Realised, not projected
50 million cubic metres of fresh water, saved
Since 2010, across 1.3 million tonnes of fabric processed by customers running our expert systems. These are measured outcomes from installed plants, not modelled savings from a business case.
Where it comes from
Why an expert system saves water at all
Almost all of it comes from getting the batch right the first time. In a dyehouse, a shade that misses is reprocessed, and a reprocess costs the water, the steam, the chemicals and the hours all over again. The same is true of a failed batch in a dairy or a detergent plant.
Recipe, not equipment
T-DH optimises the recipe and the machine settings against a built-in knowledge base plus rules specific to your plant. Fewer misses means fewer reprocesses, and fewer reprocesses is where the 38 litres per kilogram comes from. No new machinery is involved.
Then the schedule
T-APS takes the second layer: sequencing work so machines run fuller, changeovers are fewer, and steam and heat are not spent bringing equipment up for a half-load. That is where much of the 350 million kilowatt hours and four million tonnes of steam were saved.
And the dosing
An optimised recipe only helps if what reaches the machine matches it. Systain DWS closes that gap between what the recipe says and what actually goes in.
The cost, in the same breath
The environmental figures and the commercial ones are the same event described twice. Water, steam, electricity and chemicals not consumed are also money not spent, which is how 1.3 million tonnes of fabric turned into somewhere between 130 and 260 million US dollars of customer savings.
Putting it in perspective
The numbers, in things you can picture
- 5 billion people50 million m³ of water covers their daily fresh water needs, on the World Health Organization's own per-person figure.
- 3,300 flights1.3 million tonnes of CO₂ equals the emissions of 3,300 flights from Beijing to London.
- 650 million treesThe same CO₂ figure is what 26,000 square kilometres of mature forest absorbs in a year.
- 25,000 truckloadsThe 500,000 tonnes of coal equivalent saved in steam and electricity would fill 25,000 lorries.
Technical call
Forty minutes with an engineer, not a salesperson
Tell us what you make and how the plant runs now. We will tell you which of the systems is relevant, what it would realistically save, and how long commissioning takes. If none of it fits, we will say so.
- No charge and no obligation
- An engineer who has commissioned these systems, not an account manager
- An honest savings range for your process, not a generic figure
- A realistic implementation timeline before you commit anything
Free, 18 pages
The Process Efficiency Benchmark 2026
What manufacturers across 25 countries actually saved per kilogram produced, and the four things that separate the top quartile from everyone else.
- Water, energy, CO₂ and cost saved per kilogram, benchmarked by sector
- Where the savings actually come from: recipe, schedule, dispensing or maintenance
- What a realistic first-year figure looks like, and how long commissioning takes
- The questions worth asking any expert-system vendor before you sign
PDF, no sign-up wall
Send me the benchmark
One email with the PDF. No sequence, no sales call unless you ask for one.
We send the report and nothing else unless you ask. See our privacy notice.