final report of pt tiara utama laundry

FINAL REPORT OF PT TIARA UTAMA LAUNDRY By Del la and Ikbal Mahsani

NATIONAL RESOURCE EFFICIENT and CLEANER PRODUCTION (RECP) PROGRAMME INDONESIA 2016

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SUMMARY FOR MANAGEMENT

In numerous developing countries, SMEs (Small and Medium Enterprises) are the backbone of economic

and industrial activity, contributing to approximately 75% of the industrial output. But with increasing

resource prices, it is becoming difficult for SMEs to sustain the high costs of energy, water, and

material resources for production while remaining competitive in the market.

The SMEs are often high polluters due to obsolete technology in their small-scale operations and/or the

lack of efficient end-of-pipe pollution control systems. Furthermore, most countries lack the necessary

institutional structures and capacity to provide the required technical support services to industries.

When limited institutional capacities exist, SMEs often suffer the most.

Those factors drive the urgent need to improve the Resource Efficiency (RE) of industrial production in

any of the world‟s regions. This, combined with the increasing awareness of environmental pollution

caused by these industries, provides the basis for promoting cleaner, safer and resource efficient

production programs.

UNIDO helps with the adaptation and adoption of Resource Efficient and Cleaner Production (RECP)

methods, technologies and systems by enterprises and other organizations in developing and transition

countries.

These contribute to:

Efficient use of natural resources, including materials, water and energy

Minimization of wastes and emissions, including those discharged to water, air or on land

Reduction of risks to humans and environment from use of chemicals and disposal of chemical

used in industry

Textile industry is one of the longest and most complicated industrial chains in manufacturing industry,

with a demand largely driven by three main end-uses: clothing, home furnishing and industrial use. The

main environmental concern in the textile/garment industry is about the amount of water discharged

and the chemical load it carries. Other important issues are energy consumption, air emissions, solid

wastes and odors, which can be a significant nuisance in certain treatments.

PT Tiara Utama Laundry which is a Garment Washing Services Company and as a part of

textile/garment industries, has agreed to participate in National Resource Efficient and Cleaner

Production (RECP) Programme Indonesia which is held on January to June 2016 (but extended to start

from April to October 2016).

Based on our observation during plant walk-through and collection of available information, we

identified some points such as no water flow meter installed on washing machine that may cause

improper usage of chemicals and water which then may cause unnecessary rework , control of

equipment maintenance, safety and health matters, leakages of water and steam, energy losses,

inefficient water usage in washing area, effectiveness of waste water treatment process, losses

goods/garments, no specific analysis on coming coal, uninsulated pipe installation, untidy cable

installation, etc. (photo attached as to give clear picture).

The identified Resources Efficient and Cleaner Production options are then to be subjected to a

feasibility analysis in the feasibility assessment phase. Options that are deemed feasible may then be

implemented and monitored.

Resource Efficient and Cleaner Production offers several complementary techniques or practices, ranging from no cost or low cost solutions to advanced clean technologies that need high investment

solutions.

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Resource Efficient and Cleaner Production practices that can be applied, as showing in below figure:

GOOD HOUSEKEEPING

Good Housekeeping changes in operational procedures and workplace and managerial actions to reduce

unnecessary wastage, it involves every phase of industrial operations e.g. repair anything that needs to

be repaired, keep staffs motivated, ensure safe operating area, improve inventory control, etc.

INPUT MATERIAL CHANGE

Means using alternative inputs that created less problematic wastage or using renewable or less

harmful/toxic materials, e.g. using renewable energy, using secondary material/water, etc.

BETTER PROCESS CONTROL

Means improving control over procedure and equipment in order to run the processes more efficient

and at lower waste and emission generation rates, e.g. monitoring standard operation procedures,

using correct recipe/liquor ratio, sub-metering water/energy/materials, etc.

EQUIPMENT MODIFICATION

Means modifying the existing equipment and utilities in order to run the processes at higher efficiency

lower waste and emission generation rates, e.g. proper alignment of production line, insulation, etc.

PRODUCT MODIFICATION

Means redesigning/modifying the product characteristics in order to reduce its environmental impact

during production, use and/or disposal, e.g. redesigning for optimal product lifetime, redesigning for

minimum use of water/energy/cleaning, etc.

PRODUCTION OF USEFUL BYPRODUCT

Means modifying/converting a previously wasted material into a substitute input material for another

company/user.

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ON-SITE REUSE & RECYCLING

Means reusing or recycle materials that might come from the process, offices and from any part of the

company. It includes reusing of the wasted materials in the same process for another useful application

within the company, e.g. recovered coconut shells and started to use them as alternative fuel in boiler.

TECHNOLOGY CHANGE

Means replacement of (process) technology using with more efficient and/or less wasteful technology,

e.g. investing new machine with update technology.

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INTRODUCTION

The United Nations Industrial Development Organization (UNIDO) and the United Nations

Environment Programme (UNEP) cooperate closely to advance sustainable industrial development and

sustainable consumption and production in developing and transition countries. Since 1994, UNIDO and

UNEP have worked together to establish and support National Cleaner Production Centers (NCPCs),

which are currently operational in over 45 countries. These centers provide services to businesses,

governments and other stakeholders in their home countries for the promotion and implementation of

Resource Efficient and Cleaner Production (RECP) methods, practices, technologies and policies. In

2009, UNIDO and UNEP agreed on a new Joint Programme on RECP, with the overall aim of expanding

and scaling up the activities and impacts of the global network of NCPCs .

Resource Efficient and Cleaner Production (RECP) is a preventive, enterprise-level approach for

improving resource use, reducing environmental pollution and contributing to sustainable industrial

development. It is based on the continuous application of an integrated preventive environmental

strategy to processes, products and services in order to increase overall efficiency and to reduce risks

to humans and the environment. RECP can be applied to the processes used in any industry, to

products and to various services provided in society.

The central element of RECP is the examination and re-evaluation of company processes. RECP is

typically undertaken at a profit or is otherwise beneficial to companies, as money is saved in two ways:

firstly, by converting valuable resources into useful products and services, and, secondly, by reducing

the costs of clean-up, remediation, transport, treatment and disposal associated with wastes and

emissions. Furthermore, RECP saves valuable natural resources, thus providing benefits for society and

the environment.

A key feature of the success of RECP initiatives is the monitoring of performance improvements in

terms both of increased resource productivity, and of decreased pollution intensity. Performance

indicators enable companies to monitor their use of energy, water and materials and the generation of

waste and emissions. The indicators selected are central to RECP and are relevant to the

manufacturing, processing and service sectors. The indicator system provides a framework for initiating

and focusing RECP activities, monitoring, setting targets, sustaining performance achievements and

reporting progress.

Implementing Resource Efficiency will make your company more cost-effective. Use materials, energy,

fuel and other resources more efficiently and cut the cost of waste disposal and input purchases.

Resource Efficiency projects let your company benefit from improved cash flow, because of reduced

expenses for materials and energy and more rapid return on investment because of less fixed capital

for stored materials and chemicals.

Companies practicing Resource Efficiency reduce environmental and business risks, thereby increasing

their credit-worthiness. You can also improve the financial performance by building a portfolio of

environmentally sound and socially responsible investments.

A basic premise behind safer production is that reducing hazard, rather than controlling exposure, most

effectively manages chemical risk. This means, it is safer to choose inherently less hazardous chemicals

rather than attempt to control the exposure risk of a hazardous chemical, which is the traditional

thinking behind risk management.

Exposure controls can and do fail, and products are used in ways that were never intended. Therefore

the most effective means to reduce risk is to reduce hazard by using inherently safer chemicals.

Your company will become more competitive, as Resource Efficiency practices improve your image and

the quality and safety of your products. Resource Efficiency also reduces environmental, health and

liability risks, and by conforming to environmental standards, your company can export to new

markets.

Benefits of Resource Efficiency for companies include:

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Reduction in cost for materials, chemicals and energy

Reduction in cost for disposal of waste and treatment of emissions

Reduce cost for compliance with laws governing waste, emissions and the use of chemicals

Over the long term, Resource Efficiency applied at large secures the supply of resources to all

businesses

Resource Efficiency meets the growing customer demand for sustainable business practice

In Indonesia, the RECP program is focused on demonstrating and replicating RECP methods and

techniques in key industrial sectors and industrial zones. The demonstrations are conducted with the

dual aim of demonstrating economic, resource conservation and environmental benefits in selected

companies. The success is measured in terms of actual implementation of appropriate RECP options by

the demonstration enterprises, and the benefits achieved thereby.

Upon completion, it is expected that the enterprises will have :

Obtained a catalogue of RECP options that will improve resource efficiency and reduce

pollution with recommendations for implementation; and

Improved awareness, understanding and capacity to manage and minimize resource

consumption and pollution generation.

RECP METHOD

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BASELINE SITUATION

The gases in the atmosphere that absorb radiation are known as “Greenhouse Gases” (sometimes

abbreviated as GHG) because they are largely responsible for the greenhouse effect. The greenhouse

effect, in turn, is one of the leading causes of global warming.

The most significant greenhouse gases are water vapor (H2O), carbon dioxide (CO2), methane (CH4),

nitrous oxide (N2O), and fluorinated gases, according to the Environmental Protection Agency (EPA).

The graph below shows how the world's total greenhouse gas emissions are continuing to increase every

year.

Greenhouse gases (GHG) heat and make the planet warmer. Human activities are responsible for

almost all of the increase in greenhouse gases in the atmosphere over the last 150 years. The largest

source of greenhouse gas emissions from human activities is from burning fossil fuels (coal, natural gas,

and oil) for electricity, heat (commercial and residential use), industry and transportation.

The main environmental concern in the textile/garment industry is about the amount of water

discharged and the chemical load it carries. Other important issues are energy consumption, air

emissions, solid/liquid wastes and odors, which can be a significant nuisance in certain treatments.

PT Tiara Utama Laundry as a garment washing Services Company plays a big and important part in

garment industries, especially in denim chain because of the umpteen effects that customers are

looking for on their jeans.

What is garment washing? It is the technology which is used to modify the appearance, outlook,

comfort ability and fashion of the garment. Depending on garments construction, different types of

washing process can be done. According to fashion trend and customer demand, apparel buyers ask for

garment washing and mention exactly what types of washing they need for the order.

To get the order done, apparel washing industries need some types of machine. The most common

machines such as :

Washing Machine

Hydro Extractor

Drying Machine

Boiler (for steam generation)

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Type of washing process that PT Tiara Utama Laundry usually do such as garment wash/enzyme

wash/enzyme stone wash/bleach wash/rinse wash/tinted/acid wash/foaming bleach/dip bleach/tie

bleach and there are a lot of chemicals used in each process which generate waste of water.

Following is a figure of flow process of ‘enzyme stone wash’

ENZYME STONE WASH PROCESS

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Table below is showing the overlaps between water efficiency, energy conservation, material

efficiency and chemicals.

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AREA OF IMPROVEMENT

In washing area we identified inefficiency usage of water and chemical as well. Increased consumption

of materials and water will typically lead to more waste and more waste water. If the energy used is

based on fossil fuels, then increased consumption will lead to increased GHG emissions. Furthermore, if

you use more materials, you will generally need more energy and sometimes more water to process

these materials. Similarly, if you use more water, you will most probably need more energy (for

heating, cooling, pumping, etc.).

Increased use of water could also lead to an increased consumption of materials owing to losses.

Moreover, increased use of energy may also affect consumption of materials and water, since you may

require more water or materials to contain or discharge waste heat. We also found some leakages of

water, steam and heat.

So based on our observations, we will prioritized on both areas, in washing area and area that related

to boiler (steam). The RECP Options which can be applied is Good Housekeeping, Better Process

Control, Input Material Change, Equipment Modification, and Onsite Re-Use & Recycling

As informed before, based on our plant walk-through, we have identified some points that RECP

Options potentially can be applied.

In washing area, we found some points:

Water spills/puddle

Ineffiency usage of water and chemical as they calculate water consumption not based on

liquor ratio but based on the level indicator of washing machine

Wastage of water in accordance to do color matching between washed goods with Buyer‟s

target sample

Leakages of steam of washing machine/pipe installation

Broken seal at the opening/door of tumble dry machine

Points that related to boiler/steam:

Leakages of boiler

Some of steam trap are not working

The opening of the boiler‟s stove is not properly closed

No specific analysis of the quality of coal

Possibility of using renewable energy

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RECOMMENDATIONS

The main environmental concern in the textile/garment industry is about the amount of water used /

discharged and the chemical load it carries. Other important issues are energy consumption, air

emissions, solid/liquid wastes and odors. Resource consumption and waste and emission generation

exceed planetary boundaries, a situation that needs to be resolved by decoupling economic

development from increased use of natural resources and environmental degradation.

Actually, the main problem related to the energy consumption is not that we use energy, but how we

produce and consume energy. As long as we continue to cover our energy needs primarily by

combustion of fossil fuels or with nuclear reactors – which release carbon and GHG into the atmosphere

or create toxic waste that cannot be re-absorbed by the planet – we are going to have environmental

and social problems. Carbon dioxide (CO2) is an air pollutant being a major contributor to global

climate change. Replacing fossil fuels with biomass results in a significant net reduction CO 2 emissions.

Wood fuels are often referred to as “carbon neutral”. This refers to the natural carbon cycle where CO 2

emitted when wood is burned continues to be a part of the overall flux of carbon, while burning fossil

fuels releases new carbon to the atmosphere that had been locked away underground. Trees capture

and store (sequester) carbon. Although the carbon is released when the wood is burned, if harvested

and burned at the rate, it grows in the forest, no net carbon is released. Burning fossil fuels increases

the net amount of carbon in the atmosphere, while burning wood doesn‟t.

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In order to minimize the environmental degradation, to minimize the global warming, we would like to

suggest PT Tiara Utama Laundry to use wood fuel (wood pellets), which is hardly a new idea, instead of

coal fuel.

WOOD PELLETS

A high density wood product with

correspondingly high calorific value.

They can be burned in appliances that offer a high

degree of automation to provide heat on demand

Wood pellets are made by compressing sawdust and wood shreds produced in sawmilling or

manufacturing. Pellets are compact and well suited to automated feed systems because they are

flowable. They also have a high energy value because of their density and low moisture content

(typically 8–10%). The energy density of pellets by volume is also more consistent than logs or chips,

making them an easily tradable commodity. From an energy balance perspective pellet production is

usually only justifiable if the sawdust raw material is a by-product of another process (which is it is).

There are some benefits of using wood fuel, such as:

produced from such waste materials as forestry residues and sawdust

reduce net carbon emissions

wood is a renewable energy, with a high energy content and clean burning fuel source

wood fuel technology is creating energy efficient

convenient and easy to use and can be bulk stored in less space

clean storage

modern wood fuel systems burn very cleanly, producing small quantities of ash, emissions and

little smoke.

reduce fuel bills compare to fossil fuel bills

Below is the table of burning efficiency and typical emissions by fuel type.

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Wood pellets usually packed with 2 packaging options :

Regular bag : 20 / 25 kg

Jumbo bag : 650 / 800 kg

As seen on pictures below, storage of the wood pellets is neat and clean. The handling is also easier

compare to coal.

Packaging in „Jumbo Bag‟

Packaging in „Regular Bag‟

Bulk wood pellets are brought to factory in a truck

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Besides energy, water is a crucial matter as well. Every industry from agriculture, electric power

generation and industrial manufacturing to tourism relies on it to grow and sustain their business.

Clean freshwater is becoming scarce globally and there is every indication that it will become even

more so in the future.

So, it is very important doing water efficiency. Saving water will reduce the cost of water, also can

provide opportunities for developing efficiencies in other areas. For example, using less water may

mean that pumping water around the site is reduced leading to savings in electricity costs and

greenhouse emissions.

Saving water can also reduce the risk of environmental contamination or pollution, as water efficiency

initiatives will lead to less wastewater. Saving water means elimination of excessive surface water

withdrawals that degrade habitat both in streams and on land adjacent to streams and lakes. Efficient

water use can also reduce the amount of energy needed to treat wastewater, resulting in less energy

demand and, therefore, fewer harmful byproducts from power plants.

All chemical exposures have potential consequences on human health. Chemical exposure may result in

life-threatening outcomes. Air pollutants can cause respiratory diseases in humans and have an impact

on the environment e.g. in the form of acid rain or the greenhouse effect.

Chemicals may cause physical damage such as explosions or fires resulting in serious injury and facility

damage. Facility and emission-related effects can include corrosive actions that degrade

equipment performance and residual contamination that limits the future use of facilities and

equipment. Environmental issues may arise as a result of spills, releases or waste chemical

inventories.

Because of safety risks to workers and the environment, and on the other hand losses of

efficiency, it is very important for companies to implement a chemical management programme.

Although chemicals are a potential hazard for everyone, workers are more often exposed to hazardous

chemicals than others due to their daily work. Therefore the use and handling of hazardous chemicals

has to be controlled.

It is important for companies to recognize chemical management as an integral part of their business

operation. They should be proactive in planning for chemical safety and set objectives rather than

solely responding to problems as they occur.

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15

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The operational cost covers: maintenance, labor and other cost follows

What we need to invest for this, is a new burner plus installation which will cost about IDR

100,000,000.00 to 120,000,000.00 or we could just modify its existing stove.

The illustration was made based on data we got from factory. To have more closely amount to

estimation saving cost, we need to do a trial.

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RECP Solutions needed for immediate implementation

Description (Existing Condition)

Recommendations Expected economic benefit

Expected resource use and/or environment benefit

GOOD HOUSEKEEPING

1. Water/steam

leakages Fixing all the

water/steam leakages

Lower the cost of

water/energy usage

1. To have a safer and

comfortable work area

2. Efficiency of water/energy

usage

2. Uninsulated steam

pipes

Insulating all steam

pipes that aren‟t insulated yet

Lower the cost of energy usage

1. To have a nice looking of

working area

2. To reduce heat in the

working area

3. Efficiency of energy usage

3. Unstandardized

safety and healthy

equipment in

permanganate

process (which is a

hazardous chemical)

Using standardize industrial mask, shoes,

glove or other safety equipment needed ;

provide exhaust fan / water curtain

Minimizing cost of medical allowance

To have healthier and safer work environment and

especially the workers

4. Improper chemical

storage

To implement

chemical management system/keeping the

storage record. Store the chemicals

according to their properties, high or low

risks substances, etc.

To avoid accident/minimize

the risk

EQUIPMENT MODIFICATION

1. No water flow meter

installed in washing

machine

Installing a water flow

meter

Lower the cost of

water usage

1. Being precise in water usage for process to

achieve the correct result

2. Efficiency of water usage

2. No valve (stop crane)

near washing

machine

Installing a valve (stop crane) near washing

machine

Lower the cost of water usage

Efficiency of water usage

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3. Broken seal of tumble

dry opening

Fixing the broken seal of the tumble dry

opening

Lower the cost of

energy usage Efficiency of energy usage

BETTER PROCESS CONTROL

1. Improper use of

liquor ratio in

washing process

Using correct liquor

ratio in washing process

Lower the cost of

water and chemical usage

Efficiency of water and chemical usage

2. No cost control

system available Providing cost control system

Possibility to lower

the cost in every division

Easier checking n control the cost of every division in order to prevent or immediately

handle any leakage cost

3. No inventory system

for garments, before

and after process

Providing inventory system, e.g. make

racks to put the garments (on before

and after process)

Eliminate losing or mix-up garments

(between each article) which may

cause extra cost

Keeping the room neat n tidy

RECP options that appear workable but need ‘requiring further feasibility analysis’

Description (Existing Condition)

Recommendation Expected economic benefit

Expected resource use and/or environment benefit

GOOD HOUSEKEEPING

Flat floor around washing area

To make floor around

washing area like „back of the turtle‟

Water will

immediately streaming down to the

drain , no need extra worker to dry up, means no extra cost

for labor

To have a safer working area, avoiding people to slip

INPUT MATERIAL CHANGE

Using fossil fuel

To use a renewable

energy, such as „wood pellet‟

Reduce the cost of fuel

Less carbon emissions (0,025

CO2 per kwh), compare to coal (0,291 CO2 per kwh)

Combustion technology is clean and efficient

Energy efficient

Easier handling and clean warehousing

A renewable energy

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ANNEXES Company name PT Tiara Utama Laundry

Profile of Company Type of activity/sector Garment Sector

Main products and/or services Garment Washing Services

Markets 80% Export, 20% Domestic Market

Ownership Private

Year of establishment 2002

Production capacity 2.000.000 Pcs per month

Capitalization PMDN (Domestic Capitalization)

Annual turnover Rp. 36.000.000.000,-

Total number of staff and workers

245 Employees

Location Jl. Bojong No. 88 Cicadas, Gunung Putri – Bogor, INDONESIA

Physical location This company is located in Bogor district which is easily reached

either from Jakarta or Bandung. Both management office and plant location is near residential area, not in a specific bonded

zone area, in spite of there are some industries nearby.

Stage 1: PREPARATION

Management Commitment Date of briefing of management

30 March 2016

Name and function of senior

manager(s) briefed

Ms. Nia Lee (Marketing Director) ; Ms. Sumiyati (Compliance Dept.

Head)

Past and ongoing environment and/or energy related

initiatives reported by management

The company has been doing an energy efficiency for quite a long time by using sun lighting roof in the production area.

As for the environment matters, following to the government regulation, for quite long time they also been doing the waste

water treatment process.

Future plans of company

reported by management

The company is just running with a new management (new owner)

so they are now on progress to reform and improve their management system, their production control, etc.

Specific environment and/or

energy related concerns expressed by management

The company has built a waste water recycling process/system to

reuse the waste water, especially in the dry season. In accordance to that, they are trying to improve their waste water treatment

process result. The owner/management are also aware that they have losses in

energy usage.

Initial focus areas of RECP assessment discussed and

agreed with management

In boiler area ; washing process area ; production area

Date of signature of cooperation agreement

30 March 2016

Project Team

Team Role Name Function

Team Leader Mr. Guntur Ramadhan Owner

Team Members 1. Ms. Nia Lee Marketing Director

2. Ms. Sumiyati Compliance Head Dept.

3. Mr. Usman Utility Dept.

4. Mr. Asep Water Treatment Dept.

RECP Experts 1. Mr. Ikbal Mahsani National Expert (NE)

2. Ms. Della National Expert (NE)

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Stage 2: INITIAL ASSESSMENT

2.1. Process flow chart and eco-map Process description

A garment washing process is asking by Buyers according to fashion trend and customer demand. There are many types of washing,

either mechanical or chemical wash, and each wash has different types of appearance on the fabric surfaces. Buyers will mention

exactly what types of washing they need for the apparels, whether they are denim or non-denim fabric.

PT Tiara Utama Laundry do some types of washing. Following are some keys/important steps in the process of enzyme stone wash on

denim : 1. Pre-treatment

2. Abrasion Process 3. Finishing

RECP baseline Profile (1) Calculation period January 2016

Total production (in units,

tons, and/or financial value)

805.209 pcs

Total materials use (in kg, ton and/or total costs)

-

Total water use (in m3, GL

and/or total costs)

2.625 m3

Total energy use (in MJ, kWh and/or total costs)

IDR. 157.294.490 (electricity)

201.820 kg (coal)

Total waste generation (in kg,

ton and/or total costs)

-

Total waste water generation (in m3, GL and/or total costs)

-

Total air emissions (in kg, ton

and/or associated costs)

-

Materials Productivity -

Water Productivity 30 liter per pcs

Energy Productivity IDR. 195.35 (electricity)

+ 0.25 kg (coal) per pcs

Waste Intensity -

Waste Water Intensity -

Emission Intensity -

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Process flow chart

Environmental Hazards

In washing area – chemical using (e.g. in using peroxide,

caustic soda, permanganate); water spills/puddle of water at working area

In chemical storage room

Near boiler area

Piping installation

Cable Installation

Ecomap

Attached

2.2.Plant Walk Through Audit

Date performed 30th March 2016 and 22nd April 2016

Participants Mulyati (PT Tiara) ; Ikbal (NE) ; Della (NE)

Documentation

Attached

Observations 1: General

workplace appearance, housekeeping and standard

operating practices

Generally, workplace appearance (a little bit messy and not clean) and housekeeping need to be improved as well as the operating

practices (photo attached)

Observations 2: Leaks, spills or other losses observed

Found steam leakage ; water spill/ water puddle around washing machine area/extractor ; also broken seal at tumble dry front

opening. (photo attached) ; water losses in washing area in the matching colour activity (photo attached)

Observations 3: Level of technology, its maintenance

and control status

Low Level. Need to be improved

Observations 4: Materials and waste – main users and

sources, current controls and handling and disposal

practices

The enterprise is a Washing Garment Services, so they don’t have their own material nor the material waste.

But there is no locked warehouse/storage room to keep the garments so that they always face lost goods.

CHECK-IN

GOODS

CHECK-

OUT

GOODS

PRE-TREATMENT (desizing process)

RAW

MATERIAL STORAGE

ABRASIO

N

PROCESS

FINISHING

Temp. : 40 0C Fresh Water

Soap : 1 g/l Aquazyme : 1 g/l Duration : 10 min

Temp. : 40 0C Fresh Water

Soap : 1 g/l Powder Bio : 1 % Pumice Stone : 50 kg Duration : 15 min

Temp. : 40 0C Fresh Water

Softener : 4 l Duration : 5 min

Liquid Discharge then Fresh Water

Added for Rinsing Process

Liquid Discharge then

Fresh Water Added for Rinsing Process

Extracted, Dried then

Unloaded

Input

Input

Input

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Observations 5: Water and waste water – main users

and sources, current control and discharge practices

Water is used in multiple operations, both in domestic and production section but washing garment process is the main user.

Water is coming from underground resource. There is no water flow meter installed, so they control/calculate water needs by following

water level that available in the washing machine. Waste water is discharged to water treatment tank.

Observations 6: Energy –

main users, losses, waste energy discharges

The main user of energy is tumble dry machine. Losses happened

because of broken seal at the opening/door of the tumble dry (photo attached). The waste energy discharged as heat.

Observations 7: Chemicals

and emissions – main users, losses, hazards

The main user of chemicals is washing garment process (both wet and

dry process). Emissions available. Losses happened when consumption of the chemicals is not based on liquor ratio.

Observations 8: Occupational health and

safety issues identified

They have first aid box in production area but its contents is not proper enough (photo attached)

They have also some extinguishers (photo attached) In dry process area, which is using potassium permanganate, the

workers are not wearing standard industrial mask

2.3. Establish Immediate Actions and RECP Priorities

RECP Practices Specific RECP options for consideration

1. Good Housekeeping Fix all leaks and spills ; Fix all the uninsulated installation ; Fix all

cable installation ; Fix the broken seal of tumble dry opening ;

2. Input Change Using a renewable energy

3. Better Process Control Using correct liquor ratio for washing process

4. Equipment Modification Install water flow meter in washing machine ; Put a faucet valve to

save water

5. Technology Change If possible, replace old washing machine with the new one which has

higher technology level

6. On Site Reuse or

Recycling

Activate the waste water recycling process more often in order to

save water usage

7. Production of Useful

Byproduct

8. Product Modification

RECP Solutions agreed for immediate implementation

Description Expected economic

benefit Expected

resource use and/or

environment

benefit

Person

responsible

1. Fixing leaks

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2. Improve control on each area

3. Install water flow meter 4. Fixing broken seal at the opening of tumble dry

machine

5. Fixing the broken automatic pressure

discharge on steam header

Overall assessment Process Area Resource

Use Environmental Burden

Costs Hazards (incl. occupational

health & safety)

Use traffic light

system to summarize team’s overall

assessment of the status of use of

materials, water and energy (‘resource

use’), of the generation of waste,

waste water and emissions (‘environmental

burden’) and associated costs in

different parts of the company. Red = high

impact or cost; orange = medium impact or

cost; and green = low impact or cost.

Incoming

goods receiving

and storage

Process 1- Washing

Area

Process 2 - Drying

Process n…

Final product

storage and dispatch

Utility

operations

Priority areas agreed for detailed RECP

assessment

1. Washing area 2. Boilerarea

3. 4.

Stage 3: DETAILED ASSESSMENT The detailed RECP assessment is aimed at compiling a comprehensive catalogue of RECP options for the established priority areas, through establishment of material, water and energy balances, root

cause diagnosis, option generation and option screening

3.1: Material, Water and Energy Balance Overall Material Balance

Material Inputs (kg or ton/day or year)

Process Steps Outputs (kg or ton/day or year)

Compile overall material balance for the selected RECP

focus areas, (using this template or attach in other

appropriate form), complement with additional water and energy balance

where relevant and appropriate (2).

1.

On/with product

2.

As waste

3.

As waste water

4.

Emitted to air

5.

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TOTAL INPUT

TOTAL OUTPUT

Locations and/or

operations with inefficient use of MATERIALS

at washing garment process – as chemical is material too

Locations and/or

operations with inefficient use of WATER

at washing garment process (washing process area)

Locations and/or

operations with inefficient use of ENERGY

at tumble dry machine and at location where all leakages exist

Locations and/or

operations which cause the generation of WASTE

liquid (chemical) waste exists in washing process

Locations and/or

operations which cause the generation of WASTE

WATER

waste water exists during washing process

Locations and/or operations which cause the

generation of AIR EMISSIONS

3.2: Root cause diagnosis Identify why inefficiencies (identified in task 3.1) occur in material, water and energy use and/or generation of waste, waste water and emissions? What factors influence the occurrence and scale of

inefficiency and/or waste generation? Use standard cause categories to guide the search of root causes.

1. How do PRACTICES OF

WORKERS AND STAFF contribute to observed

resource inefficiencies and/or waste generation?

The workers and the staffs

2. How does SELECTION AND

USE OF PROCESS INPUTS contribute to observed

resource inefficiencies and/or waste generation?

3. How do PROCESS

CONDITIONS contribute to observed resource

inefficiencies and/or waste generation?

4. How do OPERATION AND

MAINTENANCE STATUS OF EQUIPMENT contribute to

observed resource inefficiencies and/or waste

generation?

5. How does the CHOICE OF PROCESS TECHNOLOGY

contribute to observed resource inefficiencies

and/or waste generation?

6. What INTERNAL VALUE

remains available in the waste streams?

7. What EXTERNAL VALUE

remains available in the waste streams?

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8. How do PRODUCT SPECIFICATIONS contribute

to observed resource inefficiencies and/or waste

generation?

3.3: Option Generation 1. What changes in (GOOD)

HOUSEKEEPING practices

are necessary to minimize observed resource

inefficiencies and/or waste generation?

Company must immediately fixing all leakages of water and steam

To insulate all steam pipes

To make floor around washing area like ‘back of the turtle’ so spilled water will be stream down so there will be no water

puddle

2. What changes in PROCESS

INPUTS are necessary to minimize observed resource inefficiencies and/or waste

generation?

The company already installed waste water recycling plant. So the recycling water can be used as secondary water for another

purpose (but should be tested first whether appropriate or not)

3. What changes in OPERATING

PRACTICES are necessary to minimize observed resource

inefficiencies and/or waste generation?

To install a screw feeder to the coal feed system

4. What changes in EQUIPMENT

are necessary to minimize observed resource

inefficiencies and/or waste generation?

To install water flow machine on washing machine

To install valve (stop crane) near washing machine

5. What changes in PROCESS

TECHNOLOGY are necessary to minimize observed

resource inefficiencies and/or waste generation?

To follow correct liquor ratio in washing process

6. How can residual value of

waste streams be REUSED ON SITE?

Waste water that has been treated can be recycled so that the

water can be re-used. The company has waste water recycling treatment but not optimisely used yet

7. How can waste streams be

converted into USEFUL BYPRODUCT for external

use?

They used wasted canister of chemical canister for dust bin

8. What changes in PRODUCT DESIGN AND SPECIFICATIONS

are necessary to minimize observed resource

inefficiencies and/or waste generation?

3.4 Option screening Review and consolidate the RECP option list (as generated in task 3.3) by combining options that have synergies and/or apply to same unit operation and determining which options are either obviously

feasible or obviously unfeasible. Sort the remaining options in three categories, respectively: ‘ready to implement’, ‘requiring further feasibility analysis’ and ‘rejected’. Summarize in following three

categories.

Category 1: RECP Solutions agreed for immediate implementation ‘ready to implement’

Description Expected economic

benefit

Expected resource use

and/or environment benefit

Person responsible

1.

2.

3.

4.

5.

26

Category 2: RECP options that appear workable ‘requiring further feasibility analysis’

Description Expected economic benefit

Expected resource use and/or environment

benefit

Person responsible

1. Using wood pellet instead of fuel

fossil

Factory will save about Rp 2 million

Lessen CO2 emission Mr. Guntur (the Owner)

2.

3.

4.

5.

Category 3: Options that appear unworkable, ‘rejected’

Description Reason for rejection

1.

2.

3.

4.

5.

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ECOMAP

Energy saving opportunity (boiler area)

Water saving opportunity (wet processing area)

28

PRODUCTION CHART

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PHOTOS RELATED TO PLANT WALK-THROUGH AUDIT

Observation 2 – Water Spills/ Water Puddle – in Washing

Area

Observation 5

Leakage of steam – at washing machine

Observations 6

Tumble Dry Machine – Broken seal at the

door

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ENVIRONMENTAL HAZARD (In accordance to Stage 2 of Initial Assessment)

Observation 8

Health & Safety Issue

PLN Central Power – Untidy (Dangerous

Environment)

Area near PLN Central Power – Storage of Hypochlorite (Untidy / Difficult Access)

Untidy Cable Installation – Dangerous Environment

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Header – Uninsulated installation Header – Unworking steam traps

Steam Pipe - Uninsulated Leakage on Stove – Coal entry not properly closed

Chemical Storage Room –

Possible to be an Hazardous

Environment

Dry Process Area – Potassium Permanganate Using Area

No exhaust fan (HAZARDOUS ENVIRONMENT)

32

Damaged Pipe Insulation

Leakage – at Steam Trap Leakage – at Boiler

Leakage – at water pipe

Un-insulated pipes

33

Wastage of Water – in Washing Area

(NO FAUCET STOPPER NEARBY)

Location of Faucet Stopper

(a little bit far from the canister)

WASTAGE – Condensate Water is exiled

(not being re-used)

34

WASTE WATER TREATMENT PLANT

Fresh Water Tank

Waste Water Treatment Process

(With Soda Ash + PAC + Aluminium Sulphate)

35

Waste Water Treatment Recycling Plant

Chemical Storage Room – Using Air Conditioner to maintain

the room temperature to avoid detriment of the chemical

36

Coal Storage – dirty and messy The dust may cause the garments dirty

Raw Material Input/Storage

Garments just laid down on the floor, no safe/locked storage available

37

Following to our suggestions, PT Tiara Utama Laundry has made some improvements, as seen on below

pictures :

BEFORE AFTER

Wastage of Water – in Washing Area

(NO FAUCET STOPPER NEARBY)

Location of Faucet Stopper (a little bit far from the canister)

Location of Faucet Stopper already installed near the

canister

PLN Central Power – Untidy (Dangerous Environment)

PLN Central Power – has been cleared

Area near PLN Central Power – Storage of Hypochlorite (Untidy / Difficult Access)

Storage of Hypochlorite – Location moved

38

BEFORE AFTER

First Aid Box – not complete First Aid Box - completed

Location of the Fire Extinguisher Fire Extinguisher – located with manual intructions

Location of the Dry Process (Permanganate using)

is in close area

Location of the Dry Process (Permanganate using)

moved to more air circulation