the water was reusable or not.

These readings helped our client in making data-backed decisions instead of being solely dependent on visual inspection. This also maximized the reusability of water to its fullest potential thereby significantly cutting down on both water and energy loss.