Cpgp day02 7- comprehensive case study-pineaple 25.6.10 -samantha

1. NCPC Sri Lanka 12/16/20151
Comprehensive Case Study
Pineapple Juice Factory
Background of the Company:
Pine Delight (Pvt) Ltd., is a Sri Lankan company that processes pineapples to produce bottled
pineapple drink for the local and export market. Members of Mr A B C Rosairo’s family and their
close relatives own the company. The Board of Directors comprises Mr Rosairo as chairman
and Managing Director, his two sons Rohan and Dilhan looking after production and marketing
respectively and Mudith functioning as Financial Director.
The marketing has been negotiating for export orders for the last two years and a German food
chain market has agreed to give a trial order to the company. However, they have insisted that
company should gear themselves for ISO 14001 certification and HACCP certification even to
supply a trial order. In addition the buyer has requested company to obtain the services of a
consultant to carry out an Environmental Audit and submit the report to the buyer for
assessment.
The company purchases its pineapple from a local planter on day-to-day basis. The sugar is
purchased weekly. The factory uses coconut water from a desiccated coconut mill about 25 km
away and the coconut water is transported by a company owned bowser daily in the evening
and stored in a refrigerated storage tank in the premises for use next day. The company
purchases 50,000 bottles at a time with other required packaging material such as labels,
corrugated boxes and polythene. The furnace oil for the boiler is purchased regularly in 6600
litre bowser loads.
The factory operates six days a week with two 8 hr shifts starting at 6 am and ending at 10 pm.
The employees are required to work overtime whenever necessary. Sunday is a non working
day but the cleaning of the entire plant is carried out on that day. The total work force in the
factory is 54. (Refer to annex 3 for the break up). The average total number of working days
per annum is about 300.
Production Process:
The production process in the making of the fruit juice is as follows –
The company processes 10,000 fruits per day in 10 batches.
1) The peeling department sorts the bad fruits and then peels the good fruits. (Average
weight of the peel is 270 grams/fruit).
2) Fruits are cut into small pieces (Both these operations are done on a tiled concrete table.
The juices from these operations are washed away with lot of water)
3) The pieces are then loaded into a blender, 200 liters of coconut water is added and then
crushed.
4) The blended mix is then filtered using a press filter.
5) The remaining solids are reloaded into the blender, 100 liters of coconut water is added
and re blended.
6) The mix is again re filtered. The total weight of the remaining fibre is 3320 kg per day.
Lab tests showed that the disposed fiber has 17% juice in it.
7) The juices from both blending operations are collected in a cooking vessel and 60 kg of
sugar is added and stirred well until all the sugar is dissolved.

2. NCPC Sri Lanka 12/16/20152
8) The sugar and juice mix is then cooked until the correct specifications are reached. It
was found that 20% of the weight is reduced while cooking and it is mainly the water
evaporated.
Packing Operation
9) The cooked juice is then allowed to cool and then packed manually as follows –
a) The glass bottles are washed in cold water and then washed in hot water at 60º C
and then sent through a steam bath upside down to steam the inside of the
bottles.
b) The bottles are then filled with pineapple juice manually and then sealed and
outside of the bottles are then washed using hot water of about 50º C.
c) The washed bottles are then stored in an autoclave and sterilized at 115º C for 30
minutes.
d) The sterilized bottles are then dried using hot air and then labeled, packed in
corrugated cartons and sent to stores.
The Utilities of the Processing Plant:
a) The factory uses electricity to run their electrical equipment and also to have lighting in
the factory. The factory is supplied with a 250 KVA, 3-phase electricity. Since their
factory is situated in an area with frequent power failures, the company has installed a
stand by generator. The generator runs on diesel.
b) The plant has a steam boiler to provide heat to juice boiling and bottle washing. The
capacity of the boiler is 1000 kg/hr of dry saturated steam produced at a pressure of 7
bar. (Refer to annex 4 on the details of the boiler and steam distribution system).
c) The factory has a shortage of water and therefore they buy water at 60 cts per 5 liters.
This water is used for washing of fruits and machinery and equipment and the floor. The
factory consumes about 55 tons of water per day.
Environmental Issues:
The local authority as well as the community groups is highly concerned about the wastewater
discharged to the nearby canal, which feeds the paddy land in the area, and the solid wastes
are being disposed in the marshy land. Many residents have complained about the foul smell
and the high population of rodents in the proximity due to these wastes. On the request of the
environmental authority regional office the company has got the wastewater analyzed. The
results of the report are given in annex II.

3. NCPC Sri Lanka 12/16/20153
Data Gathered:
The company upon request has disclosed following data to the environmental officer.
Input
Total pineapple purchased per day – 10,000 fruits at average of Rs.15/- per fruit
Average weight of a pineapple – 1.2 kilograms
Sugar consumption 60 kg per batch at Rs.30,000/= per M/Ton
Coconut water purchased at Rs.500/= per days requirement and transport cost
Rs.700/=.
Electrical Consumption 6,200 units and the total bill comes to about Rs.84,000/=.
Losses
Weight of Peel 270 grams per fruit
Juice washed away 78 grams per fruit
Juice in fiber 17%
Total fiber for the day 3320 kilograms
Spillages of juice 32 liters per batch
Evaporation loss during boiling is 20% of the total weight
Bottle Breakage – 150 per day
Output
Bottles removed to finished goods stores 800 Nos of 750 grams each per batch
General Data
Sale price Rs.80/= per bottle
Labour cost Rs.5/50 per bottle
Overheads Rs.6/10 per bottle
Cost of solid waste removal – Rs.1,500/= per day
Cost of operating wastewater treatment plant – Rs.3,500/= per day.
Exercise:
Draw the process flow diagram for the operations of the plant, conduct a material balance
quantifying each waste stream and find out the total loss of resources and its cost.
Note:
Confine your assessment only to material and water flows; not necessary to assess energy
flows.

4. NCPC Sri Lanka 12/16/20154
Case Study of Pineapple Juice Factory – Part 2
Costing Exercise on Loss of Energy in the Boiler Plant
The pineapple juice bottling plant has a steam boiler for supplying its processing steam
requirement. The capacity of this boiler is 1000 kg/hr of dry saturated steam produced at a
pressure of 7 bar. The factory operates 16 hrs a day and 300 days for a year.
The plant has a shortage of water and therefore they buy water from an external party at
Rs.0.60 per 5 litres. The pineapple juice boiling pans are steam jacketed and therefore 50% of
the steam used is indirect. The steam main which feeds the pans is at 4 bar. The bottle
washing machine is fed with hot water made through a coil immersed in the water tank. The line
pressure of the coil is 7 bar and out of the balance steam 20% is used directly to heat the water.
Initially there was a condensate recovery pipe system in the factory but due to the lack of
attention and poor maintenance it has gone into disuse. Therefore, all the condensate from the
indirect steam using processing machined is discharged directly into the internal drains at 100º
C. The sterilization chamber is fed directly by saturated steam at 2 bar and the condensate from
the chamber is also discharged to the drain.
It was also observed that there are 6 small holes on the steam mains (pressure 7 bar) running
from the boiler header to the plant which discharge steam to the atmosphere. Holes were
measured to be 2.5 mm in diameter approximately.
The operators blow down the boiler once every 8 hours. The steam loss at every blow down is
3% of the hourly output.
The steam mains are 3 inches in diameter and along a length of 60 meters the insulation is
broken. The steam pressure is reduced by PRV stations located near the operating areas.
The factory uses cold water at 30º C as feed water.
A well known steam equipment service company has offered to replace the existing condensate
recovery system at a cost of Rs.0.8 million. The Managing Director is under the opinion that
their additional cost due to use of fresh cold water is about Rs.40,000/- per annum. Therefore,
he is reluctant to reinstall the condensate recovery system at the given cost.
The boiler thermal efficiency is 75% and the cost of furnace oil is Rs.22/= per litre. The enthalpy
of steam at 7 bar is 2769 kj/kg. The enthalpy of cold water at 30º C is 217 kj/kg. The calorific
value of oil is 40,000 kj/kg.
Fuel consumption : 70 kg/hr
Density of fuel : 0.91
Heat transfer efficiency: 0.35

5. NCPC Sri Lanka 12/16/20155
Annex I:
Pineapple Juice Factory. The Boiler Plant and Steam Distribution.
The pineapple juice bottling plant is having a steam boiler for supplying its processing steam
requirement. The boiler capacity is 1000 Kg/hr of dry saturated steam produced at a pressure of
7 bar. The factory operates 16 hrs a day and 300 days for a year.
The plant has a shortage of water and therefore they buy water from an external party at
Rs.0.60 per 5 liters. The pineapple juice boiling pans are steam jacketed and therefore 50% of
the steam used is indirect. The steam mains which is feeding the pans is a 4 bar. The bottle
washing is fed with hot water made through a coil immersed water tank. The line pressure of
the coil is 7 bar and out of the balance steam 20% is used directly to heat the water for bottle
washing. Initially there was a condensate recovery pipe system in the factory but due to lack of
attention and poor maintenance it has gone into disuse. Therefore all the condensate from the
indirect steam using processing machines is discharged directly to the internal drains at 100º C.
The sterilization chamber is fed directly by saturated steam at 2 bar and the condensate
from the chamber also is discharged to the drain.
It was also observed that there are 6 small holes on the steam mains (pressure 7 bar) running
from the boiler header to the plant which discharge steam to the atmosphere. Holes were
measured to be of 3 mm diameter approximately.
The operators blow down the boiler once every 8 hours. The steam loss at every blow down is
4% of the hourly rated output.
The steam mains are 1.5 in diameter and in 60 meters of line length the insulation is broken.
The steam pressure is reduced by PRV stations located near the operating areas.
The factory uses cold water at 30º C as feed water.
A well-known steam equipment service company has offered to replace the existing condensate
recovery system at a cost of Rs.0.8 Million. The Managing Director is under the opinion that
their additional cost due to use of fresh cold water is about Rs.20,000/= per annum. Therefore
he is reluctant to reinstall the condensate recovery system at the given cost.
The boiler thermal efficiency is 75% and the cost of furnace oil is Rs.22/= per liter. The enthalpy
of steam at 7 bar is 2769 kj/kg. The enthalpy of 4 bar steam is 2731 kj/kg. The enthalpy of
steam at 2 bar is 2702 kj/kg. The enthalpy of cold water at 30º C is 217 kj/kg. The calorific
value of oil is 40,000 kj/kg.

6. NCPC Sri Lanka 12/16/20156
Annex II: Pineapple Fruit Juice Plant
Data Gathered
Input Pineapple 10,000 fruits per day at Rs.12.00 per fruit
Weight per pineapple 850 grams
Coconut Water 300 liters (kg) at Rs.100/= per 1000 lit.
Sugar 60 kg at Rs.30,000/= per ton
Electrical Energy Rs.2,200/= per day (200 units)
Gas for heating Rs.600/= per batch
Losses Peel 270 gms/fruit
Juice 78 gms/fruit
Juice in Fiber 17% of 3320 kg for the day
Spills 32 liters
Loss of Water 20% of juice
Output per batch 500 bottles of 750 gms each
General Data: Water for Floor Cleaning & Bottle
Washing and employee use – 35,000 lit/day
Bottle Breakage 150 per day
Sale price Rs.80/- per bottle
Labour Cost Rs.2/25 per bottle
Overheads Rs.6/10 per bottle
Number of working days 25 per month
Number of employees 50
Cost of Solid waste removal – Rs.1,500/day
Cost of Operating Treatment Plant – Rs.3,500/day
Details of the Environmental Report
pH : 4.2
BOD : 8200 ppm
COD : 13,500 ppm
TSS : 6400
Temp : 37º C
Oil : 4%