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WM MAKE GOOD ENVIRONMENT SENSE
Chatpati Thermostrip Roleplay


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.

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