practical assignment_ENS4122_2019asb03.pptx

cleaner production Assessement on small food processing industry

1. Cleaner Production Assessment for Small-Scale food producing Industry 2019/ASB/03

2. Phase I: Planning and organization Phase II: Pre-assessment (qualitative review) Phase III: Assessment (quantitative review) Phase IV: Evaluation and feasibility study Phase V: Implementation and Continuation Conclusion Recommendations References Cp Assessment for Small-Scale food producing Industry Table of Contents

3. Phase I: Planning and organization Cleaner production (CP) aims to minimize waste and emissions and maximize product output by implementing environmentally-friendly and efficient processes. Aim: To enhance the sustainability and efficiency of the dhothal food-making process by reducing resource consumption, minimizing waste, and improving overall production practices through cleaner production methods. Objectives: To identify inefficiencies in the current production process. To propose feasible cleaner production techniques to optimize resource usage. To reduce waste generation and explore opportunities for waste reuse or recycling. To improve energy efficiency and lower production costs. To enhance environmental performance and compliance with local regulations. Cp Assessment for Small-Scale food producing Industry 02

4. Phase II: Pre-assessment (qualitative review) Industry description: Name : Bombay sweets and Chocolates Address : Al Aqsa junction, Beach Road, kattankudy- 03 Established : from 1986 running still Scale : small-scale (wholesale and retail) Ownership : Private Employees : 08 Productions : Dhothal , Muscat, Nei boondi , Wattalapam , Rava halwa Production is carried out daily, with an average of 200 kilograms of Dhothal being produced per month. Cp Assessment for Small-Scale food producing Industry 03

5. Phase III: Assessment (quantitative review) Raw materials: for 10kg dhothal Rice flour : 1.5 kg Sugar : 4 kg Coconut : 08 Water : 15 L Coconut oil : 02 l Fried Green gram : 100 g Salt : 10 g Cardamom powder : 10 g Used Resources : Water for soaking and cleaning Electricity for grinders firewood for frying. Cp Assessment for Small-Scale food producing Industry 04

6. Rice Process Flow Diagram (PFD) Mixing Frying Shaping Packaging Fried Dhothal Electricity Rice flour Soaking & Grinding Sugar Coconut- water mix Salt Heat (firewood) Cardamom powder Fried Green gram Coconut Oil Polythene Dhothal mixture Grated coconut Coconut shells Dhothal Waste Heat Emission & excess gas Oil evaporation Wasted oil Waste polythene Wasted oil Waste polythene Charcoal Cp Assessment for Small-Scale food producing Industry 05

7. Cp Assessment for Small-Scale food producing Industry 06

8. Material Balance Diagram for 10 kg Dhothal Mixing Frying Shaping Packaging Rice flour : 1.45 kg Waste water : 3.2 kg waste flour : 0.05 kg Total : 4.7 kg Soaking & Grinding Rice flour : 1.45 kg Coconut milk- water mix : 10.7 kg Sugar : 4 kg Salt : 0.01 kg Total : 16.16 kg Firewood : 18.6 kg Dhothal mixture : 14.71 kg Coconut Oil : 1.7 kg Cardamom powder : 0.01 g Fried Green gram : 0.1 kg Total : 35.12 kg Dhothal : 10.05 kg Polythene : 0.07 kg Total : 10.07 kg Dhothal mixture : 14.71 kg Grated coconut : 0.9 kg Coconut shells : 1.3 kg Total : 16.91 kg Dhothal : 10.3 kg Coconut Oil : 1.9 kg Charcoal : 3.4 kg Total : 15.6 kg Packed Dhothal : 10.05 kg Wasted oil : 0.05 kg Waste polythene : 0.02 kg Total : 10.12 kg Cp Assessment for Small-Scale food producing Industry 07 Dhothal : 10.05 kg Wasted oil : 0.2 kg Waste polythene : 0.03 kg Total : 10.28 kg Rice : 1.5 kg Water : 3.4 kg Total : 4.9 kg Dhothal : 10.3 kg Polythene : 0.03 kg Total : 10.03 kg

9. Energy Balance Diagram for 10 kg Dhothal Mixing Frying Shaping Packaging Rice flour : Wasted water : waste flour : Total : Soaking & Grinding Rice flour : Coconut milk- water mix : Sugar : Salt : Total : Firewood : Dhothal mixture : Coconut Oil : Cardamom powder : Fried Green gram : Total : Dhothal : Polythene : Electricity : 0.9 MJ Total : Dhothal mixture : Grated coconut : Coconut shells : Total : Dhothal : Coconut Oil : Charcoal : Total : Packed Dhothal : Wasted oil : Waste polythene : Total : Cp Assessment for Small-Scale food producing Industry 08 Dhothal : Wasted oil : Waste polythene : Total : Rice : Water : Electricity : 5.4 MJ Total : Dhothal : Polythene : Total :

10. Assessment Data Initial Observations Water usage: about 300 liters/day Electricity consumption: about 10 kWh/day Oil usage: about 15 liters/day (10% waste due to spills and overuse). Solid waste: about 20 kg/day Charcoal, 10 kg grated coconut material Identified Issues High level emission from firewood burning Excess level of electricity usages Excessive water usage for soaking and cleaning High oil waste Improper disposal of charcoal and grated coconut Polythene usages Cp Assessment for Small-Scale food producing Industry 09

11. Cleaner Production Opportunities A. Process Optimization Use water-efficient soaking methods to reduce water usage by 20%. Install timers on grinders to optimize electricity use. Use the LP gas instant of firewood B. Waste Management Reuse grated coconut as animal feed or compost material. Collect used oil for biodiesel production or safe disposal. Reuse the charcoal for water filtration or other purposes Charcoal production from wasted coconut shells Wash the tools once in the day Use the biodegradable material for packaging Conventional water treatment for the washed water C. Energy Efficiency Switch to energy-efficient fryers. Use solar panels to supplement electricity needs. Use the wooden coconut scraper Cp Assessment for Small-Scale food producing Industry 10

12. Selected cleaner Production Opportunities for evaluation and feasibility study Use the LP gas instant of firewood Reuse grated coconut as animal feed or compost material. Collect used oil for biodiesel production or safe disposal. Use the biodegradable material for packaging\ Use the wooden coconut scraper Cp Assessment for Small-Scale food producing Industry 11

13. Cp Assessment for Small-Scale food producing Industry 12 Criteria Idea A Idea B Idea C Idea D Idea E Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Investment (40%) × × × × × Rate of return (20%) × × × × × Likely profit (10%) × × × × × Expected life (30%) × × × × ×

14. Cp Assessment for Small-Scale food producing Industry 13 Scoring of ideas Idea A (1*0.4 + 4*0.2 + 4*0.1 + 5*0.3) = 3.1 Idea B (5*0.4 + 5*0.2 + 4*0.1 + 4*0.3) = 4.6 Idea C (1*0.4 + 3*0.2 + 3*0.1 + 3*0.3) = 2.2 Idea D (3*0.4 + 3*0.2 + 4*0.1 + 1*0.3) = 2.5 Idea E (4*0.4 + 4*0.2 + 3*0.1 + 1*0.3) = 3.0 Selection of ideas : B, A, E

15. Phase IV: Evaluation and feasibility study A. Financial Feasibility Reduced operational costs. Potential revenue from waste by-products like biodiesel or compost material. B. Technical Feasibility Water recycling and oil filtration systems are locally available. Energy-efficient fryers are compatible with current operations. Solar panels can be integrated into existing electrical systems. Simple installation procedures with minimal downtime. Worker training ensures smooth adoption. Regular maintenance for new systems is straightforward and cost-effective. Cp Assessment for Small-Scale food producing Industry 14

16. C. Environmental Feasibility Recycling water reduces the strain on local water resources. Used cooking oil repurposed for biodiesel minimizes hazardous waste. Switching to energy-efficient fryers reduces energy use Solar panel adoption cuts reliance on non-renewable electricity. D. Social Feasibility Cleaner, safer environment due to reduced waste and emissions. Enhanced morale among workers through training and sustainable practices. Opportunities to partner with local farmers or waste management services. Attracts environmentally conscious customers. Increased market competitiveness due to sustainable branding. Cp Assessment for Small-Scale food producing Industry 15

17. Phase V: Implementation and Continuation Implementation Plan: Preparation: Train workers on new practices and technologies. Procure necessary equipment and materials. Establish timelines and allocate responsibilities. Execution: Integrate CP measures step-by-step to ensure minimal disruption. Monitor progress using baseline data for comparison. Evaluation: Review initial results to identify any bottlenecks or required adjustments. Cp Assessment for Small-Scale food producing Industry 16

18. B. Continuation Plan: Regular Monitoring to ensure sustained benefits. Feedback Mechanism to Create channels for workers to suggest further improvements. Periodic Upgrades for Evaluate and invest in advanced CP technologies as the business grows. Documentation for Maintain detailed records of processes, outcomes, and cost savings for future reference. Cp Assessment for Small-Scale food producing Industry 17

19. Conclusion The CP assessment highlights that significant improvements in resource efficiency and waste management can be achieved in the dhothal -making industry. By adopting cleaner production measures, the industry not only reduces environmental impacts but also achieves cost savings and enhances overall sustainability. Cp Assessment for Small-Scale food producing Industry 18

20. Recommendations Conduct regular training for workers on CP practices. Continuously monitor resource usage and waste generation. Explore partnerships with local businesses for waste repurposing. Scale CP initiatives as the business grows. Cp Assessment for Small-Scale food producing Industry 19

21. References United Nations Environment Programme (UNEP). (2019). Cleaner Production Guidelines. Retrieved from https://www.unep.org Local Food Industry Best Practices Reports. (2022). Smith, J., & Brown, R. (2020). Case Studies on Small-Scale Food Industry CP Implementation. Journal of Sustainable Food Production, 15(3), 45-60. Anderson, P. (2018). Waste Management Strategies in Food Processing. Environmental Practices Quarterly, 10(2), 87-94. Cp Assessment for Small-Scale food producing Industry 20

22. Cp Assessment for Small-Scale food producing Industry