“Green Framework of Innovative Strategy (GFIS) for Sustainable Consumption and Production”
Technical Working Group MeetingICETT-EMB
November 19, 2007Sycamore Room, Richmonde Hotel
Prepared by:Prepared by:W.C. H. SantosW.C. H. Santos
Vision and Mission:Vision and Mission:
To be a world class corporation by adapting the Four Best To be a world class corporation by adapting the Four Best Concept. ”Best Customer Service”, “Best Value”, “Best Concept. ”Best Customer Service”, “Best Value”, “Best
Technology”, “Best Quality”Technology”, “Best Quality”
““The Four Best Concept”The Four Best Concept”
“Best Value”
“ “ Best Technology”Best Technology”
““Best Customer Service”Best Customer Service”
“Best Quality”
The Company Owners: 100% Filipino, Family Corporation Nature of Business: Meat Processing Years in the Business: 40 years (since 1967) Location: Dela Paz Norte, City of San Fernando, Pampanga, Philippines Total Site Area: 37 Hectares Total Building Area: 1.2 Hectares Product Lines: Tocino,Hotdogs,Longaniza,Hams,Bacon,Corned Beef and
more. Production Capacity: 100MT per day Systems in Place: HACCP/GMP Programs,Sanitation Program,Pest
Control Program,Waste Management,Food Fortification Program Facilities: 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).
Plant Category: “AAA” Accredited (Highest International Standard given to a Meat Processing Plant) by DA-NMIS
Employees: 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 Straight 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 areopportunities for using more environmentally benign sources of energy.Opportunities include replacing fuel oil or coal with cleaner fuels, such asnatural gas, possibly purchasing electricity produced from renewablesources, or co-generation of electricity and heat on site. For some plantsit may also be feasible to recover methane from the anaerobic digestionof high-strength effluent streams to supplement fuel supplies.
Work Ethics/AttitudesEnsure 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 SystemDrainage System
Information DisseminationInformation Dissemination
Information Information DisseminationDissemination
Yellow Lane Yellow Lane (Discipline Zone)(Discipline Zone)
Sanitary practicesSanitary practices
Solid Waste SegregationSolid Waste Segregation
Water ManagementWater Management
Energy and Fuel Energy and Fuel ManagementManagement
Materials Recovery Materials Recovery Facility ProjectFacility Project
System ResultsHigh 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 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
July August September October
Dry cleaning Techniques
Reduced water usage as much as
5m3
Reduced water usage as much as
5m3
Reduced water usage as much as
5m3
Reduced water usage as much as
5m3
Reduce number of faucets per department (50%)
Water minimization
No metering device No metering device No metering device No metering device
Reuse of Effluent water discharge for watering the greens.
(WWTP discharges about 200m3 per day)
n/a Savings of 60-70m3 of fresh water plus
6% in electric power consumption per
15Hp booster pump
Savings of 60-70m3 of fresh water plus
6% in electric power consumption per
15Hp booster pump
Savings of 60-70m3 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
Cartons 21.150 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
Plastics 2.760 tons
2,760Php Cash value
1.410 tons
1,410Php Cash value
915 kilos
915Php Cash value
576 kilos (partial)
576Php Cash value
Others
August September October November
Materials Recovery Facility
Proposal for construction
Start of construction (on going)
Water treatment facility upgrade (for better water quality)
Start of improvements
On going work 40-50% completion 70-80% completion
Others
August September October November
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/a 12 hour operation (Savings of 533L of
fuel)
12 hour operation (Savings of 533L of
fuel)
12 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
Our Products!Tocino, Longaniza, Hams, Bacon, Hotdogs, Corn Beef and more…
Thank You!
Thank You!