he application of cleaner technology in the survey and

preliminary assessment of swine slaughter housePornpun Wiruch, Pannipa Tasak, Netnapa Makhamrueang, Noppol Leksawasdi

Department of Food Engineering, Faculty of Agro-Industry,

Chiang Mai University, Chiang Mai, 50100, Thailand;

telephone: +66 53 948274, mobile: +66 81 9506 544

fax: +66 53 948238; e-mail: noppol@hotmail.com

The survey and pre-assessment were carried out at the Chiang Mai – Lumphun Hog Feeder Co-operative Co. Ltd. during March to May 2009 on the technical, economical, and environment aspects to accompany the decision in selecting the problem(s) that required immediate corrective action. The issue relating to mashed cassava was ranked first with loss level of 9.78 kg/tonne. This was followed by electrical energy consumption for swine feed production factory and slaughter house with corresponding average electrical bills of 13,283.53 and 9,250.84 baht/month, respectively. The third was firewood utilization with an average consumption level of 9,730 baht/month. The corrective actions to alleviate the identified problems were the installation of industrial fan to ventilate the area (20,000 baht investment, to improve the health of workers), the change of electrical billing rate to Time Of Use (TOU) rate (36,380 baht investment, with expected investment returns in 271 days), and the relocation of firewood entrance to the oven (20,000 baht investment, with expected investment returns in 100 days).

Abstract

Three problems of Chiang Mai - Lumphun Hog Feeder Co-operative regarding (1) raw materials loss and dust distribution, (2) expensive electricity bills at swine feed production factory and slaughter house, as well as (3) expensive firewood were identified and prioritized based on the preliminary assessment strategies of clean technology. The suggested corrective actions included the installation of industrial fan, the application of TOU electrical billing rate, and the relocation of firewood oven entrance. The overall investment of 76,380 baht/year was recommended with the expected benefits of 122,446 baht/year.

Conclusions

This project was supported by Cleaner Technology Network (2009), CMU

Acknowledgement

(1) Cleaner Technology Team (2009) Cleaner Technology Workshop Manual, CT Publishing, Chiang Mai, Thailand(2) Chiang Mai – Lumphun Hog Feeder (2009) Raw Materials Database, CMLHF database, Lumphun, Thailand

References

The Chiang Mai – Lumphun Hog Feeder Co-operative Co. Ltd. was situated in Lumphun province and comprised of three main sections which included (1) feed manufacturing, (2) main office and (3) slaughterhouse. The following problems at Chiang Mai - Lumphun Hog Feeder Company Co. Ltd. were identified.Raw Materials: Mashed Cassava Dust

The feed manufacturing process was mostly resulted in the powder form product. These materials, especially mashed cassava powder, were easily distributed throughout the plant and caused dust gathering within the production area (Figure 1).

Figure 1: The accumulation of mashed cassava dust at the factory floor.

Energy: Expensive Electricity BillsFeed Production Factory: The crucial machineries used in the factory included hammer mill and mixer. The frequent voltage drop resulted in the electrical drain during restarting of the machines which contributed to the high electricity bills. In addition, the size of installed mixer was relatively small with the production capacity of only 1 tonne per each production round. Slaughter House: Numerous electrical apparatuses were installed and used frequently such as electrical shock unit, hair removal machine, lifting unit, and digital balance. The allocated operational time was between 08:00 PM – 03:00 AM which spanned the off peak period in accordance to TOU rate.

Energy: Expensive firewood costThis oven was situated at the distance of

1.30 and 1.85 m away from the first and second boilers, respectively (Figure 2) which contributed to the uneven boiling time and excessive firewood consumption level.

Figure 2: The original location of firewood oven and boilers.

Introduction

The survey for data collection, interview, factory visiting, student training and evaluation (on the technical, economical and environmental aspects) were conducted according to CT standard [1]. The data on raw materials usages (corn, mashed cassava, rice bran, and soybean meal), level of feed production as well as electricity bills were all obtained from the factory database [2] which was dated back for the period of 4 months (October 08 – January 09). The most important item to be investigated was selected after addition of all three weighed aspects and ranked the summation in descending order.

Methodology

In this study (see Table 1), mashed cassava was ranked first (with loss level of 9.78 kg/tonne and weighed summation of 14.2) followed by electricity (with electrical bills of 13,283.53 and 9,250.84 baht/month for feed production factory and slaughter house as well as weighed summation of 12.2 and 9.8, respectively) and firewood (with firewood utilization of 9,730 baht/month and weighed summation of 10.2).

Table 1: Summation of technical, economical and environmental aspects of each item

1FP = feed production factory2SH = slaughter house*RT = ranking of technical aspect from the lowest (1) to the highest (10)#RE = ranking of economical aspect from the lowest (1) to the highest (10)$REnv = ranking of environmental aspect from the lowest (1) to the highest (5)aW = weighing factor of each aspect; WT + WE + WEnv = 1

Criteria for selection of R and W based on a careful discussion with production supervisor of the factory

Result

The installation of industrial fan to ventilate the area: The released amount of processing dust such as mashed cassava in Table 1 might be detrimental to the health of workers. The proposed solution strategy was the installation of industrial fan to ventilate the area. In addition, the clearer working atmosphere will decrease the threat of exposing the worker to the respiratory illnesses.The change of electrical billing rate to Time Of Use (TOU) rate: In case of feed production factory; The normal operating time between 08.00 – 16.30 and modified the day-offs (Table 2) from (1) only Sundays which could save up to 15.24% of the original electrical bills to (2) moving the day-offs to one of the official working days once a week but working on Sundays, this could save up to 17.05% of the original electrical bills. In case of slaughter house; The slaughtering was done between 20.00 – 03.00 The EGAT should be informed to authorize the application of the lower TOU rate. Such practice should be able to save up to 19.68% of the original electrical bills.

Table 2: Comparison of saved electrical cost based on conventional and TOU rate

The relocation of entrance for firewood oven: The relocation of entrance for firewood oven for both water boilers by closing the original opening and drilling for the new firewood opening that was more adjacent to the boilers. Type 1 the employed dimension (Width Length Height) of 0.60 0.40 0.60 m3. The saved firewood in this case was up to 60% of the original firewood consumption. Type 2 would have the dimension of 0.60 0.60 0.60 m3. The saved firewood was valued at 40% of the consumption.Economical benefits to be gained by the factory are summarized and given in Table 3

Table 3: Summary of economical benefits to be gained by the factory.

* Estimated value based on personal communications with production supervisor # ROIP = (365 days/year) (I/EB), each figure was rounded up to the nearest whole day

Corrective actions

Item

Technical Economical EnvironmentalOverallMark

Ranking*RTat #RE WE

$Rend Wend

Mashed Cassava 10 0.4 3 0.4 45 0.2 14.2 1

Electricity FP1 7 0.4 10 0.4 27 0.2 12.2 2

Firewood 1 0.4 2 0.4 45 0.2 10.2 3

Electricity SH2 2 0.4 9 0.4 27 0.2 9.8 4

Corn 4 0.4 9 0.4 12 0.2 7.6 5

Soybean Meal 8 0.4 8 0.4 6 0.2 7.6 5

Rice Bran 8 0.4 2 0.4 16 0.2 7.2 6

Fuel 1 0.4 1 0.4 18 0.2 4.4 7

LocationOriginal Billing

Costs(baht/month)

ExpectedTOU

Billing Costs (baht/month)

Saved Cost (baht)

Saving (%)One month One year

Feed Production FactoryDay-off on Sunday

13,283.53 11,258.66 2,024.88 24,298.50 15.24

Feed Production FactoryWorking on Sunday

13,283.53 11,018.71 2,264.82 27,177.84 17.05

Slaughter House 9,250.84 7,430.45 1,820.40 21,844.78 19.68

Identified Problems CT Proposal Expected Benefits(EB in baht/year)

Investment(I in baht/year)

Return Of Investment Period (ROIP)

1. The Distribution of Dust from Mashed Cassava

Install industrial fan to ventilate the area

Decrease the threat of exposing the workers to the respiratory illnesses

20,0003 months

(healthy workers)*

2. High ElectricityBilling Costs

Replacement of electricity charging from normal to TOU rate

49,024 36,380 271 days#

3. Uneven Boiling Times and Excess Firewood Consumption

Relocation of firewood oven appropriate for both water boilers

73,422 20,000 100 days#

Total 122,446 76,380

Boiler1

Boiler2

Position of firewood entrance to oven