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In pursuit of cleaner technology |
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In
pursuit of cleaner technology
| Published on July 9, 2001 |
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 Thiti
Lertsatchayam, SMTC Co., Ltd's charismatic factory manager,
is a man with a mission. During a recent seminar organized
by the Federation of Thai Industries at this year's THAIFEX
/ THAIMEX show, Thiti explained how SMTC, a leading rice
cracker manufacturer, had implemented the concept of Clean
Technology (CT) at its plant in Samut Prakarn.
Intrigued by the presentation, I recently visited SMTC's
factory, where I was welcomed by Thiti and members of
SMTC's CT team.
Thiti told  FoodMarketExchange
that around 40 per cent of the CT initiatives the company
had undertaken originated from non-executive employees,
who are encouraged to point out areas in the production
process where they feel the company could make improvements
to boost efficiency. In many cases the measures involved
may seem rather insignificant, be it the replacement of
a part, or an adjustment in a process. However, the subsequent
results of the company's CT initiatives are impressive
both in financial terms and in terms of a heightened level
of awareness among employees at every level of the organization.
An exact art
art SMTC Co., Ltd., a Thai-Japanese joint venture that
includes Mitsubishi Corporation and Thailand's Capital
Rice as its major shareholders, is one of Thailand's premiere
producers of rice crackers, or arare in Japanese.
The company currently produces about 4,000 metric tons
of rice  crackers,
and was the first rice cracker manufacturer in the world
to receive HACCP certification. SMTC has now thrown its
weight fully behind the concept of CT, having being introduced
to the idea by the Federation of Thai Industries (FTI).
The FTI was awarded a grant from Denmark to promote the
concept throughout Thailand's industrial sector.
Thiti explained the importance of water in the production
of rice crackers, and indeed many of the initiatives undertaken
have focused on more efficient use of the natural resource.
One such initiative simply involved the replacement of
a nozzle used to spray water during the mochi cutting
process. An employee pointed out that the machinery appeared
to deliver excessive water, so a more efficient replacement
was fitted. Although the part cost just 2,900 baht, it
resulted in a cost saving of 2,520 per annum. The meant
that the replacement paid for itself in just over a year.
Another initiative involved reusing condensate from air
conditioning units. This cost the company nothing to implement
(they were able to use an old storage tank at zero cost),
but resulted in a cost saving of 2,980 baht per annum.
 While
such savings may be considered minimal, bear in mind that
the production of rice crackers is an exact art, especially
when 80 per cent of the output is bound for the food-safety
conscious Japanese market. The production process itself
involves 15 steps (see Figure 1), so if continuous improvements
could be undertaken that affect just a fifth of the entire
process, the cost saving potential of CT can be seen in
a clearer context.
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Clean
Technology
Clean technologies are recognized as the keen essential
element of cleaner production. One must first understand
the definition, goals and objectives of Cleaner
Production. Cleaner production requires application
of know-how, improving technology, and changing
attitudes.
The following definition can explain the clean technology
as defined by United Nations Environment Program.
Cleaner Production can be defined as the continuous
application of an integrated preventive environmental
strategy to processes, products and services to
increase efficiency and reduce risks to humans and
the environment.
For production processes cleaner production can
be applied by conserving raw materials and energy,
eliminating toxic raw materials, and reduction in
the quantity and toxicity of all emissions and wastes
before they leave a process.
For products, cleaner production can be applied
by reducing impacts along the entire life cycle
of the product, i.e. from raw materials extraction
to the final products to ultimate disposal of the
products.
For services, cleaner production reduces the environmental
impact of the services provided over the entire
life cycle. This entire life cycle considers the
stages from system design and use to the entire
consumption of resources required to provide the
services.
UNEP's program for cleaner production encompasses
approaches towards certain criteria as processes,
products and services including their design, usages
of raw materials and energy and utilization thereof.
Thus cleaner production considers all types of wastes
such as hazardous or toxic wastes released into
the air, water and soil. Thus, cleaner production
acknowledges that it not only requires the improving
the efficiency and material substitution with the
help of certain tools as know how and technology
initiatives but also new managerial skills and required
policies with the importance of the design and use
of products and services as well.
parayavarandwar.com |
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Why CT?
The relationship between industry and the environment
globally is often an uncomfortable one. CT aims to improve
the environment while lowering costs for businesses. Thiti
said that the 'Polluter Pay' principle led to a 'lose-lose'
situation in that it increases costs for businesses and
the government, while being difficult to implement effectively
for the benefit of the general public. 'End of Pipe Treatment'
could benefit society as a whole, but again incurred high
costs for industry. In contrast, CT offered 'self-generated'
environmental improvements that also provided companies
with the opportunity for lowering costs.
"It does not mean that the other alternatives do not have
their place, but illustrates the practical benefits of
CT," Thiti said.
The other real benefit derived by implementing a CT program
is heightening environmental awareness and an understanding
of continuous improvement among members of the workforce
at all levels. The company's CT team holds regular meetings
to discuss issues and monitor progress. This encourages
team spirit, while expressing the feeling that employees'
views really do count.
Finally, I asked Thiti whether or not the company would
one day be able to reuse or recycle all water used in
the production process?
"That is our dream," Thiti said with a smile. I have a
feeling that if the company maintains its current level
of dedication to the use of CT, his dream will not be
an impossible one. |
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