water conservation in smes through small and medium enterprise
TRANSCRIPT
Water Conservation in SMEs through
Small and medium enterprise
Importance of Water in the Manufacturing Processes
Water Use in Manufacturers as:Primary products: beverages, water
related drinks, canning etc.Means to obtain products, washing
process, cleaning operation, heat treatment, cooling operation etc.
Wastewater generated from manufacturing process
High amounts of wastewater with low pollutant loads.
Low amounts of wastewater with high pollutant loads.
.
Lack of water conservation policy in SMEs
Water is considered cheap.Some washing process and cooling water
do not need treated water.Without environmental regulations or
weak enforcement
Wastewater Generated in the Selected Factories
Amount Wastewater
Canning Factories
M3/day M3/Ton RM
Fruit Salad 8.93 4.72Fruit Salad 86 4.35Corn Cob 89 4.45Lychee 82 3.73Pineapple 134 1Corn Cob 238 5.29
Wastewater Generated in the Selected Factories (Cont.)
Amount Wastewater
Fruit Preservation Factories
M3/day M3/Ton RM
Preserved Fruit
3 3
Preserved Fruit
5 1.47
Preserved Vegetables
83 4.37
Ginger 550 7.43Ginger 800 2.15
Water Conservation
Water conservation in large scale factories was normally taken into consideration during the planning and design stage.
SMEs are neither equipped with new technology, nor properly planned during the design stage, water conservation seems to be a difficult task for them.
GP methodology for implementation in manufacturing organization.
Getting startedPlanningGeneration & Evaluation of optionsImplementation of OptionsMonitoring and ReviewSustaining
Water consumption monitoring
Water meters installation Direct measurement like stop watch and
volumetric flask.Direct measurement in the tanks (containers)Spillages may be measured by using containers
shaped like pans or other specific shapes.In some areas, weir notch could be a good
method to measure wastewater flow instead of water used.
Level of monitoring there are 4 levels of monitoring in industries
1.Plant level this will show the overall input and overall output of the plant itself
2. Department level or process level in many SMEs,, we may need to dig deeper into areas, departments or processes to obtain information on water use.
3. Sub-department level that will need to go further in each process for clarification of water used.
4. Machine level In each process, some particular machines may have a greater and more significant water consumption than other machines.
1. Plant Level
PlantInput Output
2. Department Level
Storage Process 1 Process 2 Offices
3. Sub-Process Level
Washing Canning Sterilizing Storage
4. Machine Level
Washing Machine 1 Machine 2 Tank 3 To Specific
From General
Options for water conservation
With proper information obtained from examining, options for water conservation could be identified. The following are few examples of options for water conservation.
Problems Identified Options Generated
Water consumption
1 No recycle facility for cooling water
2 No recycle machine for can washing process
3 Too big water hose for floor cleaning
1 Build storage tank for recycle & floor cleaning
2 Install recycle can washing machine
3 Change hose size from big to smaller hose
Examples of options for water conservation in food industry sector
Problems Identified Options Generated
4 No valve at the end of water hose
5 No jet floor cleaning
6 Pipe leakage
7 segregation of wastewater
4 Install valve at the end of water hose
5 Install spray gun for floor cleaning
6 Change pipe connection
7 Separate brine wastewater from normal waste
Examples of options for water conservation in food industry sector (Cont)
Problems Identified Options Generated
8 Spillage of syrup
9 Hot wastewater discharge directly into sewage drain
10 Worker s had no awareness on good house keeping
8 Install syrup collection system
9 Use heat exchanger in recycling hot water
10 Training course required
Examples of options for water conservation in food industry sector(Cont)
Case study of Food Industry
Water conservation from food industry sector in northern Thailand is as shown in table. Significant amount of wastewater reduction could be obtained through implementation of recommendations.
Factory
Before Implementation
waste / unit RM. (m3/ton)
After Implementation
waste / unit RM. (m3/ton)
1.Lychee factory
1.1 Saving chemical through soaking process
1.2 Changing washing process
1.3 Maintenance of washing machinery
1.38
5.55
0.38
0.96
3.10
0.20
Wastewater reduction
Factory
Before Implementation
waste / unit RM. (m3/ton)
After Implementation
waste / unit RM. (m3/ton)
2. Pineapple factory
Change whole process
2.45 1.01
Wastewater reduction ( Cont )
Factory
Before Implementation
waste / unit RM. (m3/ton)
After Implementation
waste / unit RM. (m3/ton)
3. Palm seed factory
3.1 Adding valve at the end of water hoses in soaking process
3.2 Training of good house keeping for workers in washing process
0.79
2.54
0.38
2.02
Wastewater reduction ( Cont )
In some cases, attempting in water conservation might give other benefit for factory. In a demonstration project of a ginger factory in Thailand, water monitoring in the factory is as
shown in table
Water Use Amount (m3/day)
Amount (L/tonRM)
BOD (mg/l)
SS
(mg/l)
1.Fresh ginger
washing water
2. Floor washing
water in raw
material area
3. Water in salting
well
4. Wash water for
QC test
360
100
13.4
14.4
4,702
1306
175.7
9,527
91
-
-
-
6,533
-
-
-
Water use and its characteristics of each process.
Water Use Amount (m3/day)
Amount (L/tonRM)
BOD (mg/l)
SS
(mg/l)
5. Wash water of
salted ginger
6. Wash water of
salted well
7. Wash water
during trimming
19.4
3.5
35.6
320
57.5
584
9,400
10,520
196
37,157
22,850
396
Water use and its characteristics of each process. ( Cont )
• Major use of water was from fresh ginger washing and floor washing. (460 cubic meters per day)
• Other uses combined were about 80 cubic meters per day
• The main cause of using high wash water was that the raw ginger contain too high soil content. (12.11%)
• In the brainstorming , the suppliers should be instructed to reduce soil content in raw materials.
Production Information Before and After Implementation
Item Year 1999 Year 2000 Change
Increase Reduce
1.Raw Ginger.
(kg.)
Ginger+Soil
Soil
Ginger for
production
2.Products (Cases )
3.Working days
4,232,107
480,213
( 11.37 % )
3,742,894
57,695
112
4,610,688
414,575
( 8.95 % )
4,196,133
81,836
117
65,638
(2.95%)
Production Information Before and After Implementation ( Cont )
Item Year 1999 Year 2000 Change
Increase Reduce
4.Groundwater use ( m3 )
5.Electricity
( kWh )
5,524
131,581
4,439
121,287
1,084
(19.63%)
10,294
(7.82%)
Financial monitoring and evaluation was performed and shown in table . The total expenses before and after were 144.814 US$ and 163,786 US$ respectively. Compare to the products, expenses per case would be 2.51 US$ and 2.28 US$ respectively. The saving cost of 0.23 US$ per case was obtained in the year 2000. Compare to the number of production at 71,836 cases. The saving of expenses would be 16,522.28 US$.
Financial Monitoring and Evaluation
Item Year 1999 Year 2000
Change
Increase Reduce
1. Labor Cost (US$)
2. Groundwater (US$)
3. Electricity (US$)
126,945
458
7,061
151,937
368
7,045
90.06
(19.63%)
15.99
(0.23%)
Financial Monitoring and Evaluation ( Cont )
Item Year 1999
Year 2000
Change
Increase Reduce
4.Maintenances (US$)
5.Total expenses (US$)
6. Expenses per case (US$/Case)
9,965
144,814
2.51
4,438
163,786
2.28
5,526.54
(55.46%)
0.23
Expense for GP Implementation
Item Expenses (US$)
1. Greening the suppliers
Awareness Program
Incentive Program
2.Equipment Improvement
Raw material washing
Process
3.Training
151.71
2,788.10
676.25
585.82
633.44
Total 4,835.32
Summary
Water conservation could be obtained from GP implementation in SMEs. Water may be considered as cheap resources but without proper management it could turn to an expensive resources in the manufacturing process. With proper monitoring program, water could be effectively utilized and the SMEs would in turn obtaining benefits from GP implementation.