Presentation on theme: "“Green Framework of Innovative Strategy (GFIS) for Sustainable Consumption and Production” Technical Working Group Meeting ICETT-EMB November 19, 2007."— Presentation transcript:
The Company OOwners: 100% Filipino, Family Corporation NNature of Business: Meat Processing YYears in the Business: 40 years (since 1967) LLocation: Dela Paz Norte, City of San Fernando, Pampanga, Philippines TTotal Site Area: 37 Hectares TTotal Building Area: 1.2 Hectares PProduct Lines: Tocino,Hotdogs,Longaniza,Hams,Bacon,Corned Beef and more. PProduction Capacity: 100MT per day SSystems in Place: HACCP/GMP Programs,Sanitation Program,Pest Control Program,Waste Management,Food Fortification Program FFacilities: Laboratory, WTF, WWTF, Refrigeration, Ice Maker,Boiler,Motor Pool,Fabrication and Engineering,Warehouse,Clinic,Canteen,Recreation Area,Smoke Rooms,Washing Area,Production Areas,Cold Storages,Weigh- Bridge, Administration Offices, AVR, Training Room and Materials Recovery Facility (under construction). PPlant Category: “AAA” Accredited (Highest International Standard given to a Meat Processing Plant) by DA-NMIS EEmployees: 1000 personnel
Activities/Services/Programs: Food Fortification Program, Joint Hog Producer-Processor Tie-up, Food Expositions and Exhibits, Trade Fair, Bar Hosting at T.V. Shows, Donations to Charity, Tree Planting Project in cooperation with DENR-EMB, Food Feeding Project in cooperation with DSWD, Waste Recycling Project, Medical Missions Affiliations: Philippine Association of Meat Processors Inc. (PAMPI) Environmental Practitioners Association (EPA) Pampanga Association of Meat Processors (PAMPRO)
Process SStraight line Production Process Raw materials (Meat,Ingredients) Cleaning/ Disinfection/weighing/ Testing Processing (curing,mixing) Cooking/Smoking Cooling/Packing/ Storing Dispatching Sales
Problems Waste Minimization -Solid waste- paper,cartons,plastics Organic waste- scrap meat,emulsions,excess food from the canteen Chemical waste- used oil,chemical disinfectants,cleaners, etc. Toxic Waste- used Batteries Water Management –Cleaning,Processing Energy Usage Minimization –fuel,electricity Work Ethic/Attitudes
Solutions Waste minimization - There must be a Sanitary/GMP/HACCP Program,SSOP,and 5’S program in place. The monitoring,recording,and documentation of all readings,results,and corrective actions taken. Formulation of a Team to train,implement,monitor,revise,formulate,modify and assess the efficiency of the programs and guidelines. Maintain good inventory control of consumables, such as cleaning chemicals, packaging materials, food additives etc., to avoid waste. Source out waste recyclers to turn recyclable materials to added savings. Maintain a Material Recovery Facility. Sun Dry Technique/ Composting for organic waste. Water Management - Preventive maintenance(pipes,valves,faucets gauges),daily monitoring, cleaning,recording and documentation. Many hoses were not equipped with shutoff nozzles and were left running when not in use. These practices resulted in excessive water use and high operating costs. Timely repair of leaking nozzles and replacement of missing nozzles was ensured during cleaner production program. Sweep up solid materials for use as by-products, instead of washing them down the drain. Fit drains with screens and/or traps to prevent solid materials from entering the effluent system. Use dry cleaning techniques to pre-clean process areas and floors before washing with water. Replacement of current urinal system to water free type urinal (under study). Installation of metering device (under negotiation)
Energy usage minimization Implement switch-off programs and install sensors to turn off or power down lights and equipment when not in use. Improve insulation on heating and cooling systems and pipe work. Insulate and cover scald tanks. Maintain a leak-free compressed air system. Improve maintenance to maximize energy efficiency of equipment. Maintain optimal combustion efficiencies on boilers. Install perimeter lighting (photocell) with automatic switch (on/off). Install capacitor bank, frequency inverter, and WYE-delta controller. Eliminate steam leaks. In addition to reducing a plant’s demand for energy, there are opportunities for using more environmentally benign sources of energy. Opportunities include replacing fuel oil or coal with cleaner fuels, such as natural gas, possibly purchasing electricity produced from renewable sources, or co-generation of electricity and heat on site. For some plants it may also be feasible to recover methane from the anaerobic digestion of high-strength effluent streams to supplement fuel supplies. Work Ethics/Attitudes Ensure that employees are aware of the environmental aspects and production costs of the company’s operations and their personal responsibilities. Train staff in good cleaning practices.
Procedure Systems Waste management Drainage System
System Results High Energy Consumption July Power Consumption August Power Consumption September Power Consumption October Power Consumption Production area reduced working days from 6 to 5 with the same production output of 30MT 712,600 KwH 676,200 KwH 5.1% Savings on our electric consumption 688,800 KwH 3.34% Savings on our electric consumption Production area reduced working days from 6 to 5. Switch Off Programs/power down for lightings 6 work days at 8 operation hours per day using 56 units (400W) metal halide lamp 1075.2 KwH consumed in 6 days 5 work days at 8 operation hours per day using 56 units (400W) metal halide lamp 896 KwH consumed 16.67% Savings 5 work days at 8 operation hours per day using 56 units (400W) metal halide lamp 896 KwH consumed 16.67% Savings
High Energy Consumption July Consumption August Consumption September Consumption October Consumption For a 8 hour operation schedule per day with 89 units (400W) metal halide lamp (Production Area) Power Down/switch off Program for Lightings 248.8 KwH consumed On a scheduled utility and maintenance day (8 hour operation) power down lights from 89 to 26 units (400W) metal halide lamp 83.2KwH consumed 66.56% Savings in comparison to having all fixtures switched ON Same 83.2KwH consumed 66.56% Savings Same 83.2KwH consumed 66.56% Savings Same 83.2KwH consumed 66.56% Savings For a 12 hour operation schedule per day with 36 units (400W) metal halide lamp (Packaging Area) Power Down/switch off Program for Lightings 172.8 KwH consumed On a scheduled utility and maintenance day (8 hour operation) power down lights from 36 to 18 units (400W) metal halide lamp 57.6KwH consumed 67% Savings in comparison to having all fixtures switched ON Same 57.6KwH consumed 67% Savings Same 57.6KwH consumed 67% Savings Same 57.6KwH consumed 67% Savings
High Water Consumption JulyAugustSeptemberOctober Dry cleaning Techniques Reduced water usage as much as 5m 3 Reduce number of faucets per department (50%) Water minimization No metering device Reuse of Effluent water discharge for watering the greens. (WWTP discharges about 200m 3 per day) n/aSavings of 60-70m 3 of fresh water plus 6% in electric power consumption per 15Hp booster pump Reduce number of working days from 6 to 5 Water minimization (no metering device as of yet)
Recyclable Materials August Consumption September Consumption October Consumption November Consumption Cartons21.150 tons 42,300Php Cash value 18.130 tons 36,260Php Cash value 13.533 tons 27,066Php Cash value 3.889 tons (partial) 7,778Php Cash value Plastics2.760 tons 2,760Php Cash value 1.410 tons 1,410Php Cash value 915 kilos 915Php Cash value 576 kilos (partial) 576Php Cash value Others AugustSeptemberOctoberNovember Materials Recovery Facility Proposal for construction Start of construction (on going) Water treatment facility upgrade (for better water quality) Start of improvements On going work40-50% completion70-80% completion
Others AugustSeptemberOctoberNovember Labor Cost (reduce working days from 6 to 5) * based on a minimum rate of 278.50Php 27 days work 1,893,399.7Php 22 days work 1,858,068.8Php 2% Savings 26 days work 2,130,271.5Php 15% Increase due to legal holiday’s and increase in production. 8 days work 627,906.55Php (partial data) Boiler Operation (reduce working days from 6 to 5) n/a12 hour operation (Savings of 533L of fuel)
Benefits Lowering Production and Maintenance costs – fuel,cleaners,utilities,office supplies,personnel,energy and time. Environmental Benefits – lowering of water consumption,minimization of wastes,maximum utilization of energy and electricity. Social Responsibility to the welfare of the community by dissemination of information by example. Improvements to product and processes; Savings on raw materials and energy, thus reducing production costs; Increased competitiveness through the use of new and improved technologies; Reduced liability associated with the treatment, storage and disposal of hazardous wastes; Improved health, safety and morale of employees; Improved company image; and Reduced costs of end-of-pipe solutions
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