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CLEANER PRODUCTION CLEANER PRODUCTION ASSESSMENTASSESSMENT

Latex Crepe Rubber Processing FactoryLatex Crepe Rubber Processing FactoryMillewa EstateMillewa Estate

Presented Presented ByBy

A. M. S. KulasekeraA. M. S. Kulasekeraandand

T. T. JinadasaT. T. Jinadasa

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What is Cleaner What is Cleaner Production?Production?

Cleaner Production is a new & Cleaner Production is a new & innovative way of improving production innovative way of improving production and reducing pollution. Cleaner and reducing pollution. Cleaner Production improves the production Production improves the production efficiency as well as the product quality efficiency as well as the product quality and at the same time Cleaner Production and at the same time Cleaner Production reduces the cost of resources, materials, reduces the cost of resources, materials, waste disposal and waste water waste disposal and waste water treatment and improve environmental treatment and improve environmental performance.performance.

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Cleaner production helps toCleaner production helps to

• Avoid leaks and spills during production and cleaning Avoid leaks and spills during production and cleaning through good housekeepingthrough good housekeeping

• Create optimal process conditions to achieve highest Create optimal process conditions to achieve highest product quality, increase production capacity, product quality, increase production capacity, minimum resource consumption and reduced waste minimum resource consumption and reduced waste generation.generation.

• Avoid using hazardous materials by substitution with Avoid using hazardous materials by substitution with less hazardous materials.less hazardous materials.

• Modify equipment to improve the production Modify equipment to improve the production processes.processes.

• Install new, efficient production equipment and re Install new, efficient production equipment and re design or reformulate the products to minimize design or reformulate the products to minimize resource consumption.resource consumption.

• Use clean technologies.Use clean technologies.

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• Eliminate waste of scarce and valuable Eliminate waste of scarce and valuable resources. Improve the profit margin resources. Improve the profit margin through reduction of input material through reduction of input material costs and reduce the cost of treatment costs and reduce the cost of treatment and disposal of waste.and disposal of waste.

• Improve the cleanliness of the Improve the cleanliness of the surrounding environment.surrounding environment.

• Improves employee relationship and Improves employee relationship and reduce conflictsreduce conflicts

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INTRODUCTION - INTRODUCTION -

ORGANISATIONORGANISATION • Lankem Tea & Rubber Plantations (Pvt) Lankem Tea & Rubber Plantations (Pvt)

Ltd – Ltd –

• Managing Agent for Kotagala & Managing Agent for Kotagala & Agarapatana Plantations Ltd.Agarapatana Plantations Ltd.

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• Kotagala PlantationsKotagala Plantations

• Twelve tea and nine rubber plantationsTwelve tea and nine rubber plantations

KPL is one of the largest rubber producers in the countryKPL is one of the largest rubber producers in the countryand has twelve rubber plantations in the Kalutara district and has twelve rubber plantations in the Kalutara district and eight manufacturing units,and eight manufacturing units,

Producing high quality pale crepe and sole crepe rubber.Producing high quality pale crepe and sole crepe rubber. Its main manufacturing unit, the Padukka factory, was the Its main manufacturing unit, the Padukka factory, was the first commercial rubber factory to be ISO 9002 certified first commercial rubber factory to be ISO 9002 certified and is considered to be one of the best rubber factories in and is considered to be one of the best rubber factories in the country. the country.

KPL has 4,500 ha under rubber and produces an average of KPL has 4,500 ha under rubber and produces an average of 4,395,000 kgs per annum. Which represents around 6% of the 4,395,000 kgs per annum. Which represents around 6% of the island’s Rubber Production. Under its re-planting programme it has island’s Rubber Production. Under its re-planting programme it has

a a further 850 ha of rubber, which is considered immature rubberfurther 850 ha of rubber, which is considered immature rubber. .

The The Company directly exports Rubber and the total quantity involved Company directly exports Rubber and the total quantity involved currently in 279,006 kgs and the exchange earned is over Rs.4.0 currently in 279,006 kgs and the exchange earned is over Rs.4.0 million.million.

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• Millewa Estate –Millewa Estate –

Western Province, Kalutara District Western Province, Kalutara District and is 42 kms. away from the city of and is 42 kms. away from the city of Colombo.Colombo.

• The total extent of the plantation is The total extent of the plantation is 394 ha, with an annual production of 394 ha, with an annual production of 281,000 kgs fetching record prices 281,000 kgs fetching record prices for latex crepe Rubber.for latex crepe Rubber.

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• Cleaner Production Team :Cleaner Production Team :

• Plantation Manager – Mr.Nalin De Silva Plantation Manager – Mr.Nalin De Silva (Team Leader)(Team Leader)

• Factory Officer– Mr.Sudath SamaraweeraFactory Officer– Mr.Sudath Samaraweera• Assistant Factory Officer - Mr. A. D. Sunil Assistant Factory Officer - Mr. A. D. Sunil • Assistant Factory Officer - K.D.D.S. GunethilekeAssistant Factory Officer - K.D.D.S. Gunethileke• Mechanic / Electrician - M. Siva KumaranMechanic / Electrician - M. Siva Kumaran

• Audit Focus :Audit Focus :• Water Water • Energy – Electricity Energy – Electricity

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Objectives of the StudyObjectives of the Study

• To reduce the overall cost of productionTo reduce the overall cost of production• To reduce use of waterTo reduce use of water• To reduce energy costTo reduce energy cost• To reduce cost of handling waste waterTo reduce cost of handling waste water• To improve the efficiency of productionTo improve the efficiency of production• To reduce discharge of hazardous waste To reduce discharge of hazardous waste

to the environment to the environment • To facilitate future direction to the Sri To facilitate future direction to the Sri

Lankan crepe rubber Lankan crepe rubber • IndustryIndustry

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Manufacture of Latex Crape Rubber – Manufacture of Latex Crape Rubber – Process Flow Diagram with Inputs & Waste Process Flow Diagram with Inputs & Waste

StreamsStreams

Straining

Standardization & Addition of Sodium Bi Sulphite

Collection & Weighing of Latex

Transportation of Latex to Factory

Straining of Latex

Receiving & DRC Determination at the Factory

Bulking of Latex

Start

Spilled latex, dirt & latexSpilled latex, bowser washing water

Filtered water

Sodium bi- sulphite

Spilled latex, dirt & latex

Spillage - latex

Spilling of latex Spilling of sodium bi sulphite

Spilled latex

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Settling & Addition of Bleaching Agent

Coagulation with Formic Acid

Milling of Rubber

Drying

Stirring & Removal of Froth

Removal of Coagulant for Milling

Stirring & Removal of Froth

Spilling of bleaching agent

Spillage of latex in frothWaste water

Spillage of latex,latex in froth, waste waterSerum, waste water

Serum, waste waterRubber particles

Water evaporationWashing waterCooling water

Formic acid

Bleaching agent

Fractionation

Straining Dirt , latex

Yellow fraction, latex, waste water

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Pre-forming

Dry Blanketing

Cutting & Sorting

Dispatching

Bailing

Grading & Packing

End

Off cuts

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MonthMonthKVKV

AACharge for Charge for

KVAKVA KWhKWhCharge for Charge for

KWh KWh

Total Total ChargChargee

Crop Crop KgsKgs

Cost - Rs / Cost - Rs / KgKg

June - June - 0303 6161 24,400.0024,400.00 76597659 54,37854,378 87,53687,536 1185111851 7.397.39

July - July - 0303 6565 26,000.0026,000.00 91219121 64,75964,759 100,715100,715 25,62125,621 3.933.93

Aug - Aug - 0303 7070 28,000.0028,000.00 1228812288 87,24487,244 127,648127,648 25,21225,212 5.065.06

Sep - Sep - 0303 7474 29,60029,600 83318331 59,15059,150 98,50598,505 18,14518,145 5.435.43

Oct - Oct - 0303 6464 26,400.0026,400.00 83898389 59,56159,561 95,43795,437 22,64322,643 4.214.21

Nov - Nov - 0303 7373 29,200.0029,200.00 86668666 61,52861,528 100,681100,681 22,44622,446 4.494.49

Dec - Dec - 0303 8080 32,000.0032,000.00 1276012760 90,59690,596 136,691136,691 42,68242,682 3.203.20

Jan - Jan - 0404 8080 32,000.0032,000.00 1228612286 87,23087,230 138,035138,035 32,81532,815 4.214.21

Feb -Feb -0404 6363 25,200.0025,200.00 80058005 56,83556,835 95,26095,260 26,05826,058 3.663.66

Mar - Mar - 0404 6464 25,600.0025,600.00 64996499 46,14246,142 83,42383,423 23,13223,132 3.613.61

May - May - 0404 6767 26,800.0026,800.00 56115611 39,83839,838 77,55477,554 10,70410,704 7.257.25

Millewa Rubber Factory - Electricity Consumption

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Mill # Mill # 11

Mill # Mill # 22

Mill # Mill # 33

Mill # Mill # 44

Mill # Mill # 55

Mill # Mill # 66

Mill # Mill # 1010

Mill # Mill # 1212 Total Total

TToottaall

lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min

Lit / Lit / MMinin DayDay

                             

Cooling WaterCooling Water 1515 1515 1515 55 99 00 00 66 6565 2340023400

                                

Washing WaterWashing Water 1818 1818 1818 2626 2626 00 1212 99 127127 4572045720

                                

Overflowing Due to Overflowing Due to Blocked Blocked                         3030 1080010800

Sand Bed 10 hp PumpSand Bed 10 hp Pump                              

                                

Overflowing From Filter Overflowing From Filter Bed Bed                         55 18001800

5 hp Pump - 5 hp Pump - EstimatedEstimated                              

                                

StandardisationStandardisation                            45004500

                                

Washing of CoagulatingWashing of Coagulating                            300300

and Standard. Tanksand Standard. Tanks                              

                                

Washing Of BowserWashing Of Bowser                            15001500

                                

                    Grand Total Per Grand Total Per

Day….....=Day….....=88028802

00

                     ( 6 hour Product Cycle)( 6 hour Product Cycle) LitresLitres

                       

                                

Waste Characterisation :

Waste Stream - Waste Water

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Cleaner Production Cleaner Production OptionsOptions

• Separating Cooling water and washing water in Separating Cooling water and washing water in the drainage systemthe drainage system

• Recycling Of Cooling WaterRecycling Of Cooling Water• Use of smaller diameter piping for cooling water Use of smaller diameter piping for cooling water

to reduce volume to reduce volume • Use a nozzle type spray mechanism for washing Use a nozzle type spray mechanism for washing

water to reduce volumewater to reduce volume• Use of rubber traps and man holes to collect Use of rubber traps and man holes to collect

sediment / sandsediment / sand• Eliminate double pumps ( 10hp & 7.5hp) at Eliminate double pumps ( 10hp & 7.5hp) at

Theppankulama main water source – repair the Theppankulama main water source – repair the water tank on the rock and install a proper sand water tank on the rock and install a proper sand filter bedfilter bed

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• Install an automatic cut off system for both pumps to Install an automatic cut off system for both pumps to prevent overflowingprevent overflowing

• Replace the old inefficient piston pump ( 5 hp) with 2 Replace the old inefficient piston pump ( 5 hp) with 2 hp centrifugal pump hp centrifugal pump

• Repair the Theppankulama water source . Have proper Repair the Theppankulama water source . Have proper boundary fence to prevent entering of buffaloes etc. boundary fence to prevent entering of buffaloes etc. for retaining water quality.for retaining water quality.

• Construction of a new tube well and use a centrifugal Construction of a new tube well and use a centrifugal pump with a lesser horse power to eliminate inefficient pump with a lesser horse power to eliminate inefficient piston pumppiston pump

• Training people in house to minimize waste water Training people in house to minimize waste water • Separate effluent disposal lines as high concentrate Separate effluent disposal lines as high concentrate

effluent and low concentrate for ease of treatmenteffluent and low concentrate for ease of treatment• Effluent Treatment –Effluent Treatment – a ) Reduction of quantity by filtering same and re-a ) Reduction of quantity by filtering same and re-

cycling cycling b) Treating only the concentrated effluent b) Treating only the concentrated effluent

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• Electricity :Electricity :• Use separate metering for Factory Use separate metering for Factory

(production) , Bungalows and staff (production) , Bungalows and staff quarters – use separate direct connection quarters – use separate direct connection to CEB system under domestic tariff for to CEB system under domestic tariff for staff quarters staff quarters

• Replace the motor of dry mill with an Replace the motor of dry mill with an energy efficient induction motor of lower energy efficient induction motor of lower horse powerhorse power

• Upgrade capacitor bank on switch board Upgrade capacitor bank on switch board to suit the existing loadto suit the existing load

• Alternate the loading cycle to reduce KVA Alternate the loading cycle to reduce KVA demand & make use of time of day tariff demand & make use of time of day tariff offered by the CEBoffered by the CEB

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ActionActionEstimated Estimated

CostCostEstimated Estimated

AnnualAnnual PaybackPaybackTechnicaTechnica

ll

EconoEconomimicc

EnvironmeEnvironmentalntal PriorityPriority

      BenefitBenefitPeriod Period YrsYrs

FeasibilitFeasibilityy

FeasibilFeasibilityity FeasibilityFeasibility   

                    

Separate cooling & wash waterSeparate cooling & wash water 15,00015,000 15,00015,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Re-cycle cooling waterRe-cycle cooling water 10,00010,000 20,00020,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium

Use of small diameter pipesUse of small diameter pipes 3,0003,000 3,0003,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium

Use of nozzles to spray waterUse of nozzles to spray water 2,0002,000 20002000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium

Use of rubber trapsUse of rubber traps 10001000 750750 1.331.33 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Eliminate double pumpsEliminate double pumps 30,00030,000 25,00025,000 1.201.20 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Install automatic cut off system Install automatic cut off system for pumpsfor pumps 5,0005,000 10,00010,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Replace piston pump with new Replace piston pump with new oneone 10,00010,000 10,00010,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium

Separate effluent lines as low/high Separate effluent lines as low/high concentrateconcentrate 5,0005,000 5,0005,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Repair Theppukulama water Repair Theppukulama water source source 10,00010,000 10,00010,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Training people to reduce waste Training people to reduce waste waterwater 3,0003,000 6,0006,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

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Install new tube wellInstall new tube well 150,000150,000 50,00050,000 3.003.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium

Use separate electricity metering for Use separate electricity metering for quartersquarters 50,00050,000 50,00050,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium

Replace motor of dry millReplace motor of dry mill 50,00050,000 70,00070,000 0.710.71 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Upgrade capacitor bankUpgrade capacitor bank 25,00025,000 50,00050,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

Make use of time of day tariffMake use of time of day tariff 5,0005,000 50,00050,000 0.100.10 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium

Improve existing drying systemImprove existing drying system 500,000500,000 240,000240,000 1.251.25 feasiblefeasible feasiblefeasible feasiblefeasible   

Reduce quantity (low/high con.)of Reduce quantity (low/high con.)of EffluentEffluent 1.9 million1.9 million       feasiblefeasible    feasiblefeasible MediumMedium

& install Treatment Plant& install Treatment Plant                     

04/09/23 20Millewa Rubber FactoryMillewa Rubber Factory

04/09/23 21Effluent Drain – Rubber ParticlesEffluent Drain – Rubber Particles

04/09/23 22Worker motivation – Attitude changeWorker motivation – Attitude change

04/09/23 23Abundant use of waterAbundant use of water

04/09/23 24Oversized motorsOversized motors

04/09/23 25Washing of latex bowsersWashing of latex bowsers

04/09/23 26CP Team at workCP Team at work

04/09/23 27Unhealthy activity - Introduce Aluminum separatorsUnhealthy activity - Introduce Aluminum separators

04/09/23 28Upgrading capacitor bankUpgrading capacitor bank

04/09/23 29Drying process - to be improvedDrying process - to be improved

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Waste water to be separatedWaste water to be separated

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Valve Clogging - Repair/ReplaceValve Clogging - Repair/Replace

04/09/23 32Excessive water – measurements takenExcessive water – measurements taken

(Bucket and stopwatch)(Bucket and stopwatch)

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