NREB Natural Resources and Environment Board Sarawak ORGANIC WASTE FROM FOOD MANUFACTURING / PROCESSING INDUSTRIES September 2004 DANIDA Danish International Development Assistance
DANIDA-SARAWAK GOVERNMENT Urban Environmental Management System Project ORGANIC WASTE FROM FOOD MANUFACTURING/PROCESSING INDUSTRIES September 2004 Report no. UEMS_TEC_02_32 Issue no. 1 Date of issue September 2004 Prepared Checked Approved Teknologi Enviro-Kimia (Malaysia) Sdn Bhd ILA
TABLE OF CONTENT 1.0 Introduction 2.0 Objectives Of Survey 3.0 Sampling Size 4.0 List Of Selected Food manufacturing/processing Industries 5.0 Method Of Survey 6.0 Survey Result 6.1 Agriculture Products Processing 6.2 Biscuits Factories/Confectioneries etc 6.3 Fish Preparation & Preservince (Fish & Prawn) 6.4 Meehon, Noddles & Related Products 6.5 Miscellaneous Food Preparation 6.6 Beverages Manufacturing Industries 6.7 Abattoir 6.8 Waste Water Treatment Facility 7.0 Public Point Of View 8.0 Discussion 8.1 Physical and Moisture Content Of the Organic Waste 8.2 method for Total Organic Waste From 21 Food Manufacturing/Processing Factories In Kuching 8.3 Of Organic Waste 8.4 Public Opinion 9.0 Conclusion 10.0 Appendix
Organic Waste From Food Manufacturing/Processing Industries 1.0 Introduction Teknologi Enviro-Kimia (Malaysia) Sdn Bhd ( TEK ) is a local total water management company based in Sarawak. TEK has been appointed by Natural Resources & Environment Board ( NREB ) to conduct a field survey on the production of re-useable organic by various industries in Kuching. 2.0 Objectives of Survey This field survey is to determine the quantity and observed quality of the organic produced by various food manufacturing/ industries in Kuching. 3.0 Sampling Size Number of Food Manufacturing/Processing factories in Kuching registered with NREB is 126 factroies (Source : Manufacturing/Processing Industries in Kuching, April 2002 by NREB and DANCED). A sampling size of 20 factories and 1 abattoir representing various major types of food manufacturing / industries have been selected for the survey. The selected factories for the survey are shown in Section 4.0. Selection of Food Manufacturing/Processing factories is based on respective sector and industry size. Sampling size for each sector is a minimum of 10 % as shown below: No. Industry Sector Total Sample Sampling Size 1 Agriculture Products Processing 8 1 13 % 2 Biscuits Factories/Confectioneries etc 23 3 13 % 3 Fish Preparation & Preservince (Fish & Prawn) 17 3 18 % 4 Meehon, Noodles & Related Products 9 3 33 % 5 Miscellaneous Food Preparation 51 9 18 % 6 Beverages Manufacturing Industries 12 3 25 % 7 Abattoir 1 1 100 %
4.0 List of the Selected Food Manufacturing/Processing Industries Agriculture Products Processing 1 Syarikat Kion Hong Oil Mill Biscuits Factories/Confectioneries etc 1 Sedap Food (Sarawak) Sdn Bhd 2 Taiten Food Industries Sdn Bhd 3 Pico Food Industry Sdn Bhd Fish Preparation & Preservince (Fish & Prawn) 1 Sea horse Corporation Sdn Bhd 2 CCK Sea products Industries Sdn Bhd 3 Kuching Frozen Food Co. Sdn Bhd Meehon, Noodles & Related Products 1 Lee Fah Mee Sdn Bhd 2 Nestle Foods (M) Sdn Bhd 3 THK Food Industries Sdn Bhd Miscellaneous Food Preparation 1 Yeo Hiap Seng (Sarawak) Sdn Bhd 2 Dahfa Food Manufacturing Sdn Bhd 3 Vanilla Foods Centre Sdn Bhd 4 Treats Dairies (S) Sdn Bhd 5 Nestle Foods (M) Sdn Bhd 6 Gulf and Pacific Industries Sdn Bhd 7 Goodwill Avenue Cold Storage Sdn Bhd 8 Heng Feng Industry Sdn Bhd 9 K&L Farming Industries Sdn Bhd Beverages Manufacturing Industries 1 Yeo Hiap Seng (Sarawak) Sdn Bhd 2 F&NCC Beverages Sdn Bhd 3 Sundrop Fruits Juices Berhad Abbatoir 1 PPES Ternak
5.0 Method of Survey Field survey was conducted in the form of interviews with the management/operational personnel and plant survey of the selected food manufacturing/ factories to determine the quantity and quality of the organic generated from their processes. Questionnaires were completed with required information, verified and stamped by the respective management at the end of the interview section (as per completed survey forms attached). 6.0 Survey Results The survey was carried out between June July 2004. The list of food manufacturing/ factories surveyed were different from the original proposed list due to either irrelevant production processes or unable to obtain permission from the management to conduct the interview and survey. However, the sampling size was maintained at 20 factories and 1 abattoir. The result of the survey is shown below.
6.1 Agriculture Products Processing No. Name of Industry Process Description Type of Waste Quantity per Month (kg/month) Physical Waste Content Moisture Content (%) Method 1 Syarikat Kion Hoong Cooking Oil Mills Sdn Bhd Palm oil and coconut oil refinery Coconut cake Waste bleaching earth 150,000 Solid Coconut press cake 30,000 Solid Wasted bleaching earth 5-7 % oil <0.1% water 3-5 % oil ~1% water Raw Raw Re-sale as Land fill at own factory premise
6.2 Biscuits Factories/Confectioneries etc No. Name of Industry Process Description Type of Waste Quantity per Month (kg/month) Physical Waste Content Moisture Content (%) Method 1 Taiten Food Industries Sdn Bhd Snack food Snack food Very minimum Solid Flour, maize grits, flavoring, coloring < 10 % water Raw Re-sale as 2 Sedap Food (Sarawak) Sdn Bhd Snack food Snack food 130 Solid Flour, corn grit, Flavoring, coloring < 10 % water Raw Re-sale as 3 Pico Food Industry Sdn Bhd Snack food Wafer biscuit Snack food Wafer 130 Solid Rice flour, corn grits, Flavoring, coloring < 10 % water Raw Re-sale as 1300 Solid Flour 70% water Raw Trieneken
6.3 Fish Preparation & Preservince (Fish & Prawn) No. 1 2 3 Name of Industry Sea horse Corporation Sdn Bhd CCK Sea products Industries Sdn Bhd Kuching Frozen Food Co. Sdn Bhd Process Description Prawn and Fish Preparation and Preservine Prawn Preparation and Preservine Prawn Preparation and Preservine Type of Waste Prawn shell and heads Fish Prawn shell and heads Prawn shell and heads Quantity per Month (kg/month) Physical Waste Content 26,000 Solid Prawn heads and shells Max 78,000 56,000 53, 000 Solid Solid Solid Fish bones, heads, skin and internal organs Prawn heads and shells Prawn heads and shells Moisture Content (%) Method ~ 60 % Raw Re-sale as ~ 80 % Raw ~ 60 % Raw Re-sale as Re-sale as ~ 60 % Raw Given to farmer as
6.4 Meehon, Noodles & Related Products No. 1 2 3 Name of Industry Lee Fah Mee Sdn Bhd Nestle Foods (M) Sdn Bhd THK Food Industries Sdn Bhd Process Description Noodles Noodles Noodles Type of Waste Noodle Flour from mixing tank cleaning Deep fried oil Noodle Noodle Cooking oil Quantity per Month (kg/month) 600 Physical Solid 400 Solid Waste Content Moisture Content (%) Flour, egg, ingredient < 10 % Raw Method Re-sale as Flour, egg, ingredient ~ 90 % Raw Trieneken 1,000 Liquid Oil Nil Raw Flour, egg, 3,000 Solid ingredient < 10 % Raw Flour, egg, Max 2500 Solid ingredient < 10 % Raw Max 150 Liquid Oil Nil Raw Re-sale for other purpose Re-sale as Re-sale as Re-sale for other purpose
6.5 Miscellaneous Food Preparation No. 1 2 3 4 5 Name of Industry Yeo Hiap Seng (Sarawak) Sdn Bhd Dahfa Food Manufacturing Sdn Bhd Gulf and Pacific Industries Sdn Bhd Treats Dairies (S) Sdn Bhd Nestle Foods (M) Sdn Bhd Process Description Soya sauce Chili sauce Artificial vinegar Fish fillet snack Concentrated fruit cordial Ice-cream Waste Water Treatment Plant Waste Water Treatment Plant Type of Waste Soya bean paste Quantity per Month (kg/month) Physical Waste Content Moisture Content (%) Method Max 24,000 Solid Soya bean, salt ~ 80 % Raw Trieneken NA NA NA NA NA NA NA NA NA NA NA NA NA NA Fish 1500 Solid Fish heads, bones, tails, skin Calamansi fruit Machine start-up 550 Solid Calamansi fruit 78 Slurry Milk powder/fat, sugar, flavouring Filter cake 1,092 Solid Milk powder/fat, sugar, flavouring Milk powder, Cake from Solid sugar, flour, 200 drying bed ingredient and flavouring 80% Raw ~ 70 % Raw Re-sale as Given as animal feed/trieneken ~ 99% Raw Trieneken ~ 80 % Treated Trieneken ~ 60 % Treated Trieneken
6 Vanilla Foods Centre Sdn Bhd Chicken and vegetable Chicken Vegetable 900 Solid Chicken internal organ, bones, heads 600 Solid ~ 60 % Raw Re-sale as Vegetable rotten leave and stems ~ 80 % Raw Re-sale as 7 8 9 Goodwill Avenue Cold Storage Sdn Bhd Heng Feng Industry Sdn Bhd K&L Farming Industries Sdn Bhd Chicken slaughtering Chicken slaughtering Chicken slaughtering Chicken Blood and washing water Chicken Chicken Skin of chicken claw Intestine 26, 000 Solid Chicken unwanted internal organ, feathers 80 % Raw Re-sale as 13,000 Liquid Blood 99 % Raw Drain 45,000 Solid Chicken feathers, intestine, coagulated blood 70 % Raw 30,000 Solid Feathers 60 % Raw 300 Solid Skin 60 % Raw 36,000 Re-sale as Collected by private company. RM 2400/month incurred. Solid Intestine 80 % Raw Re-sale as
6.6 Beverages Manufacturing Industries No. 1 2 3 Name of Industry Yeo Hiap Seng (Sarawak) Sdn Bhd F&NCC Beverages Sdn Bhd Sundrop Fruits Juices Berhad Process Description Type of Waste Quantity per Month (kg/month) Physical Waste Content Moisture Content (%) Soya bean drink Soya bean paste 1,200 Solid Soya bean paste 60 % Raw Chrysanthemum drink Waste water Treatment Plant Soya bean drink Chrysanthemum drink Coffee drink Grass jelly drink Chrysanthemum extract Max 80 Solid Chrysanthemum extract Method Re-sale as 60 % Raw Trieneken Sludge cake 400 Slurry Organic sludge 98 % Treated Soya bean paste Chrysanthemum extract Coffee bean Grass jelly Collected by tanker. RM 100/trip 1,200 Solid Soya bean 60 % Raw Re-sale for other purpose 9,000 Solid Soya bean < 10 % Roasted Re-sale as 384 Solid Chrysanthemum extract 60 % Raw Re-sale for other purpose Max 4800 Solid Coffee bean 60 % Raw Re-sale for other purpose 800 Solid Grass jelly extract 80 % Raw Re-sale for other purpose
6.7 Abattoir No. Name of Industry Process Description Cattle, camel, goat and deer farm Type of Waste Animal from cattle and camel Animal from goat and deer Quantity per Month (kg/month) 450 7.5 Physical Waste Content Moisture Content (%) Method Slurry Dung and urine 95 % Raw Taken by farmer Solid Dung and urine 60 % Raw Taken by farmer 1 PPES Ternak Sdn Bhd Animal slaughtering house Slaughtering 4500 Liquid 1236 Solid Blood, stomach & intestine content Stomach & intestine content 99 % Raw Pond 80 % Raw Trieneken Pig Slaughtering House Slaughtering 7800 Slurry Dung, stomach juice and blood ~ 90 % Raw Holding pond 5.2 Solid Pig hair/fur ~ 80 % Raw Holding Pond
6.8 Waste Water Treatment Facility S/N Factory Name Waste water volume produced per day (Liter) Handling Method for water Type of Treatment 1 Syarikat Kion Hong Oil Mill 50 Nil Nil 2 Sedap Food (Sarawak) Sdn Bhd 100-150 Nil Nil 3 Taiten Food Industries Sdn Bhd 100-150 Nil Nil 4 Pico Food Industry Sdn Bhd 100-150 Nil Nil 5 Sea horse Corporation Sdn Bhd 5 000 10 000 Waste water treatment plant Water clarification and solid catchments 6 CCK Sea products Industries Sdn Bhd 5 000 10 000 Waste water treatment plant Construction in progress 7 Kuching Frozen Food Co. Sdn Bhd 3 000 5 000 Nil Nil 8 Lee Fah Mee Sdn Bhd 500 Nil Nil 9 THK Food Industries Sdn Bhd 500 Nil Nil 10 Dahfa Food Manufacturing Sdn Bhd 60 000 80 000 Waste water treatment plant Construction in progress 11 Vanilla Foods Centre Sdn Bhd 5 000 10 000 Nil Nil 12 Treats Dairies (S) Sdn Bhd 12 500 Waste water treatment plant Chemical and biological treatment 13 Nestle Foods (M) Sdn Bhd 10 000 Waste water treatment plant Biological treatment 14 Gulf and Pacific Industries Sdn Bhd 3 000 5 000 Nil Nil 15 Goodwill Avenue Cold Storage Solid catchments at outlet 500 Nil Sdn Bhd to drain 16 K&L Farming Industries Sdn Bhd 150 000 Nil Nil 17 Heng Feng Industry Sdn Bhd 150 000 Nil Nil 18 Yeo Hiap Seng (Sarawak) Sdn Bhd 10 000 Waste water treatment plant Biological treatment 19 F&NCC Beverages Sdn Bhd 15 000 Waste water treatment plant Biological treatment 20 Sundrop Fruits Juices Berhad 1000-2000 Waste water treatment plant Construction in progress 21 PPES Ternak 4500 Holding Pond Nil
7.0 Public Point of View 7.1 Question: Do you support the idea of Organic Waste Recycling or Reuse for a cleaner environment? Feedback: Yes No 100 % 0 % 7.2 Question : Are you willing to pay a small fee to a management company or a government agency which offer a proper organic management system to handle your factory s organic? Feedback : Yes No 48 % 52 %
8.0 Discussion 8.1 Physical and Moisture Content of the Organic Waste From this survey, 44 types of have been identified from the 21 selected food manufacturing/ factories. 79.55 % of the 44 types of organic is in solid form and the remaining 20.45 % is in slurry or liquid form (this did not include water from floor and machine cleaning). Beverages, ice-cream, cooking oil from noodle and animal blood from chicken slaughtering house are the main contributors to the liquid or slurry organic.
Number Of Waste Type Teknologi Enviro-Kimia (Malaysia) Sdn Bhd Chart 1 : % Of Solid Content For Waste Type 14 % Of Solid Content For Waste Type 13 12 10 9 9 8 6 4 2 0 7 4 2 0 0 0 0 0 0 0 0 0 0 0 < 5% 10% 15% 20% 25% 30% 35% 40% 50% 55% 60% 65% 70% 75% 80% 90% > 90% % Solid Content Liquid/Slurry Waste Solid Waste Number Of Waste Type
Based on Chart 1, 36 type (79.55%) are in solid form and 8 type (20.45 %) are in liquid/slurry form which include 2 oil. 8.2 Method for Organic Waste from Food Manufacturing/Processing Industries Total organic from the 21 factroies is estimated to be around 610 metric tonnes per month. Out of 613 metric tonnes of the organic, 81.35 % were re-used as animal feed or as fertilizer; 4.89 % used as landfill at their own premise; 9.63 % collected and disposed off by either private company or Trienekens and 4.13 % directly discharged into pond or drain. Chart 2 : Main Method For Total Organic Waste From 21 Food Manufacturing/Processing Factories in Kuching Method for Organic Waste 4.13% 4.63% 5.00% 4.89% 8.81% Resale for or other purpose Given to farmer as fertilizer or Used as landfill at their own premise Being collected by private company for disposal Disposed by Trieneken 72.54% Discharge into pond or drain.
Beverages Manufacturing Industries Meehon, Noodles & Related Products Agriculture Products Processing Fish Preparation & Preservince (Fish & Prawn) Miscellaneous Food Preparation Biscuits Factories/Confectioneries etc Abattoir Percentage of by Weight Teknologi Enviro-Kimia (Malaysia) Sdn Bhd Chart 3 : Organic Waste Method by Each Industrial Sector 100% Organic Waste Method By Each Industry Sector 80% 60% 40% 20% 0% Re-sale for or other purpose Used as landfill at their own premise Discharge into pond or drain Given to farmer as fertiliser or Being collected by private company for disposal Trieneken
Based on Chart 2 and Chart 3, most of the 21 food manufacturing/ factories reuse ~ 86 % of the organic. Only ~ 14 % of total organic is not recycled but disposed off by Trienekens or private company or discharge into pond or drain. 8.3 of Organic Waste 90% of the organic were disposed in its raw condition/form. The remaining 10 % of the organic were treated before disposal and it consists mainly of sludge cake, organic sludge from water treatment plant and oven dried soya bean paste. The treated organic s from water treatment plant have been blended with organic compound during treatment. 8.4 Public Opinion All the 21 food manufacturing/ factories selected for this survey agreed and supported the idea of recycling or reusing the organic for a cleaner environment. However, only 48% of the factories surveyed were willing to pay for a fee if it were imposed by the government or private company to collect the organic for proper management, provided that the imposed fees were reasonable and would not be a burden to the industry. 52 % of the 21 factories did not agree or willing to pay fees for the disposal of their organic because the organic from the industry still has a re-sale value. They feel that the Government or private company should help the food manufacturing / industry with a proper organic system rather than just imposing disposal cost. 9.0 Conclusion From this survey on the 21 selected food manufacturing / factories, the quantity of organic produced is feasible for collection for further. However, 80% of these solid organic still has a re-sale or re-usable value, therefore, collection of these may incur cost rather than collecting disposing fees from the generators. The Government or private company should take into consideration of the cost of the if they intend to collect the organic from food manufacturing/ industries. Besides the food manufacturing/ industries, restaurants; bakeries and wet market are other industries, which are also the major organic producers. A survey should also be conducted for these food outlets and eateries.
10.0 Appendix