A practical approach to water recovery

Water recovery has become one of the most practical and reliable ways to ease that pressure. Instead of treating water as single use, recovery focuses on how to reuse or recycle it within the process, safely, effectively and with measurable benefit.

To clarify the difference:

• Water recovery means capturing or recovering water that would otherwise go to waste. 

• Water re-use is using water from one process to then perform another without any treatment ie using rinse water for flushing the next cycle of a cleaning regime

• Water recycling goes a step further, where water is recovered, then treated so it can be used safely for another application or process.

Thinking differently about water use

Many food and drink facilities have already reduced their water use, but recovery provides an opportunity to go further. It is not just about lowering intake but making use of existing water more than once, often with only minimal treatment, in areas where it makes operational sense.

Examples include reusing rinse water from cleaning systems for washdown, or diverting pasteuriser overflow to cooling. These are not radical changes, but practical steps grounded in a solid understanding of the process. Starting with a clear water balance is essential. Mapping where water enters, where it is used, and where it leaves helps identify potential opportunities for reuse, recovery and recycling, especially when paired with operational knowledge of the site.

Large scale and smaller scale examples

Carlsberg’s brewery in Fredericia, Denmark, demonstrates what recovery can achieve when it is built into the utility strategy from the outset. Since 2021, the site has operated a large scale water recycling plant that recovers over one million cubic metres of water each year, reducing reliance on freshwater by more than half. Recovered water is treated to drinking quality and returned to production. The system incorporates biological treatment, membrane filtration, reverse osmosis and advanced oxidation, yet it is designed around the site’s operational needs, which is what makes it effective.

Most projects are not on this scale. In the UK, for example, a chilled food site faced rising mains water costs and tighter discharge limits. A detailed water mapping exercise revealed that rinse water from vegetable washing and tray cleaning was relatively clean and suitable for recovery. A system using membrane filtration and ultraviolet disinfection was installed, enabling the site to recycle water for washdown and cooling. This reduced mains water use in those areas by more than 35 percent, with the system paying for itself in under two years. The project succeeded because it was simple, practical, and closely aligned with existing operations.

Where to look first

Every site is different, but certain areas consistently offer opportunities for recovery. These include final rinse water from clean in place systems, overflow from pasteurisers, blowdown from cooling towers, and dilute waste streams from low risk processes. Data is the key to identifying viable options. If a stream appears to be waste but is relatively clean, low in solids, and consistent in temperature, it may be suitable for recovery, especially for non-contact uses such as washdown or utilities.

Making safety a priority

Quality and safety are valid concerns when considering recovery, particularly in food and drink production. The two are not in conflict, but risk assessment is essential. Each project should begin by identifying biological, chemical and operational risks, defining how these will be controlled, and establishing clear monitoring processes. At Carlsberg Fredericia, this approach was built into the design phase and continues as part of daily operations. For smaller systems the treatment may be simpler, but the principles remain the same. Confidence in quality and clarity in controls are fundamental.