Driving Sustainability Through Innovation: Dean Shelvey Leads Water Reduction Project at Kersia Bury

Water is one of our planet’s most precious resources, and at Kersia, we believe it’s our responsibility to protect it. In line with our commitment to the United Nations Sustainable Development Goals and our ambitious target to reduce carbon emissions by 42% by 2030, sustainability isn’t just a goal, it is an integral part of everything we do.

One example of this dedication comes from our Bury site, where Dean Shelvey, Production Manager, has led an innovative and impactful water reduction project that’s already delivering remarkable results.

 

The Challenge: Turning Waste into Opportunity

At Kersia Bury, a key part of our operations involves blending chemicals for supply into a wide variety of industries, predominantly detergents and disinfectants for industrial cleaning in the food & drink sector.  To maintain the highest hygiene and safety standards, our vessels must be thoroughly washed to prevent product contamination. However, the water used in this cleaning process, up to 13,000 litres per week, was historically disposed of as waste which was costly and time-consuming.

Recognising the need for change, Dean was tasked with addressing this challenge: could this water be recovered, recycled, and reused?

 

Innovative Thinking Meets Teamwork

Dean took the challenge head-on, describing it as “the biggest project I’ve ever led.” He began by assembling a cross-functional team that included Roy Woodall (Production Manager), Steven Spray and Carl Swindells (Production Supervisors), our Production Team and Sam Clemson (Regulatory Manager), Sue Frisicaro (QC Supervisor) and QC Lab. Together, they approached the problem as one team with fresh eyes and open minds.

Key steps included:

• Consulting with the Kersia Quality Control Laboratory for sampling and testing.
• Collecting and analysing samples of used wash water from each blending vessel.
• Developing a tailored plan based on technical advice and data insights.

Through a collaborative effort, the team engineered a new process that ensured every wash was captured in a clean IBC tank and stored for future use, only when blending the same product. The result? Wastewater that was once discarded is now effectively recycled.

 

Impressive Results: 90% Water Reduction

The numbers speak for themselves:

• Previous usage: 10 IBCs (~13,000 litres) of wastewater disposed of weekly.
• Current usage: Just 1 IBC (1,300 litres) of new water required per week.
• That’s a reduction of over 90%, saving more than 500,000 litres of water per year.

This shift doesn’t just save water, it also lowers costs, reduces the site’s environmental footprint, and aligns perfectly with our global sustainability commitments.

 

A Ripple Effect of Awareness

Beyond the water savings, this project has promoted a wider awareness among the Bury team about the importance of sustainable practices.

When reflecting on the project’s success, Dean modestly shares: “It was a team effort to achieve a shared goal.” And while he may downplay his leadership, his role in turning historic practice into a sustainable solution is nothing short of inspirational.

 

Looking Ahead

With the new process now fully embedded and delivering consistent results, the Bury site stands as a benchmark of what’s possible when innovation, teamwork, and sustainability come together.

At Kersia, we’re proud of Dean and the entire Bury team for showing how local action can drive global impact.  We are looking forward to seeing what is next for the operations team!