What goes into a process must come out somewhere else. Based on the process flow chart and quantified inputs and outputs prepared in the previous tasks, try to “balance” the inputs and outputs side.

Any inputs that do not come out as useful outputs (e.g. product, steam) are considered “losses”. These can include losses of energy (e.g. through heat, blow-down, flue gases, un-burnt materials), and losses of products and materials (e.g. water, chemicals, product rejects and off cuts).

Using the cost information (task 2d), calculate the costs of the losses. This will allow you to focus on options from a cost and resource point of view.

Completing a full and detailed material and energy balance could take a long time, especially if there is little data on inputs and outputs at the company. It is also more difficult to determine energy losses because energy is not as tangible as raw materials and wastes.

It is important to be practical and focus on quantifying at least the biggest and most expensive losses, because this will form the basis of identifying options for improvement. See Company examples for examples of companies that participated in the GERIAP project on how they prepared a useful material and energy balance.

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