M/s.
Chatpati Peanut Factory owned by Mungu Bhai is situated at Chatori
Gali. The industry makes deep fried salted peanuts. The product was
till recently sold only in the local market. Mr Mungu Bhai has
recently got an enquiry- from Germany to supply peanuts, which were
found to go very well with beer. However the importer has insisted
that the company's environmental performance has to be compatible
with the best in the world.
With a view to improve the
environmental performance and also to cut down the losses, the
company has decided to launch a waste minimisation audit.
PROCESS Shelled
peanuts (shell already removed) are procured in 50 Kg jute bags. The
bags are manually opened and the peanuts transferred to a daily
storage hopper. The frying medium, refined oil is procured in 15 Kg.
Tines and stored. Salt is procured in 100 Kg. bags. The process
consists of heating the oil in a large frying pan. The oil from the
tin is transferred manually to the frying pan. The pan holds 25 Kgs.
of oil per batch. The
heating is done by large LPG burners. After the oil attains a
temperature of 190 oC, 10 Kgs. of peanuts are fried for 5 minutes
with periodic churning. The fried peanuts are removed and
transferred to a tray. Requisite quantity of salt is added to
peanuts and is thoroughly mixed. The peanuts are cooled and packed
in size of 100 gms., 250 gms., 500 gms. and 1000 gms.
After
a few batches (at the end of day) of frying, during which make up
oil is also added, the oil gets contaminated with dirt, broken and
burnt peanuts etc. This oil is unloaded into empty cans and disposed
off as waste oil. At the end of every day the pan is washed with
soap and detergents including several water rinses before the next
batch is started.
THE TASKS 1. Form
a Waste Minimisation (WM) Team 2. Prepare a process flow diagram 3.
Prepare a material (& energy) balance 4. Identify sources of
waste generation. 5. Identify causes of waste generation 6.
Suggest possible WM measures - After lot of probing and
questioning, Mr. Mungu Bhai has given the following data.
- Approximate quantity of
make up oil after every five batches.
5 Kg
-
Average quantity of peanuts fired every day. 500
Kg/day
-
Average quantity of salt used per batch. 1
Kg
-
Average quantity of water consumed every day.
5
KI
-
Average quantity of detergent used. 0.5
Kg/day
-
Average number of packing /day. 1450
-
LPG Consumption /day. 10
kg
- Final Output. 505
Kg as detailed below 1.0 Kg * 200 =200 Kg 0.5 Kg * 300 =150
Kg 0.25 Kg * 400 =100 Kg 0.10 Kg * 550 =55 Kg
-
Pan Material. Cast
Iron
-
Pan thickness 7.0
mm
Organisational
Structure: Mr. Mungu Bhai (Owner)
Looking after Purchase, marketing and dealing with regulatory
agencies Nephew (Supervisor/operator)
Responsible
for the key activity of frying & salting in addition to the
additional load of stores 2 Packing men
For peanuts weighing and packing 4
workersfor loading/unloading/transfer etc.
- Burnt
oil removal and pan cleaning done at the end of the day
Few
observations: - Churning : Manual - After peanuts
frying, the adhered oil is not strained out. - Regarding spent
oil, a year back it was reused however it has been discontinued as
suggested by consultant for quality reasons. - Burner is not
closed throughout the day, However when oil burning fumes are seen
the burner is put to minimum position. - After salting and
cooling the peanuts are transferred to packing sections trey and the
salting trey is cleaned by a fabric for the next batch.
The
heating is done by large LPG burners. After the oil attains a
temperature of 190 oC, 10 Kgs. of peanuts are fried for 5 minutes
with periodic churning. The fried peanuts are removed and
transferred to a tray. Requisite quantity of salt is added to
peanuts and is thoroughly mixed. The peanuts are cooled and packed
in size of 100 gms., 250 gms., 500 gms. and 1000 gms.
Responsible
for the key activity of frying & salting in addition to the
additional load of stores