1. 04/26/14 1
CLEANER PRODUCTIONCLEANER PRODUCTION
ASSESSMENTASSESSMENT
Latex Crepe Rubber Processing FactoryLatex Crepe Rubber Processing Factory
Millewa EstateMillewa Estate
PresentedPresented
ByBy
A. M. S. KulasekeraA. M. S. Kulasekera
andand
T. T. JinadasaT. T. Jinadasa

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What is Cleaner Production?What is Cleaner Production?
Cleaner Production is a new & innovative wayCleaner Production is a new & innovative way
of improving production and reducing pollution.of improving production and reducing pollution.
Cleaner Production improves the productionCleaner Production improves the production
efficiency as well as the product quality and atefficiency as well as the product quality and at
the same time Cleaner Production reduces thethe same time Cleaner Production reduces the
cost of resources, materials, waste disposal andcost of resources, materials, waste disposal and
waste water treatment and improvewaste water treatment and improve
environmental performance.environmental performance.

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Cleaner production helps toCleaner production helps to
• Avoid leaks and spills during production and cleaning throughAvoid leaks and spills during production and cleaning through
good housekeepinggood housekeeping
• Create optimal process conditions to achieve highest productCreate optimal process conditions to achieve highest product
quality, increase production capacity, minimum resourcequality, increase production capacity, minimum resource
consumption and reduced waste generation.consumption and reduced waste generation.
• Avoid using hazardous materials by substitution with lessAvoid using hazardous materials by substitution with less
hazardous materials.hazardous materials.
• Modify equipment to improve the production processes.Modify equipment to improve the production processes.
• Install new, efficient production equipment and re design orInstall new, efficient production equipment and re design or
reformulate the products to minimize resource consumption.reformulate the products to minimize resource consumption.
• Use clean technologies.Use clean technologies.

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• Eliminate waste of scarce and valuableEliminate waste of scarce and valuable
resources. Improve the profit margin throughresources. Improve the profit margin through
reduction of input material costs and reduce thereduction of input material costs and reduce the
cost of treatment and disposal of waste.cost of treatment and disposal of waste.
• Improve the cleanliness of the surroundingImprove the cleanliness of the surrounding
environment.environment.
• Improves employee relationship and reduceImproves employee relationship and reduce
conflictsconflicts

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INTRODUCTION - ORGANISATIONINTRODUCTION - ORGANISATION
• Lankem Tea & Rubber Plantations (Pvt) Ltd –Lankem Tea & Rubber Plantations (Pvt) Ltd –
• Managing Agent for Kotagala & AgarapatanaManaging Agent for Kotagala & Agarapatana
Plantations Ltd.Plantations Ltd.

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• Kotagala PlantationsKotagala Plantations
• Twelve tea and nine rubber plantationsTwelve tea and nine rubber plantations
KPL is one of the largest rubber producers in the countryKPL is one of the largest rubber producers in the country
and has twelve rubber plantations in the Kalutara districtand has twelve rubber plantations in the Kalutara district
and eight manufacturing units,and eight manufacturing units,
Producing high quality pale crepe and sole crepe rubber.Producing high quality pale crepe and sole crepe rubber.
Its main manufacturing unit, the Padukka factory, was theIts main manufacturing unit, the Padukka factory, was the
first commercial rubber factory to be ISO 9002 certifiedfirst commercial rubber factory to be ISO 9002 certified
and is considered to be one of the best rubber factories inand is considered to be one of the best rubber factories in
the country.the country.
KPL has 4,500 ha under rubber and produces an average ofKPL has 4,500 ha under rubber and produces an average of
4,395,000 kgs per annum. Which represents around 6% of the4,395,000 kgs per annum. Which represents around 6% of the
island’s Rubber Production. Under its re-planting programme it has aisland’s Rubber Production. Under its re-planting programme it has a
further 850 ha of rubber, which is considered immature rubberfurther 850 ha of rubber, which is considered immature rubber.. TheThe
Company directly exports Rubber and the total quantity involvedCompany directly exports Rubber and the total quantity involved
currently in 279,006 kgs and the exchange earned is over Rs.4.0currently in 279,006 kgs and the exchange earned is over Rs.4.0
million.million.

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• Millewa Estate –Millewa Estate –
Western Province, Kalutara District and is 42Western Province, Kalutara District and is 42
kms. away from the city of Colombo.kms. away from the city of Colombo.
• The total extent of the plantation is 394 ha, withThe total extent of the plantation is 394 ha, with
an annual production of 281,000 kgs fetchingan annual production of 281,000 kgs fetching
record prices for latex crepe Rubber.record prices for latex crepe Rubber.

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• Cleaner Production Team :Cleaner Production Team :
• Plantation Manager – Mr.Nalin De Silva (Team Leader)Plantation Manager – Mr.Nalin De Silva (Team Leader)
• Factory Officer– Mr.Sudath SamaraweeraFactory Officer– Mr.Sudath Samaraweera
• Assistant Factory Officer - Mr. A. D. SunilAssistant Factory Officer - Mr. A. D. Sunil
• Assistant Factory Officer - K.D.D.S. GunethilekeAssistant Factory Officer - K.D.D.S. Gunethileke
• Mechanic / Electrician - M. Siva KumaranMechanic / Electrician - M. Siva Kumaran
• Audit Focus :Audit Focus :
• WaterWater
• Energy – ElectricityEnergy – Electricity

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Objectives of the StudyObjectives of the Study
• To reduce the overall cost of productionTo reduce the overall cost of production
• To reduce use of waterTo reduce use of water
• To reduce energy costTo reduce energy cost
• To reduce cost of handling waste waterTo reduce cost of handling waste water
• To improve the efficiency of productionTo improve the efficiency of production
• To reduce discharge of hazardous waste to theTo reduce discharge of hazardous waste to the
environmentenvironment
• To facilitate future direction to the Sri Lankan crepeTo facilitate future direction to the Sri Lankan crepe
rubberrubber
• IndustryIndustry

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Manufacture of Latex Crape Rubber – Process FlowManufacture of Latex Crape Rubber – Process Flow
Diagram with Inputs & Waste StreamsDiagram with Inputs & Waste Streams
Straining
Standardization & Addition of Sodium Bi
Sulphite
Collection & Weighing of Latex
Transportation of Latex to Factory
Straining of Latex
Receiving & DRC Determination at the
Factory
Bulking of Latex
Start
Spilled latex, dirt & latex
Spilled latex, bowser
washing water
Filtered water
Sodium bi- sulphite
Spilled latex, dirt & latex
Spillage - latex
Spilling of latex Spilling of
sodium bi sulphite
Spilled latex

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Settling & Addition of Bleaching Agent
Coagulation with Formic Acid
Milling of Rubber
Drying
Stirring & Removal of Froth
Removal of Coagulant for Milling
Stirring & Removal of Froth
Spilling of bleaching agent
Spillage of latex in froth
Waste water
Spillage of latex,
latex in froth, waste water
Serum, waste water
Serum, waste water
Rubber particles
Water evaporationWashing water
Cooling water
Formic acid
Bleaching agent
Fractionation
Straining Dirt , latex
Yellow fraction, latex,
waste water

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Pre-forming
Dry Blanketing
Cutting & Sorting
Dispatching
Bailing
Grading & Packing
End
Off cuts

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MonthMonth KVAKVA
Charge forCharge for
KVAKVA KWhKWh
Charge forCharge for
KWhKWh
TotalTotal
ChargeCharge Crop KgsCrop Kgs
Cost - Rs /Cost - Rs /
KgKg
June - 03June - 03 6161 24,400.0024,400.00 76597659 54,37854,378 87,53687,536 1185111851 7.397.39
July - 03July - 03 6565 26,000.0026,000.00 91219121 64,75964,759 100,715100,715 25,62125,621 3.933.93
Aug - 03Aug - 03 7070 28,000.0028,000.00 1228812288 87,24487,244 127,648127,648 25,21225,212 5.065.06
Sep - 03Sep - 03 7474 29,60029,600 83318331 59,15059,150 98,50598,505 18,14518,145 5.435.43
Oct - 03Oct - 03 6464 26,400.0026,400.00 83898389 59,56159,561 95,43795,437 22,64322,643 4.214.21
Nov - 03Nov - 03 7373 29,200.0029,200.00 86668666 61,52861,528 100,681100,681 22,44622,446 4.494.49
Dec - 03Dec - 03 8080 32,000.0032,000.00 1276012760 90,59690,596 136,691136,691 42,68242,682 3.203.20
Jan - 04Jan - 04 8080 32,000.0032,000.00 1228612286 87,23087,230 138,035138,035 32,81532,815 4.214.21
Feb -04Feb -04 6363 25,200.0025,200.00 80058005 56,83556,835 95,26095,260 26,05826,058 3.663.66
Mar - 04Mar - 04 6464 25,600.0025,600.00 64996499 46,14246,142 83,42383,423 23,13223,132 3.613.61
May - 04May - 04 6767 26,800.0026,800.00 56115611 39,83839,838 77,55477,554 10,70410,704 7.257.25
Millewa Rubber Factory - Electricity Consumption

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Mill # 1Mill # 1 Mill # 2Mill # 2 Mill # 3Mill # 3 Mill # 4Mill # 4 Mill # 5Mill # 5 Mill # 6Mill # 6 Mill # 10Mill # 10 Mill # 12Mill # 12 TotalTotal TotalTotal
lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min lit / Minlit / Min Lit / MinLit / Min DayDay
Cooling WaterCooling Water 1515 1515 1515 55 99 00 00 66 6565 2340023400
Washing WaterWashing Water 1818 1818 1818 2626 2626 00 1212 99 127127 4572045720
Overflowing Due to BlockedOverflowing Due to Blocked 3030 1080010800
Sand Bed 10 hp PumpSand Bed 10 hp Pump
Overflowing From Filter BedOverflowing From Filter Bed 55 18001800
5 hp Pump -5 hp Pump - EstimatedEstimated
StandardisationStandardisation 45004500
Washing of CoagulatingWashing of Coagulating 300300
and Standard. Tanksand Standard. Tanks
Washing Of BowserWashing Of Bowser 15001500
Grand Total Per Day….....=Grand Total Per Day….....= 8802088020
( 6 hour Product Cycle)( 6 hour Product Cycle) LitresLitres
Waste Characterisation :
Waste Stream - Waste Water

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Cleaner Production OptionsCleaner Production Options
• Separating Cooling water and washing water in the drainageSeparating Cooling water and washing water in the drainage
systemsystem
• Recycling Of Cooling WaterRecycling Of Cooling Water
• Use of smaller diameter piping for cooling water to reduceUse of smaller diameter piping for cooling water to reduce
volumevolume
• Use a nozzle type spray mechanism for washing water to reduceUse a nozzle type spray mechanism for washing water to reduce
volumevolume
• Use of rubber traps and man holes to collect sediment / sandUse of rubber traps and man holes to collect sediment / sand
• Eliminate double pumps ( 10hp & 7.5hp) at TheppankulamaEliminate double pumps ( 10hp & 7.5hp) at Theppankulama
main water source – repair the water tank on the rock andmain water source – repair the water tank on the rock and
install a proper sand filter bedinstall a proper sand filter bed

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• Install an automatic cut off system for both pumps to preventInstall an automatic cut off system for both pumps to prevent
overflowingoverflowing
• Replace the old inefficient piston pump ( 5 hp) with 2 hpReplace the old inefficient piston pump ( 5 hp) with 2 hp
centrifugal pumpcentrifugal pump
• Repair the Theppankulama water source . Have proper boundaryRepair the Theppankulama water source . Have proper boundary
fence to prevent entering of buffaloes etc. for retaining waterfence to prevent entering of buffaloes etc. for retaining water
quality.quality.
• Construction of a new tube well and use a centrifugal pump withConstruction of a new tube well and use a centrifugal pump with
a lesser horse power to eliminate inefficient piston pumpa lesser horse power to eliminate inefficient piston pump
• Training people in house to minimize waste waterTraining people in house to minimize waste water
• Separate effluent disposal lines as high concentrate effluent andSeparate effluent disposal lines as high concentrate effluent and
low concentrate for ease of treatmentlow concentrate for ease of treatment
• Effluent Treatment –Effluent Treatment –
a ) Reduction of quantity by filtering same and re-cyclinga ) Reduction of quantity by filtering same and re-cycling
b) Treating only the concentrated effluentb) Treating only the concentrated effluent

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• Electricity :Electricity :
• Use separate metering for Factory (production) ,Use separate metering for Factory (production) ,
Bungalows and staff quarters – use separateBungalows and staff quarters – use separate
direct connection to CEB system under domesticdirect connection to CEB system under domestic
tariff for staff quarterstariff for staff quarters
• Replace the motor of dry mill with an energyReplace the motor of dry mill with an energy
efficient induction motor of lower horse powerefficient induction motor of lower horse power
• Upgrade capacitor bank on switch board to suitUpgrade capacitor bank on switch board to suit
the existing loadthe existing load
• Alternate the loading cycle to reduce KVAAlternate the loading cycle to reduce KVA
demand & make use of time of day tariff offereddemand & make use of time of day tariff offered
by the CEBby the CEB

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ActionAction
EstimatedEstimated
CostCost
EstimatedEstimated
AnnualAnnual PaybackPayback
TechnicaTechnica
ll
EconoEcono
mimi
cc
EnvironmeEnvironme
ntalntal PriorityPriority
BenefitBenefit
PeriodPeriod
YrsYrs
FeasibilitFeasibilit
yy
FeasibilFeasibil
ityity FeasibilityFeasibility
Separate cooling & wash waterSeparate cooling & wash water 15,00015,000 15,00015,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Re-cycle cooling waterRe-cycle cooling water 10,00010,000 20,00020,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium
Use of small diameter pipesUse of small diameter pipes 3,0003,000 3,0003,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium
Use of nozzles to spray waterUse of nozzles to spray water 2,0002,000 20002000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium
Use of rubber trapsUse of rubber traps 10001000 750750 1.331.33 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Eliminate double pumpsEliminate double pumps 30,00030,000 25,00025,000 1.201.20 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Install automatic cut off systemInstall automatic cut off system
for pumpsfor pumps 5,0005,000 10,00010,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Replace piston pump with newReplace piston pump with new
oneone 10,00010,000 10,00010,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium
Separate effluent lines as low/highSeparate effluent lines as low/high
concentrateconcentrate 5,0005,000 5,0005,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Repair Theppukulama waterRepair Theppukulama water
sourcesource 10,00010,000 10,00010,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Training people to reduce wasteTraining people to reduce waste
waterwater 3,0003,000 6,0006,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh

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Install new tube wellInstall new tube well 150,000150,000 50,00050,000 3.003.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium
Use separate electricity metering forUse separate electricity metering for
quartersquarters 50,00050,000 50,00050,000 1.001.00 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium
Replace motor of dry millReplace motor of dry mill 50,00050,000 70,00070,000 0.710.71 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Upgrade capacitor bankUpgrade capacitor bank 25,00025,000 50,00050,000 0.500.50 feasiblefeasible feasiblefeasible feasiblefeasible HighHigh
Make use of time of day tariffMake use of time of day tariff 5,0005,000 50,00050,000 0.100.10 feasiblefeasible feasiblefeasible feasiblefeasible MediumMedium
Improve existing drying systemImprove existing drying system 500,000500,000 240,000240,000 1.251.25 feasiblefeasible feasiblefeasible feasiblefeasible
Reduce quantity (low/high con.)ofReduce quantity (low/high con.)of
EffluentEffluent 1.9 million1.9 million feasiblefeasible feasiblefeasible MediumMedium
& install Treatment Plant& install Treatment Plant

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Millewa Rubber FactoryMillewa Rubber Factory

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Effluent Drain – Rubber ParticlesEffluent Drain – Rubber Particles

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Worker motivation – Attitude changeWorker motivation – Attitude change

23. 04/26/14 23Abundant use of waterAbundant use of water

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Oversized motorsOversized motors

25. 04/26/14 25Washing of latex bowsersWashing of latex bowsers

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CP Team at workCP Team at work

27. 04/26/14 27Unhealthy activity - Introduce Aluminum separatorsUnhealthy activity - Introduce Aluminum separators

28. 04/26/14 28Upgrading capacitor bankUpgrading capacitor bank

29. 04/26/14 29Drying process - to be improvedDrying process - to be improved

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Waste water to be separatedWaste water to be separated

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Valve Clogging - Repair/ReplaceValve Clogging - Repair/Replace

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Excessive water – measurements takenExcessive water – measurements taken
(Bucket and stopwatch)(Bucket and stopwatch)

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