maximising bioresources energy generation (without new assets)

As pressure mounts on water companies to increase energy self-sufficiency and meet ambitious carbon targets, many are asking: Are we really getting the most out of the assets we already have? 

For many, the answer is no. Significant opportunities to boost Combined Heat and Power (CHP) performance remain untapped, not because of technology gaps, but because of operational ones. 

The good news? Improving energy generation doesn’t always require expensive capital investment. Sometimes, all it takes is a sharper operational focus, better supplier management, and smarter planning.  

Here’s how organisations are doing it. 

The Hidden Causes of Underperformance 

Across the sector, we see similar themes when it comes to underperforming energy generation from sludge: 

  • Unplanned downtime due to reactive or poorly managed CHP maintenance 

  • Long lead times for engine overhauls, creating asset gaps 

  • Maintenance backlogs that reduce availability and create instability in digestion 

  • Site-level planning that optimises individual plants, but not the system as a whole 

These issues rarely stem from a lack of commitment or capability. They come from misaligned focus, fragmented responsibility, and a lack of real-time performance visibility. 

What High Performers Are Doing Differently 

Leading operators are closing this performance gap by focusing on three key levers: 

1. Aligning Production Planning to Regional Performance 

Rather than optimising site-by-site, they plan energy production at a regional level, enabling better prioritisation of resources and balancing demand with CHP availability. 

2. Reframing the Role of Operations 

They elevate energy generation as a core operational goal, embedding it in team structures, KPIs, and daily routines. This shift brings clarity and urgency to decision-making. 

3. Tightening Maintenance Supplier Management 

Instead of accepting reactive service levels, they introduce proactive KPIs, collaborate on improvement plans, and apply lean principles to major overhaul planning, which reduces lead times and boosts uptime. 

What’s Possible Without New Spend? 

By focusing on process, performance, and accountability, one operator recently: 

  • Increased annual generation by 9%, avoiding over £1.8m in costs 

  • Reduced CHP engine overhaul times by 64% 

  • Improved maintenance team efficiency by 17%, saving £370k 

  • Achieved an 11:1 ROI and in-year payback 

And they did it without investing in new technology or infrastructure. 

Are You Leaving Energy (and Value) on the Table? 

Every wastewater treatment site has potential, but real system optimisation takes more than targets. It takes the right focus, structures, and routines to translate sludge into consistent, high-value output. 
 
Whether you’re struggling with asset reliability, missing generation targets, or simply looking to optimise the performance of your CHP supplier, we can help. 

Want to see what hidden value your existing bioresources operation could unlock? 

Get in touch and we’d be happy to share our approach! 

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maximising energy yield from sludge: mastering the energy generation systems    

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