“Green Framework of Innovative Strategy (GFIS) for Sustainable Consumption and Production”

Technical Working Group MeetingICETT-EMB

November 19, 2007Sycamore Room, Richmonde Hotel

Prepared by:Prepared by:W.C. H. SantosW.C. H. Santos

Vision and Mission:Vision and Mission:

To be a world class corporation by adapting the Four Best To be a world class corporation by adapting the Four Best Concept. ”Best Customer Service”, “Best Value”, “Best Concept. ”Best Customer Service”, “Best Value”, “Best

Technology”, “Best Quality”Technology”, “Best Quality”

““The Four Best Concept”The Four Best Concept”

“Best Value”

“ “ Best Technology”Best Technology”

““Best Customer Service”Best Customer Service”

“Best Quality”

The Company Owners: 100% Filipino, Family Corporation Nature of Business: Meat Processing Years in the Business: 40 years (since 1967) Location: Dela Paz Norte, City of San Fernando, Pampanga, Philippines Total Site Area: 37 Hectares Total Building Area: 1.2 Hectares Product Lines: Tocino,Hotdogs,Longaniza,Hams,Bacon,Corned Beef and

more. Production Capacity: 100MT per day Systems in Place: HACCP/GMP Programs,Sanitation Program,Pest

Control Program,Waste Management,Food Fortification Program Facilities: Laboratory, WTF, WWTF, Refrigeration, Ice Maker,Boiler,Motor

Pool,Fabrication and Engineering,Warehouse,Clinic,Canteen,Recreation Area,Smoke Rooms,Washing Area,Production Areas,Cold Storages,Weigh- Bridge, Administration Offices, AVR, Training Room and Materials Recovery Facility (under construction).

Plant Category: “AAA” Accredited (Highest International Standard given to a Meat Processing Plant) by DA-NMIS

Employees: 1000 personnel

Activities/Services/Programs: Food Fortification Program, Joint Hog Producer-Processor Tie-up, Food Expositions and Exhibits, Trade Fair, Bar Hosting at T.V. Shows, Donations to Charity, Tree Planting Project in cooperation with DENR-EMB, Food Feeding Project in cooperation with DSWD, Waste Recycling Project, Medical Missions

Affiliations: Philippine Association of Meat Processors Inc. (PAMPI)

Environmental Practitioners Association (EPA)

Pampanga Association of Meat Processors (PAMPRO)

Process Straight line Production Process

Raw materials(Meat,Ingredients)

Cleaning/Disinfection/weighing/

Testing

Processing(curing,mixing)

Cooking/Smoking Cooling/Packing/Storing Dispatching

Sales

Problems

Waste Minimization -Solid waste- paper,cartons,plastics

Organic waste- scrap meat,emulsions,excess food from the

canteen

Chemical waste- used oil,chemical disinfectants,cleaners,

etc.

Toxic Waste- used Batteries Water Management –Cleaning,Processing Energy Usage Minimization –fuel,electricity Work Ethic/Attitudes

Solutions

Waste minimization - There must be a Sanitary/GMP/HACCP Program,SSOP,and 5’S program in place. The monitoring,recording,and documentation of all readings,results,and corrective actions taken. Formulation of a Team to train,implement,monitor,revise,formulate,modify and assess the efficiency of the programs and guidelines.

Maintain good inventory control of consumables, such as cleaning chemicals, packaging materials, food additives etc., to avoid waste.

Source out waste recyclers to turn recyclable materials to added savings. Maintain a Material Recovery Facility. Sun Dry Technique/ Composting for organic waste.

Water Management - Preventive maintenance(pipes,valves,faucets gauges),daily monitoring, cleaning,recording and documentation.

Many hoses were not equipped with shutoff nozzles and were left running when not in use. These practices resulted in excessive water use and high operating costs.

Timely repair of leaking nozzles and replacement of missing nozzles was ensured during cleaner production program.

Sweep up solid materials for use as by-products, instead of washing them down the drain.

Fit drains with screens and/or traps to prevent solid materials from entering the effluent system.

Use dry cleaning techniques to pre-clean process areas and floors before washing with water.

Replacement of current urinal system to water free type urinal (under study). Installation of metering device (under negotiation)

Energy usage minimization Implement switch-off programs and install sensors to turn off or power down lights and equipment when not in use.Improve insulation on heating and cooling systems and pipe work.Insulate and cover scald tanks.Maintain a leak-free compressed air system.Improve maintenance to maximize energy efficiency of equipment.Maintain optimal combustion efficiencies on boilers.Install perimeter lighting (photocell) with automatic switch (on/off).Install capacitor bank, frequency inverter, and WYE-delta controller.Eliminate steam leaks.

In addition to reducing a plant’s demand for energy, there areopportunities for using more environmentally benign sources of energy.Opportunities include replacing fuel oil or coal with cleaner fuels, such asnatural gas, possibly purchasing electricity produced from renewablesources, or co-generation of electricity and heat on site. For some plantsit may also be feasible to recover methane from the anaerobic digestionof high-strength effluent streams to supplement fuel supplies.

Work Ethics/AttitudesEnsure that employees are aware of the environmental aspects and production costs of the company’s operations and their personal responsibilities.Train staff in good cleaning practices.

Procedure Systems

Waste management

Drainage SystemDrainage System

Information DisseminationInformation Dissemination

Information Information DisseminationDissemination

Yellow Lane Yellow Lane (Discipline Zone)(Discipline Zone)

Sanitary practicesSanitary practices

Solid Waste SegregationSolid Waste Segregation

Water ManagementWater Management

Energy and Fuel Energy and Fuel ManagementManagement

Materials Recovery Materials Recovery Facility ProjectFacility Project

System ResultsHigh Energy Consumption

July Power Consumption

August Power Consumption

September Power

Consumption

October Power Consumption

Production area reduced working days from 6 to 5 with the same production output of 30MT

712,600 KwH 712,600 KwH 676,200 KwH

5.1% Savings on our electric

consumption

688,800 KwH

3.34% Savings on our electric

consumption

Production area reduced working days from 6 to 5. Switch Off Programs/power down for lightings

6 work days at 8 operation hours per day using 56 units (400W) metal halide lamp

1075.2 KwH consumed in 6 days

5 work days at 8 operation hours per day using 56 units (400W) metal halide lamp

896 KwH consumed

16.67% Savings

5 work days at 8 operation hours per day using 56 units (400W) metal halide lamp

896 KwH consumed 16.67% Savings

High Energy Consumption

July Consumption

August Consumption

September Consumption

October Consumption

For a 8 hour operation schedule per day with 89 units (400W) metal halide lamp (Production Area)

Power Down/switch off Program for Lightings

248.8 KwH consumed

On a scheduled utility and

maintenance day (8 hour operation)

power down lights from 89 to 26 units

(400W) metal halide lamp

83.2KwH consumed

66.56% Savings in comparison to

having all fixtures switched ON

Same

83.2KwH consumed

66.56% Savings

Same

83.2KwH consumed

66.56% Savings

Same

83.2KwH consumed

66.56% Savings

For a 12 hour operation schedule per day with 36 units (400W) metal halide lamp (Packaging Area)

Power Down/switch off Program for Lightings

172.8 KwH consumed

On a scheduled utility and

maintenance day (8 hour operation)

power down lights from 36 to 18 units

(400W) metal halide lamp

57.6KwH consumed

67% Savings in comparison to

having all fixtures switched ON

Same

57.6KwH consumed

67% Savings

Same

57.6KwH consumed

67% Savings

Same

57.6KwH consumed

67% Savings

High Water Consumption

July August September October

Dry cleaning Techniques

Reduced water usage as much as

5m3

Reduced water usage as much as

5m3

Reduced water usage as much as

5m3

Reduced water usage as much as

5m3

Reduce number of faucets per department (50%)

Water minimization

No metering device No metering device No metering device No metering device

Reuse of Effluent water discharge for watering the greens.

(WWTP discharges about 200m3 per day)

n/a Savings of 60-70m3 of fresh water plus

6% in electric power consumption per

15Hp booster pump

Savings of 60-70m3 of fresh water plus

6% in electric power consumption per

15Hp booster pump

Savings of 60-70m3 of fresh water plus

6% in electric power consumption per

15Hp booster pump

Reduce number of working days from 6 to 5

Water minimization (no metering device as of yet)

Recyclable Materials

August Consumption

September Consumption

October Consumption

November Consumption

Cartons 21.150 tons

42,300Php Cash value

18.130 tons

36,260Php Cash value

13.533 tons

27,066Php Cash value

3.889 tons (partial)

7,778Php Cash value

Plastics 2.760 tons

2,760Php Cash value

1.410 tons

1,410Php Cash value

915 kilos

915Php Cash value

576 kilos (partial)

576Php Cash value

Others

August September October November

Materials Recovery Facility

Proposal for construction

Start of construction (on going)

Water treatment facility upgrade (for better water quality)

Start of improvements

On going work 40-50% completion 70-80% completion

Others

August September October November

Labor Cost

(reduce working days from 6 to 5)

* based on a minimum rate of

278.50Php

27 days work

1,893,399.7Php

22 days work

1,858,068.8Php

2% Savings

26 days work

2,130,271.5Php

15% Increase due to legal holiday’s and increase in

production.

8 days work

627,906.55Php

(partial data)

Boiler Operation (reduce working days from 6 to 5)

n/a 12 hour operation (Savings of 533L of

fuel)

12 hour operation (Savings of 533L of

fuel)

12 hour operation (Savings of 533L of

fuel)

Benefits Lowering Production and Maintenance costs –

fuel,cleaners,utilities,office supplies,personnel,energy and time. Environmental Benefits – lowering of water consumption,minimization

of wastes,maximum utilization of energy and electricity. Social Responsibility to the welfare of the community by

dissemination of information by example. Improvements to product and processes; Savings on raw materials and energy, thus reducing production

costs; Increased competitiveness through the use of new and improved

technologies; Reduced liability associated with the treatment, storage and disposal

of hazardous wastes; Improved health, safety and morale of employees; Improved company image; and Reduced costs of end-of-pipe solutions

Our Products!Tocino, Longaniza, Hams, Bacon, Hotdogs, Corn Beef and more…

Thank You!

Thank You!