Evaluating the potentials of adopting cleaner production techniques to reduce the manufacturing cost of rice flour and coffee
No Thumbnail Available
Date
2015
Journal Title
Journal ISSN
Volume Title
Publisher
Uva Wellassa University of Sri Lanka
Abstract
The increment of cost of production (COP) whilst consumer pressure for a lower price is a major
constraint for the sustainable growth of rice and coffee processing sector in Sri Lanka. Several studies
have been investigated to find effective ways of minimizing COP, (Brezet and Schelleman, 1995)
however literature do not evidence any use of cleaner production, a waste zeroing system. This study
was aimed to evaluate the cleaner production concept in rice and coffee processing sectors, as a
solution for minimizing COP. Cleaner production is the continuous application of an integrated
preventive strategy to processes, products and services, to increase eco-efficiency and to reduce risks
to humans and the environment (Brezet and Schelleman, 1995).
Methodology
Using Ruhunu Foods (Pvt). Ltd flour and spice processing factory as the host, the production process
was analyzed to identify possible waste streams and their causes. Using direct measurements and
material balance calculations, the waste streams were then quantified. This was done during a period
of one month batch production from both processing sections. The quantified wastes were then
expressed in terms of their monetary value. Significant waste streams were identified using Pareto
analysis. Control measures for them were suggested using CP philosophy and CP techniques as a
guide. Ten minute power logger data were obtained from both hammer mill machine and flour mill
machine. Then the power factor correction was done to find the payback period for the energy saving
process.
Result and Discussion
According to the findings of this study, both avoidable and unavoidable wastes occur in the coffee
flour manufacturing process. The average loss per batch of money due to avoidable wastes of red
rice, white rice and coffee processing are respectively LKR.3885.07, LKR.7612.5, and LKR.1529.39.
Significant waste streams which contribute to this monetary loss are stuck red and white rice flour
and coffee powder inside the milling and grinding machines (89.75%, 93.59%, 97.46%), rejected
coffee beans (59.51%). The possible control measures for these waste streams are good
housekeeping, better process controlling and equipment modifications. Ten minute power logger data
were indicted both flour mill and hammer mill have a low power factor. According to the power
factor correction both milling process takes less than 4 years payback period to recover the cost of
the energy upgrade from the energy savings. Usage of premium efficiency motors and capacitor
banks will save the energy. Immediate implementation of cleaner production will uphold the
company image and increase the quality, productivity, worker satisfaction and profit.
Description
Keywords
Science and Technology, Technology, Agriculture, Export Agriculture, Crop Production, National Cleaner Production