This study addresses water consumption optimization in the liquid household cleaning products (Home Care Liquids, HCL) plant at Unilever Andina S.A. in Cochabamba, Bolivia. Although the plant operated with a Washing Matrix specifying recirculation and waiting times for product changeover cleaning, significant inefficiencies were identified, including excessive water use, non-standardized operator practices, and recurrent cross-contamination incidents. An applied, quantitative, experimental study was conducted combining time-and-motion analysis, water consumption measurements across 105 equipment wash cycles and 60 packaging-line cycles, and semi-structured operator interviews. A multi-criteria evaluation framework was employed to select and prioritize five improvement proposals: production schedule reorganization to reduce changeover frequency; updating the Washing Matrix infographic and standardized operating procedures; introducing hot-water washing with SCADA-controlled dosing cycles; replacing conventional hoses with pressure washers; and eliminating an unnecessary bottle-rinse tank in the ROTAC packaging line. Validation between December 2024 and March 2025 confirmed a 20% reduction in monthly water consumption for cleaning activities, from 45.6 m³/month to 36.48 m³/month, equivalent to a saving of 9.12 m³/month. The overall water consumption indicator per ton produced fell 24.69%, from 1.62 m³/t to 1.22 m³/t. Complementary benefits included zero cross-contamination incidents, reduced wastewater plant loading, improved packaging-line efficiency, and an estimated monthly cost saving of BOB 4,539. The integrated methodology demonstrates a replicable framework for water stewardship in fast-moving consumer goods manufacturing, with direct alignment to corporate sustainability targets and Bolivia's Environmental Law No. 1333.

Keywords

Water consumption optimization, washing matrix, standardized procedures, SCADA automation, industrial hygiene.