Turn your losses into profit
Discover the true cost of product lost at changeovers. Calculate how much product your plant is losing and what it is costing you.
The dairy and beverage industry average is 40,000 L/h.
Number of product changeovers (product/water or water/product interfaces) per day.
Additional cost of treating and disposing of wastewater because of product that ends up in the drain during changeovers. The dairy industry average in Europe is 0.0012 euros per litre.
The carbon footprint of milk production, expressed as CO2 equivalent per litre, varies but generally falls within 1.3 to 7.5 kg CO2e per litre. The calculator defaults to 1.3, the low end of that range. Source: FAO, World Food and Agriculture Statistical Yearbook 2023, https://doi.org/10.4060/cc8166en
Errors in valve timings, excluding automation delays. The dairy and beverage industry average is between 10 and 180 seconds. Errors come from systematic offsets in valve timings or from batch-to-batch variation in product volume and quality. With Collo you can measure these errors and uncover the hidden losses.
Potential savings/year:
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Liters of products saved:
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Potential CO₂ reduction:
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Estimated payback period:
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Assumptions (updated 28 October 2026): the loss is the product that goes to drain in the timing error at each changeover, multiplied by flow rate, changeovers per day, production days and lines. Product cost, wastewater cost and CO2e per litre are plant-specific; the defaults are European dairy and beverage averages and the low end of the FAO carbon footprint range. The calculations are estimates based on industry averages and Collo's existing deployments; increased capacity and productivity are not included. Contact us for a detailed loss analysis of your plant.
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