2020 Water Benchmark Results
February 2022
Table of Contents
- Introduction
- Methodology
- Water Benchmarks
- Water Usage Profiles
- Year-on-Year Comparison of Water Use Benchmarks
- Water Management Practices
- Conclusion
- Recommendations
1. Introduction
In 2017, Blue North Sustainability was contracted by the Packhouse Action Group (PAG) to conduct a study on the water risks faced by pome fruit packhouse and cold storage operations and provide water consumption benchmarks for these facilities. Since 2017 Blue North has concluded two further rounds of benchmarking (Phase 2 & 3).
This report concludes the fourth phase of this project, and includes data from January to December 2020. The objectives of the fourth phase were to:
- Replicate the water use benchmark study undertaken in Phase 1, Phase 2 and Phase 3
- Increase packhouse participation
- Provide a year-on-year comparison of water use in the packhouse and cold storage operations
- Collect more detailed data around water management and recycling practices
- Incorporate an electricity benchmarking component into the project
This report presents the results from Phase 4 (2020 data) and draws a comparison between the Phase 1 (2017), Phase 2 (2018), and Phase 3 (2019) results in terms of water benchmarks. Lastly, the report summarises the different water management and recycling methodologies applied at the packhouses. Electricity benchmark results were compiled in a separate report.
2. Methodology
All new participating packhouses were onboarded with a virtual call to introduce them to the project and provide them with training on the data collection tool. Packhouses that participated in the previous phases of the project were given the option to request a training session in the new data collection tool if they deemed it necessary. A guidance video on the new data collection tool was also sent to all the participating packhouses.
2.1 Development of the data collection tool
Data was collected via the data collection tool and sense checked by the project team. Data anomalies were discussed with participants and, where applicable, rectified or reasons for the anomalies were recorded.
Phase 4 followed a similar approach to the previous phases, but included the following updates and changes to the data collection tool:
- Additional data capture fields for drenching and pre-sorting
- Additional data capture fields for water sources
- Moved the “pack line processes” section to a “water management practices” tab
- Added a tab with data fields to capture information on water recycling technologies applied
- Incorporation of electricity use and cost data capture fields
- Added a tab with data fields to capture information on the energy management practices applied
2.2 Scope of the data collection
The following five areas in pome fruit packhouses were benchmarked in terms of water consumption:
- Drenching: Water consumption for the drenching of fruit
- Pre-sort: All dedicated pre-sort line water consumption
- Packing Lines: All packing line water consumption, of which flume water use makes up the majority
- Cold Storage: Regular Atmosphere (RA) and Controlled Atmosphere (CA) facilities. Cooling tower water consumption made up the majority of cold storage water consumption
- Ablutions, Canteen & Offices: Staff water consumption
2.3 Participation
- 21 packhouses were invited to participate, of which 12 provided data.
- Of the 12, four had participated in Phase 1 and 2, in Phase 3, and three packhouses participated for the first time.
- One packhouse committed to providing data, but no further response was received after multiple follow-ups.
- Three more packhouses did not provide data for Phase 4, but committed to participating in future data collection rounds.
2.4 Notes on the data
- All data sets for Phase 4 correspond to the 2020 calendar year (January to December). Packhouses are anonymised in the report (named A to N).
- Caveats apply to some data points and where applicable, they are acknowledged in this report under “Notes”.
- In graphs, blue bars always indicate accurate/metered data, whereas the yellow bars indicate calculated or estimated data.
3. Water Benchmarks
3.1 Drenching Benchmark
3.1.1 Calculation
The Drenching benchmark is calculated as follows:
Drenching water consumption (m³) × 1000 / Tonnes of pome fruit drenched
Unit of Measure: Litres per Tonne of pome fruit drenched.
3.1.2 Results
- Only packhouses who provided drenching data are shown.
- Water consumption of Packhouses D, F, H and K were estimated due to insufficient metering.
- Packhouse I and N drenched their pome fruit, but the water used for drenching is not recorded and could not be estimated. Metering was installed in 2021.
- Packhouse B reuses drenching water approximately 5 to 6 times before the drenching tank is drained and refilled.
3.2 Dedicated Pre-sorter Benchmark
3.2.1 Calculation
Pre-sort water consumption (m³) × 1000 / Tonnes of pome fruit for dedicated pre-sort line
Unit of Measure: Litres per Tonne of pome fruit for dedicated pre-sort line.
3.2.2 Results
- Only packhouses with a dedicated pre-sort line are shown.
- Only packhouse M could provide metered water use data for the pre-sort line; the benchmarks for the other packhouses are all estimates due to a lack of metering.
3.3 Packing Line Benchmark
3.3.1 Calculation
Flume & pack floor water consumption (m³) × 1000 / Tonnes of pome fruit packed
Unit of Measure: Litres per Tonne of pome fruit packed.
3.3.2 Results
- Water consumption of Packhouses D, F, H, K and M were estimated due to insufficient metering.
- Packhouse B’s pack line water benchmark is very high due to inclusion of water used for ablutions and garden irrigation.
- Packhouse C, I, L, and N’s benchmarks are low or estimated due to allocation or metering issues.
3.4 Cold Storage Benchmark
3.4.1 Calculation
Cold storage water consumption (m³) × 1000 / (CA & RA Tonne.Days)
Unit of Measure: Litres per Tonne.Day of fruit stored.
3.4.2 Results
- Water consumption of Packhouses C, F, H, K and M were estimated due to insufficient metering.
- Packhouse L and N’s cold storage water consumption was not metered.
- Considering only packhouses with good quality data (A, B, D, G & I), cold storage water consumption varies greatly (up to seven times) between them.
3.5 Ablutions, Canteen & Offices Benchmark
3.5.1 Calculation
Ablutions, Canteen & Offices water consumption (m³) × 1000 / (Staff man days)
Unit of Measure: Litres per Person per Day.
3.5.2 Results
- Water consumption of ablutions, canteens and offices for some packhouses could not be clearly allocated or estimated.
- Good quality data (Packhouse A & D) ranged from 39 to 48 litres per person per day.
3.6 Overall Packhouse Benchmark
- The overall benchmark for each packhouse incorporates water use for all sections of the packhouse, excluding water consumption allocated as “other”.
- Unit of Measure: m³ per tonne of pome fruit packed.
- In 2020, a packhouse used approximately 1 to 1.5 m³ of water per tonne of pome fruit packed.
4. Water Usage Profiles
It is useful to compare the water use profiles of different packhouses.
4.1 Results
Table 1: Summary of packhouse data quality for the different areas/activities
| Packhouse | Drenching | Pre-sort | Packing line | Cold storage | Ablutions, canteens and offices |
|---|---|---|---|---|---|
| A | Metered | N/A | Metered | Metered | Metered |
| B | Metered | N/A | Estimated | Metered | Estimated |
| C | N/A | N/A | Estimated | Estimated | Estimated |
| D | Estimated | Estimated | Estimated | Metered | Metered |
| F | Estimated | Estimated | Estimated | Estimated | Estimated |
| G | N/A | N/A | Metered | Metered | Estimated |
| H | Estimated | N/A | Estimated | Estimated | Estimated |
| I | No data | Estimated | Estimated | Metered | Estimated |
| K | Estimated | Estimated | Estimated | Estimated | Estimated |
| L | N/A | Estimated | Estimated | Estimated | Estimated |
| M | Metered | Metered | Estimated | Estimated | No data |
| N | No data | N/A | Estimated | No data | No data |
4.2 Variation in Water Use Profiles
Large variances in the water use profile of participating packhouses could be attributed to:
- Lack of metering (thus estimations)
- Water consumption that is metered, but cannot be allocated to specific areas
- Lack of water consumption records
- Errors in water consumption records
- Different types of flume technology used
- Different water recycling technologies applied
5. Year-on-Year Comparison of Water Use Benchmarks
- Year-on-year water benchmark comparison for Phase 1 (2017), Phase 2 (2018), Phase 3 (2019), and Phase 4 (2020).
- Upward trend in water consumption from 2017-2019 could be attributed to the lifting of water restrictions.
- In 2020, water consumption for the packing line and the ablutions, canteen and offices has gone up only by a very small margin, while cooling tower water consumption has shown a decrease.
6. Water Management Practices
Packhouses were asked a series of quantitative and qualitative questions around packing line and water reuse technologies and practices.
6.1 Flume Technology Age
- Majority of the packhouses use flume technology that is more than 10 years old.
- Only packhouse I makes use of the latest flume technology.
6.2 Flume Water Management
6.2.1 Standard Water Management Processes
pH Management:
- Five packhouses monitor pH levels at regular intervals; one does not make adjustments.
- Five packhouses have no pH management process.
- One manages only ORP levels.
- One measures water pH once a year.
Acceptable pH levels reported:
- 6.5 – 7.8 by one packhouse
- 7.0 – 7.5 by one packhouse
Chlorine Management:
- Nine packhouses monitor chlorine levels at regular intervals.
- One uses chlorine dioxide, one uses hypochlorite chlorine.
- Corrective actions are taken as necessary.
Acceptable chlorine levels reported:
- 2–5 ppm by one packhouse
- 4–5 ppm by one packhouse
- 10–30 ppm by one packhouse
- 25 ppm by one packhouse
- 50 ppm by two packhouses
6.2.2 Cumulative Flume Water Holding Capacity
- 11 packhouses reported capacity ranging from 15–400 m³.
- Average cumulative packhouse flume water holding capacity: 191 m³.
6.2.3 Flume Water Drainage Cycle
- Eight of the 12 packhouses drain 100% of their flume water once a week.
- Packhouse C: once every two weeks.
- Packhouse I: keeps water for three months, then filters via reedbeds.
- Packhouse L: drains only two or three times per year, otherwise just tops up.
- Packhouse M: drains packing line flumes twice per week and pre-sort plants 4–5 times per season.
6.2.4 Flume Cleaning Processes
- All packhouses use the same cleaning method: drain, wash/rinse with high-pressure water and soap, broom, rinse/flush, refill.
- Some add chlorine after refilling; some do not use chemical treatment.
6.3 Water Recycling Technologies
6.3.1 Flume Water
- Four packhouses drain flume water into a dam or pond, then to river, groundwater, or wetland.
- Three do not recycle flume water.
- One recycles for three months before filtering via reedbeds.
- Two filter via reeds or wetland.
- Two dispose via storm drain system.
6.3.2 Rainwater
- Four packhouses harvest rainwater.
- Two use for refrigeration plant condensers.
- One uses for production line, borehole water, and gardens.
- One pumps to natural filtration system, then to supply dam.
6.3.3 Drenching
- Four packhouses use technologies in drenching process:
- Perforated grid (3mm mesh)
- Drains to dam, then to municipal water source
- Multiple filtration and sterilisation technologies; 70% sprayed on roads
- Sand filter system in borehole
6.3.4 Pre-sort/Packing Line
- Five packhouses use technologies in pre-sort/packing line:
- Lime filtration, AFM, GAC, auto backwash, ozone, micro bag, chlorine sterilisation
- Standard MAF RODA filtration
- Gas filters
- Sand filters (four packhouses)
- UV sterilization (four packhouses)
- Carbon filters (three packhouses)
6.3.5 Cold Storage
- Four packhouses use recycling technologies in cold storage:
- Defrost water to refrigeration plant room tanks
- TDS controller for water levels
- 60% of defrost water to natural filtration
- Re-uses condenser water in holding tanks
6.3.6 Ablutions, Canteens and Offices
- Two packhouses use recycling technologies:
- Wastewater to municipal facility; fresh drinking water from rainwater tanks
- Biozone sewage treatment system
7. Conclusion
- Nine packhouses from Phase 3 returned for Phase 4; three new packhouses participated.
- More participation increases benchmark value.
- Most common reason for not participating: insufficient water metering, technologies, and procedures.
- Year-on-year comparison builds value and raises discussion points.
- More accurate data from more packhouses is required to confirm trends.
- Collection of drenching and pre-sort water use data, as well as water management practices and recycling technologies, has proved valuable.
- Splitting out drenching and pre-sort water use allows for more accurate packing line benchmarks.
- Differences in water management practices and recycling technologies could explain variances in benchmarks.
Areas of concern:
- Many packhouses do not meter specific areas, so do not have an accurate picture of water consumption.
- Water meters are sometimes not read or recorded.
- Rainwater harvesting and recycling technologies lower water consumption but are only applied by a few packhouses.
8. Recommendations
- Communicate the impact of metering, record keeping, and data issues on benchmark results.
- Understand reasons for metering issues in the next round of data collection.
- Implement good water management practices:
- Metering and consistent record keeping
- Formalised strategy/water policy and management plan
- Setting water reduction targets
- Staff training on water use efficiency
- Use alternative water supplies (rainwater, groundwater, surface water, basement water)
- Re-use water where possible
- Maximise cooling tower cycles of concentration
- Longer retention of drenching and flume water
- Regular inspection and repair of leaks and equipment
- Use efficient fittings and technologies (flow restrictors, tap aerators, autostop sensors, automatic shut off valves, waterless urinals, dual flush toilets, etc.)
- Ask participating packhouses for suggestions to improve the data collection tool and processes.
- Include questions on preventative maintenance (leak detection and repair) in the next round of data collection.