Ecodesign of Industrial Cleaning Agents: How to Reduce Water and Energy Consumption Without Losing Efficiency

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Industrial cleaning and washing agents are an essential part of manufacturing processes, but their use often results in high consumption of water, energy, and chemicals. With increasing pressure for sustainability and reducing operational costs, more and more companies are focusing on ecodesign – the design of products and processes that minimize environmental impact. The key to success lies not only in selecting more sustainable raw materials but also in optimizing the entire cleaning cycle. How can this be achieved without compromising efficiency? The answer lies in combining the right chemical components, technological adjustments, and a systematic approach to processes.

Ecodesign as a strategy for sustainable production of cleaning agents

Ecodesign of industrial cleaning agents is not just a fashionable trend but a necessity in an era of growing demands for sustainability and reducing environmental impacts. The foundation of ecodesign is the minimisation of resource consumption—water, energy, and raw materials—while maintaining or even improving cleaning efficiency. In practice, this means re-evaluating the entire product lifecycle, from raw material selection through manufacturing processes to application and disposal of residues. For example, replacing traditional petroleum-based surfactants with biodegradable alternatives from renewable sources can reduce the ecological footprint by up to 30% without compromising detergency.

An important aspect is also the optimisation of active substance concentrations. Many industrial cleaning agents are used in excessive quantities, increasing water consumption during rinsing and burdening wastewater treatment plants. Ecodesigned products often work with lower dosages but higher efficiency due to synergy between components. For instance, combining anionic and non-ionic surfactants allows achieving the desired cleanliness at a lower concentration, saving not only raw materials but also the energy required to heat water.

Reducing Water Consumption: Effective Techniques and Product Formulations

Water consumption represents one of the biggest environmental challenges associated with industrial cleaning. Solutions include adjusting the composition of cleaning agents and optimising application processes. A key role is played by so-called low-foaming surfactants, which enable effective cleaning even at lower temperatures and with less water. These substances reduce the surface tension of water, improving wetting and facilitating the removal of dirt without the need for intensive mechanical action.

Another approach is the use of enzymes or microorganisms that break down organic impurities even at low temperatures. This allows the temperature of washing or cleaning baths to be reduced by 10–20 °C, leading to energy savings and, at the same time, lower water consumption. In industrial operations, water recirculation systems have also proven effective, where rinse water is filtered and reused. This can reduce overall water consumption by up to 50% without compromising cleaning quality.

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Energy savings: How to optimise temperature regimes and processes

The energy intensity of industrial cleaning is often an underestimated factor, even though heating water and operating cleaning equipment account for a significant portion of operational costs. Eco-designed cleaning agents enable effective cleaning at temperatures as low as 30–40 °C, which is 20–30 °C lower than with traditional products. This can be achieved, for example, by combining surfactants with chelating agents, which soften water and prevent the deposition of mineral impurities, thereby reducing the need for high temperatures.

In industrial operations, it is also important to optimise time and temperature regimes. For instance, pre-treating surfaces with low-temperature cleaning agents can shorten the main washing cycle, saving energy. Another effective measure is the use of waste heat from other processes to pre-heat water. Combined with modern dosing systems that minimise chemical waste, energy savings of up to 40 % can be achieved without negatively impacting cleaning quality.

Certifications and legislation: How to navigate ecological requirements

Selecting environmentally friendly cleaning agents is complicated by the multitude of certifications and legislative requirements. The basic regulation in the EU is REACH, which governs the use of chemical substances and emphasises their safety for health and the environment. Additionally, attention must be paid to the CLP/GHS regulation, which sets rules for the classification, labelling, and packaging of chemical mixtures. However, these regulations do not directly address environmental friendliness, so manufacturers often turn to voluntary certifications such as EU Ecolabel or Nordic Swan.

When selecting cleaning agents, it is important to verify whether the product meets requirements for biodegradability, toxicity to aquatic organisms, and the content of hazardous substances. For example, the EU Ecolabel guarantees that the product has minimal environmental impact throughout its entire life cycle. For industrial applications, certifications focused on specific sectors, such as food processing or healthcare, are also important, where hygiene and safety requirements are particularly stringent.

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Selecting Raw Materials with a Low Environmental Footprint: Biodegradability and Renewable Sources

A key step in the ecodesign of industrial cleaning agents is the selection of raw materials that minimize environmental impact. Priority should be given to substances with high biodegradability, which rapidly break down into harmless components without forming toxic metabolites. For example, anionic surfactants based on fatty acids from vegetable oils (e.g., coconut or palm) achieve biodegradability of over 90% within 28 days according to standard tests, significantly reducing the risk of accumulation in ecosystems.

Another criterion is the use of renewable resources. Polyols derived from sugarcane or starch represent a sustainable alternative to petrochemical derivatives while maintaining the required technical properties, such as low volatility or compatibility with other components. When selecting additives (e.g., complexing agents), it is advisable to prefer substances with low phosphorus or nitrogen content to limit the eutrophication load on water bodies. It is also important to verify that raw materials comply with REACH regulations and are not listed as substances of very high concern (SVHC).

Optimizing Concentration and Dosage: Less Is More

Unnecessary overdosing of cleaning agents not only increases costs but also environmental burden. Modern formulations therefore aim to maximize efficiency with the minimum amount of active substances. For example, concentrated products with a surfactant content of 15–25% (compared to the usual 5–10%) can reduce the volume of agent used by up to 50% without compromising cleaning performance. Synergy between components plays a key role – combining anionic and nonionic surfactants can enhance efficiency at lower concentrations due to improved wetting and emulsifying properties.

Automated dosing systems with an accuracy of ±2% further minimize waste. In industrial applications such as cleaning machine components or surfaces, continuous monitoring methods (e.g., measuring surface tension or pH) can be used to adjust dosing in real time based on the current level of contamination. This not only saves raw materials but also the energy required for heating water or operating cleaning lines. It is important for customers to provide clear dosing instructions and operator training to prevent application errors.

Innovative Technologies for Gentler Cleaning: From Ultrasound to Enzymatic Systems

Traditional mechanical cleaning often requires high temperatures and aggressive chemicals, which increases energy and water consumption. Physical methods such as ultrasonic cleaning offer an alternative, utilizing cavitation to remove dirt even at temperatures below 40 °C. Ultrasonic baths with a frequency of 20–40 kHz can reduce the need for chemical agents by up to 70%, while shortening cleaning time by 30–50%. This technology is particularly effective for sensitive materials such as electronic components or medical instruments, where surface damage must be minimized.

Another promising approach is enzymatic cleaning systems, which break down organic contaminants (fats, proteins, starches) using specific enzymes at temperatures of 20–50 °C. Enzymes such as lipases or proteases work in a targeted manner and do not damage materials, making them suitable for use in the food or pharmaceutical industries. Additional benefits include low toxicity and easy biodegradability. However, to achieve optimal results, it is necessary to carefully match the type of enzyme with the nature of the contamination and process conditions (pH, temperature, exposure time).

Need advice on selecting raw materials?

Every production process has its specific requirements, which is why it is important to choose the right tailor-made chemical composition. GCG Group provides detailed technical and safety data sheets for every raw material, and our experts will be happy to advise you on selecting more environmentally friendly alternatives that meet your requirements for both efficiency and sustainability. Contact us – or browse our catalogue of over 1,300 products right away.