RENCANA DESAIN FUNGSIONAL DAN KONDISILINGKUNGAN MIKRO PADA GUDANG BERAS

PASCA PANEN DI BULOG

REENGINEERING WAREHOUSINGMANAGEMENT

Indra Sapta Noegraha

DAMAGE FACTOR• Insect damage – identify species and count numbers per

kilogram. Compareagainst relevant standards, and thestandard that was specified when the commodity wasordered, as described on tender, shipping orphytosanitary documents.

• Physical damage – sieve and count damaged fractions.Compare against international standards, and thestandard that was specified in the order.

• Moisture content – measure using internationally agreed(ISO) oven methods, or calibrated electrical resistanceand capacitance meters. Compare result with thespecified standard for the commodity.

INSECT DAMAGE

USING CHEMICAL TOXICITY

Handling and storage of food aidcommodities

• a good store must be selected and prepared• commodities must be received in good condition• intake must be orderly and recorded• quality maintenance must be assured• security against theft and loss must be provided• any loss incurred must be identifiable and accountable• the end-use requirements must be met.

RECEIVING COMMODITIES• Prior to receiving commodities, an assessment must be

made of the usable capacity within the store• A storage plan should be prepared that will take into

account the expected pattern of demand the store willhave to meet, and the likely size and frequency ofdeliveries and discharges that need to be achieved.

• Incoming stocks must be carefully inspected. Delivery isone of the few occasions when the storekeeper is able toinspect all parts of the consignment.

STORAGE OF COMMODITIES• Every attempt must be made to store food commodities

under a waterproof roof. Only exceptionally, as withemergency programmes, should outdoor storage undertarpaulins or plastic sheets be considered.

STACKINGIn this type, six blocks are formed to make standard stack of 9.14m x6m size. Each block is of the size 6m x 1.5m. In the block, one layer isput lengthwise and other breath-wise.• Chinese method , Bagged grains with 14% moisture content or lower

could be piled in Chinese method. Sacks are piled side by side andone on top of the other over malathion sprayed wooden pallets

• Japanese method , Bagged grains with moisture content of morethan 14% are piled in this method. This system of stacking providesventilation space between bags and allows circulation of convectiveair currents that provide a medium for heat dissipation

• Criss-cross stacking, In this type bags are laid in complete length-wise or breath-wise tiers in alternate layers systematically. The firstlayer will have 11 bags in 9.14m direction with 11 such rows. Thesecond layer of bags would be laid width-wise with 16 bags in 9.14mdirection of stack with 7 such rows.

PALLETS

Storage structures: selection anddesign warehouse

The survey should include information on:• location of the storage facility• number of stores and their dimensions• capacities, both nominal and actual• construction materials• state of repair• hardstandings• road access• time and distance for delivery from a supply centre• sustainability for routine or emergency food storage• ownership• source of data• additional comments.

FUNCTIONS AND REQUIREMENTS OFFOOD AID STORESThe main function of most food aid stores is to provide transitfacilities. The storage period frequently cannot be determined inadvance, but is usually less than 12 months and frequently lessthan 3 months. Short-term food aid transit storage dictates thefollowing major requirements:• security from theft• protection of stocks from rain, flash floods, rising damp, solar

heating and pests,especially rodents and birds• easy intake and despatch of goods, including good access to

the store• good in-store handling arrangements and access to all stocks

for inspection,• physical stock-taking and insect pest control where necessary• easy maintenance of the store structure• satisfactory working conditions for staff and labourers.

EXISTING BUILDINGS• Inspection• Security• Site• Roof• Floors• Walls• Hygiene

Modification to existing buildings• Re-roofing• Re-flooring• Doors• Ventilation• Security• Management

Warehouse Location• It shall be accessible to land or water transport. There

should be ample space to facilitate movement andparking of transport

• The site shall be dry and located at relatively highelevation to avoid water logging and safe from naturalflooding calamities.

• It shall not be near any facility where the danger of fire isconstantly present.

• Warehouses should preferably be protected by trees orother surroundings from steady direct sunlight. The longaxes of the warehouses should be oriented East-West orsited across the prevailing wind. The building should besituated where it will not be exposed to afternoon sunlight.

Warehouse Location 2

• The structure shall be on solid ground.• Warehouses, which will be fumigated from time to time,

shall not be located near busy public facilities such asschools, hospitals, etc.

• Ample space shall be provided for future expansion.• Surroundings in the vicinity shall be satisfactorily sanitary.• Electricity, water services and drains shall all be available

and reasonably economical.

DESIGN CONSIDERATIONSSITING THE STORE1. The soil load-bearing capacity is all-important.2. Excessively wet areas, and dry areas that suffer from flash floods, are also

difficult sites.3. The long axis of stores should be oriented at right angles to the prevailing

wind, with the principal doors located on the long sides, unless otherconsiderations prevail.

4. A sloping site has to be cut into. This is expensive, and requires one or moredrainage channels to be made across the slopes uphill from the store, to leaddrainage water around and away from the environs of the store without causingsoil erosion.

5. Store floors need to be above ground level, with surrounding ground and roadsurfaces sloping away from the walls and doors.

6. Access by vehicles both to the site, and around the store to doors or ramps, isimportant and needs to be carefully considered in relation to the site.

7. An office may be needed for the store manager. A well ventilated store for pestcontrol chemicals and a separate store for other equipment are advisable.

8. Water, electricity, sewage disposal and general drainage may influence thechoice of site.

NEW CONVENTIONAL WAREHOUSESThe two most important aspects to decide whenconstructing new food warehouses are what is needed, andhow it should be built. Buildings designed specifically forthe storage of food aid commodities generally fall into twocategories:• small 50–200 tonne capacity units, constructed locally• medium 500–2000 tonne capacity, often using imported

materials

ROOF 1• Internal pillars supporting roof frames shall be avoided because it can

interfere with e pest control and other stock management procedures. Astandard roof truss of 14.5-m span (or larger) should be used.

• Roof frames made of wood or steel shall be designed so that theytransfer the weight of the roof to the supporting columns or to the walls.

• It must be provided with the necessary lateral and vertical wind brace toresist forces due to strong winds and earthquakes.

• The strength of the roof construction should be sufficient to handle theweight of the strongest winds that can be expected

• The roofing materials made of galvanized iron sheets shall be in lightcolors (white or beige).

• The chosen materials may be fire proof and highly refractory.• The inclination of the roofs should be sufficient to drain rainwater quickly,

taking into account that the water may be forced up by the wind.• Rainwater drainpipes should be closely spaced, of sufficient size and

installed without bends.

ROOF 2

Building structure requirements• There shall be provisions for water tightness, to prevent liquid

water from reaching the grain.• There shall be provisions for efficient loading and unloading.• There shall be provisions for aeration.• There shall be provisions for bird, insect and rodent proofing.• There may be provisions for air tightness and facilities during

fumigation.• The building shall have a clear inside span and has no inside

pillars which could obstruct stacking arrangement.• The building should have a ledge or podium.• Provisions for drying facilities that may be necessary in

conjunction with the storage facilities to assure that food grainsare in the range of 12 to 14 percent moisture content prior tostoring.

Illuminations• There should be provisions for sky lightings.• Illuminations should be sufficient that lights shall not be too

bright or too dim. Artificial lighting by fluorescent lamp ispreferable for the interior of the warehouse.

• The minimum requirement for illumination is 3 watts per squaremeter.

Floor• The floor should be adequately strong and capable of withstanding

heavy loads and vibrations.• The floor shall be elevated or constructed higher than the existing

ground.• The floor should be 1m above the ground to permit easy loading or

unloading into trucks at the sides of the warehouse.• If loading and unloading of trucks will be permitted inside the

warehouse the floor shall be 0.3m above the ground.• There shall be provisions for wear resistance and safety

(refractoriness and elimination of skidding risks).• The floor should be smooth and easy to clean.• It should be free from cracks where moisture from the ground may

affect the stored grain. Moisture sealing compound or asphaltshould be provided to fill the floor cracks against moisture.

Floor 2

Walls• The internal surfaces of the walls shall be smooth and free

from projections to eliminate dust-laden surfaces, facilitate cleaningof the store and avoid interference with other operations.

• Gravel concentrations in concrete walls, protruding brick work,horizontal planes or rims, window sills, protruding door or windowposts and other ledges should either be avoided completely or beshedded at a minimum angle of 60 o.

• The walls shall be painted white, on the inside to facilitate thedetection of insect pests and on the outside to help keep thewarehouse look as cool as possible.

• There shall be no opening between wall and roof.• The wall should be made of 150 mm thick concrete hollow blocks

(CHB) with 12 mm diameter reinforcing bars with horizontal andvertical spacing of 600 mm

Walls 2• A water/damp-proof barrier should

be incorporated into the base ofthe walls. Water proofingcompound should be incorporatedduring the plastering and finishingof the walls.

• A concrete strip about one (1)meter wide shall be laid aroundthe warehouse to prevent rain fromeroding the base of the walls belowthe damp course.

Doors• There shall be at least two doors so as to be able to rotate stocks on a “firstin, first out” basis.

• The door shall be wide for easy access, yet fit tightly for insectcontrol and fumigation. Roll up doors are generally used because of itscapability to close tightly.

• Preferably the door shall be made of steel or at least reinforced along theirlower edges with metal plate as protection against rodents.

• If swing doors are fitted, they shall be open outwards in order not toreduce the storage capacity of the warehouse.

• Preferably the door should be doubly sheeted, with adequate clearance,having good shock absorption and sufficient heavy-duty hinges.

• The door should be fire retardant and provided with a locking system not toosensitive to dust.

• The size of the entrance is 6 meters wide and 4 meters high for normaltemperature warehouse.

• A canopy shall be constructed over every entry door to allow continuousloading and unloading even when it rains.

Ventilation• Vents should be provided near the floor level, at the top of the walls

near the grid line and at the top of the roof and the ridge.• Ventilation openings such as louvers shall be fitted on the outsidewith anti-bird grills (20mm mesh) and on the inside (10 cm behindthe grills) with insect screens (removable for cleaning), which willdeter most insects.• Adequate natural ventilation openings shall be provided with

shutters so that ventilation may be controlled• Rotary ventilators or continuous ridge vent are built on the roof topwhich provide good ventilation in addition to the louvers all over thewarehouse.• The total surface area of windows and light wall panels, compared to

the total surface of the outside walls should never be too large.• In addition to natural ventilation exhaust fans could beintroduced for forced ventilation.

Facility requirement• Quality control laboratories• Workshops• Garage for vehicles• Dead stock store• Bag stacker• Poisonous chemicals store• Isolation shed• Toilets and washing facilities• Personnel office• Safety• Guards for machines should be

provided• Illuminations should be sufficient

that lights shall not be too bright ortoo dim

• Warning signs or boards shall befixed in hazardous/dangerous places

• Fire fighting equipment (fireextinguishers, fire hydrants) shall beprovided and be installed in aconspicuous and accessible location.

• There shall be provisions for first aidfacilities

• There shall be provisions for properexhaust and ventilating system

• All utilized warehouses shall beidentified by their warehousename, code and location printed ona standard billboard exhibited outsidethe warehouse

Pathways• A central aisle ranges from 3-3.65 m wide or not less than 1m

wider than the width of the widest vehicle loaded should bedesigned when two or more forklift trucks are being usedsimultaneously during warehouse operation

• If there is only one forklift to be used, the central aisle shouldbe designed with a width of not less than 0.6m wider than thewidth of the widest vehicle loaded

Factors to consider when selectingappropriate packaging for stored food

TYPE DAMAGE

SAMPLE TOOLS

Warehouse Design