บริษัท เจ. ที. เจริญไทย จำกัด เป็นโรงงานอุตสาหกรรมอาหารขนาด กลาง ซึ่งดำเนินธุรกิจผลิตอาหารสัตว์สำหรับไก่ไข่และหมู โดยมีสองกระบวนการ ผลิตคืออาหารอัดเม็ดและผงจากข้าวโพด, รำละเอียด, กากถั่วและกากปาล์ม จาก การประเมินเบื้องต้น ได้ข้อมูลปัญหาเรื่อง การสูญหายของข้าวโพดระหว่าง กระบวนการผลิตในช่วงเดือนตุลาคม 2548 (17.6%) และช่วงเดือนมีนาคม 2549 (10.7%), ปัญหาด้านค่าไฟฟ้าต่อหน่วยที่สูงและแกว่งขึ้นลงอยู่ระหว่าง บาทต่อหน่วยในช่วงเดือนตุลาคม 2548 (17.6%) – มีนาคม 2549 (10.7%) รวมถึงปัญหาฝุ่นจากเครื่องบดแบบค้อนและเครื่องอัดเม็ด การ ดำเนินการแก้ไขเพื่อลดปัญหาที่เกิดขึ้นได้แก่การจัดตั้งทีมงานตรวจสอบการ ทำงานของคนงานที่มาตรชั่งน้ำหนักรถบรรทุกและบริเวณที่เก็บข้าวโพดและจัด ตารางเวลาเปลี่ยน “ ค้อน ” ในเครื่องบดแบบค้อนทุกๆ 1 – 2 เดือน ( เงินลงทุน 4,500 บาท, คาดผลคืนทุนใน 3 เดือน ), การเปลี่ยนระบบคิดค่าไฟฟ้าจากอัตรา ปกติเป็นอัตรา TOU (23,000 บาท, 15 วัน ), และการติดตั้งถุงดักฝุ่นที่เครื่องบด แบบค้อนและเครื่องอัดเม็ด (5,000 บาท, 3 เดือน ) การประยุกต์ใช้เทคโนโลยีสะอาดในการสำรวจและประเมินเบื้องต้นเพื่อแนะนำทางเลือก อื่น สำหรับการลดการสูญเสียวัตถุดิบและพลังงานในโรงงานแปรรูปอาหารสัตว์ (The Application of Cleaner Technology in the Survey & Preliminary Assessment to Suggest the Alternative Methods for the Minimization of Raw Materials & Energy Losses in Animal Feed Processing Factory) (The Application of Cleaner Technology in the Survey & Preliminary Assessment to Suggest the Alternative Methods for the Minimization of Raw Materials & Energy Losses in Animal Feed Processing Factory) บทคัดย่อ 3. Some Examples of Suggested Corrective Actions 4. References 1. Identified Problems Replacement of “hammer” inside the hammer mill on a regular basis The decision of replacing the “hammar” blade based on the problem of corn size reduction inefficiency mentioned by the production supervisor and poor binding of mixed feed in the pelletizer that can be observed visually. A series of rectangular iron bars with sharp edges inside the hammer mill should be replaced on a regular basis to maintain size reduction efficiency at high level with additional benefits of decreasing energy consumption, minimizing processing time and eventually lower the cost of electricity bills. The formation of loss prevention team was also suggested to monitor inventories and actions of workers during weighing and unloading of raw materials. Application of TOU instead of residential electrical charging rate To compare the electrical cost from residential and TOU rate, a TOU rate measuring device was hired (2,000 Bahts/month) from Electrical Generating Authority of Thailand (EGAT) and installed in parallel with the existing electrical measuring device for the period of two months. The electrical cost computed from the TOU rate was cheaper by almost 5 times. Fig. 2 clearly suggested the benefits of TOU rate implementation. (1) Cleaner Technology Team (2006) Cleaner Technology Workshop Manual, CT Publishing, Chiang Mai. (2) Chareon Thai, JT (2006) Raw Materials Database, JT database, Uttaradit. ภาควิชาวิศวกรรมอาหาร คณะอุตสาหกรรมเกษตร มหาวิทยาลัยเชียงใหม่ (Department of Food Engineering, Faculty of Agro-Industry, Chiang Mai University) Abstract J.T. Chareonthai Co. Ltd. is a medium size animal feed factory which produces animal feed for laying-hen and swine. Two available production processes include pelletized and powder feeds from corn, rice bran, soybean and palm meals. The preliminary assessment indicated the significant loss of corn during production period in October 2005 (17.6%) and March 2006 (10.7%), high and fluctuating electricity cost per unit (5.96 – 11.3 Bahts/Unit) during October 2005 – April 2006 and high level of dust from hammer mill and pelletizer. The corrective actions to alleviate the identified problems were setting up a loss prevention team to monitor workers action at the drive-through weighing scale and corn silo as well as scheduling the replacement of “hammer” inside the hammer mill on a regular basis (every 1-2 months) (4,500 Bahts Investment, Expected Investment Returns in 3 months), switching electrical charging service from residential to Time-Of-Use (TOU) rates (23,000 Bahts, 15 days) and installation of an industrial vacuum cleaner as well as dust keeper (5,000 Bahts, 3 months). Raw Materials: Corn Loss After preliminary assessment and identification of an individual problem, the loss of corn was the most crucial and had been ranked first in an evaluation list that includes technical, economic and environmental assessments. The locations where the corn loss most likely to occur were at the loading bay before storage in the silo, silo (through loss of moisture content during drying), hammer mill, mixer, pelletizer and feed packaging area. After data collection, the areas that contributed to the highest losses were at loading bay and hammer mill. The decrease in moisture content during storage in the silo also played part in overall weight loss with the value of 20-25% (w/w) prior to storage and 13-14% (w/w) after drying inside the silo. The investigation of corn loss at the hammer mill showed that the “hammer”, made from a series of sharp edge rectangular shape iron bars (Fig. 1(a)), used to masticate the corn were worn out to rounded edge bars as illustrated in Fig. 1(b). The grinding process with worn out “hammer” would decrease efficiency in size reduction greatly, require an extended period of time and energy to grind the corn, and generate a high level of dust that could affect the health of workers and machines inside the factory. Long grinding period also contributed to the losses of raw materials. In addition, the impact of inefficiency in size reduction could also be transferred to the feed mixer and pelletizer which were located downstream by lowering the efficiency of mixing and pelletization processes. The formation of heterogeneous mixture from the feeds of unequal particle size resulted in poor binding of raw materials in the pelletizer and thus low quality pellet feed which could be easily disintegrated. 1. Identified Problems (Continued) Energy: Expensive Electricity Bills Before implementation of cleaner technology (CT), the electricity bill of the factory was Bahts/unit which was relatively high in comparison with the average factory bill of 2.09 Bahts/unit. The cause of such high price stemmed from the incompatibility between production process planning and electrical rating system. The factory used to pay the electricity bill on the normal rate basis that also includes the demand charge (DC). This is in contrary with Time-Of-Use (TOU) rate where the DC charge is excluded and hence allows the factory to save an electricity bill by up to 50,000 Bahts per month. 2. Methodology The survey for data collection, interview, factory visiting, student training and evaluation (on the technical, economical and environmental aspects) were conducted according to CT standard (1). The data on raw materials usages (corn, rice bran, fish meal, palm meal and peanut meal), level of feed production as well as electricity bills were all obtained from the factory database (2) which was dated back for the period of 7 months (October 05 – April 05). The most important item to be investigated was selected after addition of all three weighed aspects and ranked the summation in descending order. In this study, corn was ranked first (with weighed summation of 4.1) followed by electricity (with weighed summation of 3.4). The percentage of raw materials losses were calculated from the ratio between the difference (in tons) of actual raw materials used and the quantity of raw materials presence in the mixed feed and the actual raw materials used. The computed percentage loss of each raw material was then compared to the standard loss criteria of 1%. 5. Acknowledgement This project was supported by Cleaner Technology Network (2005), CMU เอกรักษ์ สำราญถิ่น (Aekarak Samranthin), นพ พล เล็กสวัสดิ์ (Noppol Leksawasdi)