Cleaner Production Case Study(MM Vitaoils Sdn Bhd)

The Department of Environment, Malaysia is happy to announce that MMVitaoils is the first Malaysian company to participate in the Dept. of Environment’s Cleaner Production Demonstration Project 2009/2010. MM Vitaoils was adopted by Dept. of Environment Malaysia to showcase how Cleaner Production is implemented in a Malaysian company.

Company Profile

MM Vitaoils is a world leader in downstream palm oil industry with full range of packaging. Founded in 1999, MM Vitaoils has penetrated 76 countries world-wide with its quality edible oil products. MM Vitaoils is the Master Brand with brand portfolios that are associated with high quality, palm oil-based products which promote and enhance a fitter and healthier lifestyle such as cooking oil, ghee, shortening, margarine and pastry margarine.

MM Vitaoils currently produces and exports 24 brands of quality edible oil products, with trademark registration in Malaysia, South Korea, China, India, Europe, USA, Uzbekistan, Africa and Japan, securing niche markets. The export market constitutes over 98% of total revenue. MM Vitaoils is the biggest supplier in Uzbekistan palm oil market.

Today, MM Vitaoils has the most modern plant in Malaysia with a total monthly combined capacity of 10,000 metric tones per month with the advantages of packing products in different packaging materials for its core business activities in manufactured oil products, salad oils, etc., working in collaboration with the Malaysian Palm Oil Board (MPOB).

The Company Philosophy – “By Our Heart, To Your Heart” simply encapsulates the Brand’s honest desire to provide only the best for its customers, with emphasis on our commitment to Quality, Health and Credibility. This is further evidenced through the accreditations that MM Vitaoils received on Quality System such as ISO 9001:2000, Hazard Analysis and Critical Control Point (HACCP) and Good Manufacturing Practice (GMP). Recently MM Vitaoils achieved ISO 22000 : 2005 on 6th February 2009.

Congratulations MM Vitaoils!

Address:
MM Vitaoils SDN. BHD.
Lot 3, Persiaran Perusahaan, Section 23,
40300 Shah Alam, Selangor Darul Ehsan, Malaysia.

Premise selection factors

In order to ensure project success eight premise selection criteria were developed:

1. The company must be a legal entity with sound financial standing.
2. Location.
3. Sufficient manpower.
4. Full commitment from management and all work force especially technical staff at the premise.
5. Willingness and competency of the premise to implement the developed CP options.
6. Willingness of the premise to share their CP implementation experience with other premises.
7. The premise have good record management ( utility bills – electricity and water, raw materials and products inventory records, etc)
8. Stable and continuous production

CP Implementation at factory

There are ten steps of activities for the implementation of Cleaner Production at MM Vitaoils premise:

1. Cleaner Production Audit
2. Cleaner Production options identification
3. Prioritization of Cleaner Production options
4. Evaluation of Cleaner Production options
5. Implementation of Cleaner Production options
6. Monitoring
7. Audio and video documentation
8. Staff training
9. Promotional activities at the premise
10. Research & Development

Examples of options that can be easily implemented:

1. Use of only sufficient lighting during day time:

2. Two tanks to collect rain water for factory floor cleaning usage.

Examples of specific options implemented:

1. Installation of Crystallizer by past pipe

• Granular ghee production
• Do not require crystallization process
• Cost RM2450 with ROI 1 month
• Before installation
• Electricity cost: RM 2500
• After installation
• Electricity cost : RM 0

2. Using a larger diameter pipe from 1.5 inch to 2.0 inch

• Reduce time for homogeneous mixing
• Cost RM3150 with ROI 16 months
• Before installation :
• Time: 4212 hours
• Electricity cost: RM 598
• After installation:
• Time: 2808 hours
• Electricity cost: RM 393

3. Installation of Pneumatic Control Valve

• Before – manual valve was used during blending process
• Could save electricity cost and enhance worker safety
• Cost RM8250 with ROI 8 months
• Before installation:
• Electricity cost: RM 1000
• After installation:
• Electricity cost: RM 0

4. Use Semi-Automatic Taping machine

• Reduce worker from 3 to 2 operators
• Cost RM 6700 with ROI 8 months
• Before installation:
• OPP tape wastage: RM 122
• Work force: RM 18 000 (annual)
• After installation:
  • OPP tape wastage: RM 0
  • Work force: RM 0

5. Use high efficiency pump motor in blending process

• Replace the existing low efficiency pump motor with a high efficiency unit.

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It's face-off in the fight for RM10K and you have a part to play in it! #NescafeChilllah

It's face-off in the fight for RM10K and you have a part to play in it! #NescafeChilllah

Cleaner Production History In Malaysia

The term Cleaner Production was coined by the United Nations Environment Programme in 1989, and is interchangeably used with the terms Cleaner Technology, Waste Minimization and Pollution Prevention.

Cleaner Technology was introduced in Malaysia in January 1996, through projects under the Danish Cooperation for Environment and Development (DANCED), a technical cooperation programme between Government of Malaysia and Government of Denmark.

The projects which implemented by SIRIM, promoted Cleaner Technology through activities such as environmental and energy audits, demonstration sites and information dissemination with few selected Small and Medium Enterprises (SMEs). Under this program, SIRIM offers two types of services i.e., Cleaner Technology Extension Services (CTES) and Cleaner Technology Information Service (CTIS).

Since then, the Department of Environment (DOE) Malaysia has embarked on many projects to further promote CP among the SMEs in the country.

References:

Pollution Prevention&Abatement Handbook 1998: Towards Cleaner Production

CTI Workshop on Energy Efficiency among Asian Countries; 18 -27 October, 2004; ICETT, Japan

Cleaner Production Definition

Cleaner Production is ‘the continuous application of an integrated preventive environmental strategy applied to processes, products, and services to increase eco-efficiency and reduce risks to humans and the environment’. Cleaner Production can be applied to the processes used in any industry, to product themselves and to various services provided in society.

For production processes, Cleaner production results from one or a combination of conserving raw materials, water and energy; eliminating toxic and dangerous raw materials, and reduction of all emissions and wastes at the source.

For products, Cleaner Production strategy focuses on reducing the environmental, health and safety impacts along the entire life cycle of a product from raw materials extraction to the ultimate disposal of the products.

For services, Cleaner Production reduces the environmental impacts of the service provided over the entire life cycle, from system design and use to the entire consumption of resources required providing the services.

Reference: United Nation Environment Program (UNEP)

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