For Laksamana Usaha Noodle Products Sdn Bhd

CLEANER TECHNOLOGY AUDIT REPORT
CLEANER TECHNOLOGY AUDIT REPORT
For
Laksamana Usaha Noodle
Products Sdn Bhd
6th January, 2010
Prepared by;
Energy and Process Engineering Group
Environmental and Bioprocess
Technology Centre
SIRIM BERHAD
Cleaner Technology Audit Program for
Small and Medium Industry (SME)
SIRIM - DOE
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CLEANER TECHNOLOGY AUDIT REPORT
Table of Contents
Executive summary
ii
1.0
Introduction
1
1.1
Cleaner technology audit
2.0
Process Description
2.1
Company Overview
2.2
Products
2.3
Production and Operation
3.0
Technology Benchmarking
3.1
Cleaner Technology in Laksamana
3.2
Role Model
4.0
Process Comparison
4.1
Yellow Noodles
4.2
Kuey Tiow
5.0
Conclusion
1-3
3-4
4-12
13
Annexes:
A
Production Process Flow Chart
15
B
Production Photos
17
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CLEANER TECHNOLOGY AUDIT REPORT
Executive Summary
A cleaner technology factory visit was carried out by the audit team comprising
officers from SIRIM and Department of Environment (DOE) at Laksamana Usaha
Noodle Products Sdn. Bhd., Kuala Lumpur on the 6th January, 2010. The
objective of the visit is to have a thorough look and better picture of the
improvement and modernization of their production operation which in line with
the cleaner technology concept.
Laksamana had been identified as the company which can become a role model
in their capacity to introduce cleaner technology concept in its business operation
by their own initiative. Even though the company only started its business in the
new factory for around five (5) years, a lot of improvement and process
modernization had been implemented. The ‘cleaner technology’ solutions have
been beneficial to the company in terms of product quality and cost savings.
The technology implemented at Laksamana can be a benchmark to other similar
industries to follow and to understand the cleaner technology concept. The scope
covers an overview of the process and technology comparison with other similar
factory which had been audited during the CP audit project duration.
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1
Introduction
1.1
Cleaner Technology Audit
Objective
The aim of the cleaner technology audit is to enhance profitability for
companies while reducing wastes and pollution by:
·
the identification of potential areas for the application of cleaner
technology solutions and
·
the identification of environmental aspects associated with the
operations
Scope
From the pre-visit to several factories all over Malaysia, the team has
identified Laksamana as the company which can become a role model in
their capacity to introduce cleaner technology concept in its business
operation by their own initiative. The scope covers an overview of the
processes and technology comparison with other similar factory which had
been audited during the CP audit project duration.
2
Process Description
2.1
Company Overview
Laksamana Usaha Noodle Products Sdn. Bhd. was established almost 40
years ago specialized in producing variety types of noodle based
products. Due to the business expansion and commitment to produce
better and quality products, they had moved to the new factory in 2005.
The new factory located at Lot 37653-37654, Jalan 2/37A, Taman Bukit
Maluri, Kepong, 52100 Kuala Lumpur.
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CLEANER TECHNOLOGY AUDIT REPORT
2.2
Products
The company produces variety types of rice and wheat based noodles as
their core business. Its products of noodles are based on Chinese noodles
such as Yellow Noodles (also known as Mee Kuning), Kuey Teow, Yee
Mee, Wantan Mee, Laksa Panjang and Laksa Pendek. Besides, they are
also producing some food ingredients such as Cili Boh and Kulit Tauhu.
In addition, they are also selling vermicelli noodles supplied through its
affiliate company.
Due to its steady growing business, the company had invested in
modernizing its production process to meet the market demand and to
produce quality products without ignoring the traditional recipes which has
been passed down from generation to generation. The process flow charts
for its main products namely Yellow Noodles and Kuey Tiow are shown in
Annex A.
2.3
Production and Operation
Main production plants in Laksamana are Yellow Noodles and Kuey Tiow.
Currently they have four (4) and three (3) production plants producing the
Yellow Noodles and Kuey Tiow respectively. Besides, they also have one
section for producing Yee Mee and other products. Some photos taken
during the audit can be referred in Annex B.
The company’s strong team of around 100 dedicated employees is welltrained and disciplined. With an efficient workforce, Laksamana is capable
of manufacturing 30-50 tons of Yellow Noodles, 50 tons of Kuey Tiow and
300-350 cartons of Yee Mee daily. Main raw materials for producing the
products among others are rice, starch, wheat flour and corn flour.
The company operates 365 days a year. This year, due to its growing
business, the operation is running 24 hours with 2 shifts operation. With its
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CLEANER TECHNOLOGY AUDIT REPORT
steady rise in noodles based business, Laksamana is still expanding,
continuously upgrading and improving its present technology to increase
output to meet the market’s needs.
Nowadays, Laksamana is one of the biggest producers of noodle based
products in Malaysia. Due to its quality products and longer shelf life, its
market is now expanding which covers all over Peninsular Malaysia and
several overseas markets.
3
Technology Benchmarking
3.1
Cleaner Technology in Laksamana
The company has big visions when it comes to the technology
applications and process improvements in the manufacturing plants. Most
of the manufacturing facilities had been modernized from the conventional
and manual processes. According to the company’s management, their
commitment to improve and to replace the old machines/methods was not
only due to business profits alone. Instead they also insisted on the
environmental awareness which eventually would provide savings to the
company.
After the gradual improvements to its manufacturing facilities for the past
few years, they are beginning to harvest the benefits in terms of cost
savings such as fuel and electricity usage, water consumption, waste
water treatment plant maintenance cost. The company own initiatives to
improve its operation is actually in line with the concept of cleaner
technology improvement which are to enhance profitability for the
companies while reducing wastes and pollution.
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3.2
Role Model
The audit team agreed that Laksamana can become a role model to other
similar companies which are producing noodle based products in
Malaysia. Even though the company only started its business in the new
factory for around five (5) years, a lot of improvement and process
modernization had been implemented. The ‘cleaner technology’ solutions
have been beneficial to the company in terms of product quality and cost
savings. To dates, within the short times the company has become one of
the major players in noodle based products in Peninsular Malaysia.
4
Process Comparison
In this report, a few technologies implemented in Laksamana will be
compared to one of the companies (Company A) which was visited by the
audit team previously. The technology focus will be on the production of
Yellow Noodles and Kuey Tiow. The lists of comparisons are as follow:
i. Yellow Noodles
a) Noodles Cooling Process
b) Packing and Weighing Process
ii. Kuey Tiow
a) Rice Washing and Grinding Process
b) Mixing Process
4.1
Yellow Noodles
i. Noodles Cooling Process
Company A
Before packing, the noodles need to be cooled down as to maximize
its shelf life and product quality. An operator was assigned to do the
conveying of noodles from place to place manually before reaching the
packing line. The current table of ‘U’-shape was a static table in which
forcing the operator to distribute the noodles from its place so that
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cooling effect will be faster. However, this process takes sometimes
before noodle was cooled and packed.
Manual Cooling Process
U-Shape Table for Cooling Effects
Laksamana
Several fan blowers were installed right after the cooking process to
provide pre-cooling to the products. To further cool down the noodles,
it will go through a 5-level conveyor system which was operates
automatically before going to the packing process.
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Fan Blower for Cooling
5-Level Conveyor for Cooling Effects
ii. Packing and Weighing Processes
Company A
After the manual cooling process, a few operators were waiting at the
end of the U-shape table for weighing and packing processes. The
processes including noodles cutting were carried out manually. The
area looks crowded and messy due to limited space of the factory.
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Manual Weighing and Packing Processes
Laksamana
The noodles will be automatically going through an automatic cutting
and weighing processes after completed the cooling effects process.
Then it will be straight away packed by the auto-packing machine
which was placed underneath. Finally the products will be conveying to
the bulk packing by the operators.
Auto-Weighing and Cutting Processes
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CLEANER TECHNOLOGY AUDIT REPORT
Packing Process
4.2
Kuey Tiow
a. Rice Washing and Grinding Processes
Company A
Both processes were done separately and manually. Firstly, an
operator will pour a few bags of rice into a Washing Tank which was
filled with water and slowly stirs by a propeller. The ‘washed’ rice then
will be discharged together with the water into a rattan basket which
eventually will remove the water. Then, it will be pour into a Grinding
Machine to produce the rice solution.
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CLEANER TECHNOLOGY AUDIT REPORT
Rice Washing Process
Rice Grinding Machine
Laksamana
The company has a few Rice Washing Machines which attached to
Grinding Machines as a single unit. The grinding machine is located at
the bottom of the washing tank. The water consumption can be
reduced to four (4) times the weight of rice and total contaminant
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CLEANER TECHNOLOGY AUDIT REPORT
amount will not change. Work loads also can be reduced since the
operators do not have to transfer the rice into the grinding machine.
Rice Washing Machines
Grinding Machine
b. Mixing Process
Company A
The process of mixing the rice solution was carried out manually by the
operators in a plastic container before transferring to the bigger
container. The ‘mixing’ was done by the operators by using bare
hands. The ‘mixing’ process was very time-consuming and tiring. In the
bigger container, the operator will again stirred the solutions by using a
wood roving panel.
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‘Mixing’ Process
Transferring of ‘Mixed’ solution
Laksamana
After the Grinding Process, the rice solution will be flowing into a
compartment which then will direct the solution into a Mixing Tank. The
solution will then will be mixed with other ingredients and stirred
homogenously.
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Rice Solution Compartment
Mixing Tank with Auto-Stirrer
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5.0
Conclusion
The cleaner technology ideas compared in this report are varies from
short term to long term effect with maximum potential savings and positive
environmental impacts. The company own initiatives to improve its
operation is actually in line with the concept of cleaner technology
improvement which are to enhance profitability for the companies while
reducing wastes and pollution. The ‘cleaner technology’ solutions have
been beneficial to the company in terms of product quality and cost
savings. To dates, within the short times the company has become one of
the major players in noodle based products in Peninsular Malaysia.
The process comparison shown covers only on major areas observed by
the audit team during the duration of the audit project. Other companies
are recommended to follow Laksamana’s commitment to improve their
production operation which will then provide the products improvement,
efficient operation and cost savings. At the same time, the company
actually helping the environment by reducing wastes and pollution.
Strategies and technologies deliver promises, the most valuable asset,
people, delivers results.
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ANNEXES
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CLEANER TECHNOLOGY AUDIT REPORT
Annex A
Production Process Flow Chart
Yellow Noodles Production
Mixing
Pressing
Forming
Cooking
Pre-cooling
Cutting
Cooling
Weighing
Packing
32
Kuey Tiow Production
Rice Washing
Grinding
Mixing
Steaming
Forming
Cutting
Weighing
Packing
CLEANER TECHNOLOGY AUDIT REPORT
Annex B
Yellow Noodles Process Section
ii
Environment & Bioprocess Technology Centre
CLEANER TECHNOLOGY AUDIT REPORT
Kuey Tiow Section
iii
Environment & Bioprocess Technology Centre
CLEANER TECHNOLOGY AUDIT REPORT
Yee Mee Section
iv
Environment & Bioprocess Technology Centre