Chapter 2
INDUSTRIAL AND INSTITUTIONAL STOVES IN ASIA (contd.)

PHILIPPINE

Bibingka Industry

Typical of stove used in Bibingka industry

Profile
Bibingka is a good source of carbohydrates and is very popular in the Philippines. The main ingredients are coco milk, ground rice, sugar, salt, and yeast. All of these ingredients are thoroughly mixed, then poured into tin cans which have been lined with banana leaves, then baked for 10 – 15 minutes.

The stove used in this survey is the only stove designed for making bibingka.

Scale
Cottage/home industry with 1–2 laborers

Fuel Type
Firewood

Size of Stove
(30 × 20 × 14) inches

Stove Makers
Owner

Stove materials
Galvanized iron shaped into a box with two layers (first layer for sticks of wood, second layer for tin cans)

Stove Utensils
Round tin cans for shape of the bibingka, using banana leaves as lining/wrapper

Stove/Industry capacity
Monday - Saturday (1 am – 11 am) produces 1,000 – 2,000 pieces of bibingka Sunday (1 am – 5 pm) produces 1,500 – 2,000 piece of bibingka

Fuel Consumption
5 bundles of 20 medium sized wood per day

Financial Calculation
Monday – Saturday profits = P 700.00 – P 800.00 Sunday profits = P 1,200.00 – P 1,500.00

Exchange rate: US $ 1 = P 42.00

Stove Operation
Firewood is lit to heat the stove evenly, meanwhile the bibingka mixtures are prepared. When an even heat is attained the tray of bibingka mixture is placed in the second layer.

Flow Chart of Stove Operation

Ergonomics
No heavy lifting nor bending are required during the cooking process.

Stove Maintenance
Ash removed after every use and users avoid spilling water on the stove to prevent rust.

Stove Durability
Usually 2 – 3 years, depending on thickness of galvanized iron.

Corn Cubs Industry

	Typical stove used in corn cub industry

Profile
Boiled corn cobs (maize) is a good source of carbohydrates. It is eaten either as snacks or sometimes as replacement for rice.

Scale
Cottage industry with one labor.

Fuel Type
Wood and sawdust.

Size of Stove
Drum size (circular, usually a recycled container of lard oil)

Stove Makers
Those involved in the business.

Stove materials
Foundation: A recycled drum filled with sawdust (compacted) with a bamboo at the center to make a hole. A hole is made outside of the drum where the wood or fuel will be inserted.

Body:
Another drum is placed on top which is used for cooking the corn cobs.

Stove Utensils
Drum of same size of the stove.

Stove/Industry capacity
100 pcs. of corn cobs in 3 hours × 2 sets per day

Fuel Consumption
3 – 4 medium sized wood used in 3 hours

Stove Maintenance
The stove is replaced every 3–4 months. Sawdust is added every after cooking (3 hours)

Stove Durability
The drum used as stove is usually changed every 3 months. The drum used to boil the corn cobs is changed every 4 months.

Hospital Stove

	Typical of stove used in the hospital

Profile
This cook stove is used by a hospital to cook meals for patients and staff. The hospital was built in 1980.

Scale
Institutional

Fuel Type
Firewood

Size of Stove
(60 × 25 × 28) inches

Stove Makers
Planned by hospital engineers

Stove materials
Foundation:

• Clay bricks - 250 pcs.
• Sand & Gravel
• Cement

Body:

• Clay bricks - 1,000 pcs.
• Sand & Gravel
• Cement
• Steel
• Tiles

Stove Utensils

Metal rings for 3 burners

Fuel Consumption
15 sticks chopped wood

Stove Maintenance
Ashes removed after every cooking

Stove Durability
In use almost 20 years, as yet no repair needed.

Flow Chart of Stove Operation

Pancit Industry

Typical of stove used in Pancit industry

Profile
Pancit is commonly eaten in and outside the country. It is widely produced as it is consumed in restaurants, as well as for special celebrations.

The main ingredients are flour, oil, water, salt, and food coloring. All ingredients are mixed together, then flattened by a machine called a “hammer”. It is then put through the slicer. After being sliced, the dough is soaked in boiling water with oil. After 5–10 minutes of boiling, it is strained and placed on the table under a fan to be cooled.

Scale
Cottage/home industry with 4 laborers.

Fuel Type
Rice Hull

Size of Stove
75 × 50 × 40) inches

Stove Makers
Owner

Stove materials
Foundation:

• Sand & Gravel - 5 cu
• Cement - 5 bags
• Hollow blocks - 500 pcs.
• Salt & brown sugar - mixed in the cement for durability

Grate:

• Stripe metal

Chimney:

• Bricks

Stove Utensils
Wok, big (permanently placed on stove plates)

Stove/Industry capacity
Pancit is usually made at night from 4 pm or 6 pm to 10 pm. during this time, 5 sacks of flour are used in one processing (4–5 hours). The final product is 250 kg pancit, or 50 kg pancit per each sack of flour.

Fuel Consumption
15 sacks of rice hulls processing (5 hours)

Financial Calculation
Net from pancit P 4.00/kg × 250 = P 1,000.00/day

Ergonomics
No heavy lifting nor bending are required during the cooking process.

Stove Maintenance
After using the stove, all ashes must be removed in preparation for use the next day. Cracks are repaired by applying cement, brown sugar and salt to guarantee durability.

Stove Durability
Has been used for almost 10 years.

Flow Chart of Stove Operation

Pinatubo Eatery

Typical of stove and utensils used in Pinatubo eatery

Profile
The restaurant is frequently visited by travelers because of its strategic location. The cookstove has been used for 9 years. It is used for cooking rice, viands and boiling water.

Scale
Small scale industry.

Fuel Type
Rice hulls 9 – 10 sacks/day from 6 AM to 9 PM.

Size of Stove
(30 × 24 × 20) inches

Stove Makers
Owner

Stove materials
Foundation & Body:

• Cement 5 sacks
• Small clay bricks 800 pcs.
• Sand and gravel 2 cu.
• Small round bars 5 pcs.

Stove Utensils
Cooking utensils; metal rings of different sizes

Stove/Industry capacity
Can cook all viand and rice needed from 6 AM to 9 PM.

Fuel Consumption
20 large pieces of wood

Ergonomics
No heavy lifting nor bending are required during the process.

Stove Maintenance
Ashes is removed daily. Water spillage is avoided to prevent cracks.

Stove Durability
This cookstove is used for 9 years with repair.

Flow Chart of Stove Operation

Rice Cake Industry

Typical of stove used in rice-cake industry

Profile of Rice Cake Industry
Rice-cake is popular and commonly consumed in the urban as well as rural areas in Phillipine. Just like bread rice cake is consumed for breakfast, merienda, a gift for special occation and a way of life for Philippinos. The materials used to make rice-cake are: rice, sugar, food color, Lye, baking powder and some water.

Scale
Small scale industry, household industry

Size
Size place is 120 sqms. The average labor is 5 person, but during peak season (Christmas) the labor are 20.

Fuel Type
Rice husk

Stove Makers
Locally available (masons)

Stove Materials
Foundation and body:

• Adobe stone size 16 × 8 inches
• Cement 10 sacks
• Sand 4 m3

Grate:

• 2 pieces of 14 × 18 inches stripe metal

Stove ring:

• ½ inch thick metal, 27 inches in diameter.
• Cost per stove = P 12,000.00

Stove Utensils

• Wok : 29 inches in diameter, used for boiling water for steaming
• Steamer: 26 inches in diameter, made of iron strip or plate with holes, placed on top of the wok.
• Steamer cover: 27 inches in diameter, serves as cover for the food inside the wok.
• Cheese cloth
• Metal basin: 2 feet tall and 17 inches in diameter, all ingredients are mixed here before put on top of the steamer.

Stove/Industry Capacity
108 kg of ground rice complete with ingredients can be processed for about 5–6 hours.

Exchange rate: US 4 1 = P 42

Stove Maintenance
Cleaning of the inside of stove and chimney must be done once a week

Stove Durability
Up to now it has been 45 years with minor repairs such as patching the cracks at the mouth or side of the stove, or just merely patching the cracks with cement.

Flow Chart of Stove Operation

SRI LANKA

Ashmee Industry

Profile of Ashmee Industry
Ashmee is a sweet delicacy famous in Sri Lanka. This is eaten on special occasions, such as Sinhala New Year, Christmas and weddings. Ashmee is made of rice flour and a special cream from wild cinammon leaves or Diya Para (Dillenia triquetra) seeds. The stove is an important part of the ashmee industry, because it requires frying the dough in deep oil for a long time.

Scale of Industry
Small scale or household industry with 2 laborers. Working space is (8 × 10) feet

Fuel Type
Fire wood, coconut husk, old tea tress, Ladap

Size of Stove
(3 × 3 × 1) feet

Stove Makers
Locally available. The stove is not made especially for the ashmee industry; it is usually the same stove for general cooking.

Stove materials
Foundation

• Concrete slab: 2.5 feet above
• Floor level
• Bricks: 10 pcs
• Cement: 3 kg
• Clay

Stove Utensils

• 3 Aluminum vessels
• 1 Pot (for boiling honey)
• 2 Frying pans

Stove/Industry capacity
5 kg ashmee/day

Fuel Consumption
0,25 square yard of wood/day

Typical of stove used in Ashmee industry

Exchange rate: US $ 1 = Rp. 77.1

Ergonomic
The stove is low and therefore requires the cook to bend for a long time.

Stove Maintenance
Cleaning out the ashes is done every day before starting ignition of the stove.

Stove Durability
Approximately 2–3 years.

Flow Chart of Stove Operation

Bakery Industry

Oven compartment (right) & combustion chamber equipped with fan (left)

Profile of Bakery Industry
Bread is the second most popular food item for daily meals in Sri Lanka. It is produced throughout the country, and the majority is made by traditional means. The traditional bakery usually uses biomass fuel. This bakery oven is an improved one with renovations made by the owner. Rice husks are used for fuel as it is locally available and the price is relatively low.

Scale of Industry
Small industry with 2 laborers. Working space is (22 × 12) feet

Fuel Type
Rice husks Kerosene (as a starter)

Size of Stove

• (4,5 × 3 × 4,5) feet for combustion chamber
• (4,5 × 3 × 4,5) feet for baking room/ oven

Stove Makers
Masons, trained people

Stove Materials
Foundation:

• Iron column and iron frame

Body:

• Iron metal sheets

Chimney: (for oven)

• Iron metal sheets

Cost of stove:

Iron and metal sheets: Rp. 50,000
Labor: Rp. 10,000
Total cost: Rp. 60,000

Stove Utensils

• Baking pan
• 8 Trays (30 inches × 18 inches)
• 4 Trays (15 inches × 18 inches)
• 350 blocks (8 inches × 4 inches)

Stove/Industry capacity
72 loaves bread/baking 400 loaves bread/day (10 hours)

Exchange rate: US $ 1 = Rp. 77.1

Ergonomics
The cook is standing while cooking. No bending is necessary, but the cook is exposed to heat while tending the fire.

Oven for bread industry

Stove Maintenance
Cleaning out the ashes is done every day before igniting the stove. Ash is the main problem of the stove. Ash has also become an environmental problem in the industry, as it also influences the quality of the bread, especially during windy days.

Stove Durability
Approximately 5 years

Flow Chart of Stove Operation

Murukku Industry

Typical of stove used in Murukku industry

Profile of Murukku Industry
Murukku is a South Indian food item which is very popular amongst the Tamil people. It is also consumed by all other ethnic group. Murukku is made from wheat flour. A snack item, murukku is mixed with peanuts, fried grams (pakade). Sometimes, all of these are mixed together.

Usually, murukku is sold in a special mobile kiosk with a glass body and wheels.

The stove is an important part of the murukku industry because the dough must be boiled for a long time.

Scale of Industry
Small-scale household industry with

2 family members and one laborer. Working space is (10 × 12) feet room, which stands apart from main house.

Fuel Type
Fire wood

Size of Stove
(1.75 × 1.5 × 1) feet

Stove Makers
Owner

Stove Materials
Foundation:

• Surface of the floor

Body:

• Bricks: 20 pcs
• Clay mixer
• Cow dung

Stove Utensils

• 2 iron barrels: capacity of 25 kg each (for boiling)
• 4 frying pans: 18" diameter
• 2 frying pans: 12" diameter

Stove/Industry capacity
Cook 20 kg of wheat flour; 5 kg peanuts; 1 kg grams/processing

Fuel Consumption
Approx. 56 kg of wood per day

Exchange rate: US $ 1 = Rp. 77.1

Flow Chart of Stove Operation

Ergonomics
The stove is low, therefore requires the cook to bend for a long time.

Stove Maintenance
Ash should be removed daily, small cracks can be plastered with clay and ash.

Stove Durability
Approximately 5 years.

Noodle Industry

Stove used in the noodle industry

Profile of Noodles Industry
Noodles are a popular food item in Sri Lanka, especially in urban areas. People usually eat noodles for breakfast or dinner. There is a variety of noodle brands differing in quality, quantity and scale or production. Some multinational companies also import the instant noodles from Singapore, Thailand, etc. Despite the competition from multinational companies, there are still many traditionally made noodle industries in Sri Lanka.

Noodles are made from wheat flour, salt, water, and coloring, which are mixed together into a dough. The dough is cut into strips by machine, then steamed for a certain period of time.

Scale of Industry
Small industry with 10 laborers. Working space is (60 × 30) feet

Fuel Type
Saw dust, Fire wood

Size of Stove
(3 × 2,5 × 2,5) feet

Stove Makers
Stove builders (locally available)

Stove Materials
Foundation:

• Stone
• Cement mixture

Body:

• Half iron barrel Bricks
• Sand
• Portland cement

Stove Utensils

• 2 iron barrels: 4 feet high
• 2 frying pans: 16 gallons capacity
• 8 cast aluminum frames (for 2 stoves)

Stove/Industry capacity
65 kg or raw noodles can be boiled at a time in each stove

Fuel Consumption

• Saw dust: approx. 25–35 kg/time
• Wood: approx. 0.25 cubic yards/time

Exchange rate: US $ 1 = Rp. 77.1

Ergonomic
There is no heavy lifting since the noodle can be processed part by part; but it requires a strong person to mix the flour and other ingredients to make the dough.

Stove Maintenance
Cleaning ash and dirt is done every day before igniting the stove.

Stove Durability
Approximately 5 years.

Flow Chart of Stove Operation

Plam Honey Industry

Typical of stove and honey boiling pot used in palm honey industry

Profile of Palm Honey Industry
Kithul (Caryota urenes) is one of the most important palm trees in Sri Lanka. This palm tree produces a sweet toddy taken from the flowers. Sweet toddy is used to make toddy, honey and jaggery. The collectors collect sweet toddy twice a day. Eight bottles of sweet toddy can be collected from one tree in one day. Honey is made from the toddy by boiling it for approximately four hours. Therefore, a stove is an important part of the palm honey production. The majority of palm honey production is still done at the household level and managed by the family members, usually the women.

Scale of Industry
Household industry

Fuel Type
Fuel wood (albizia), Coconut husk, Melia dubia, waste wood from timber mill.

Stove Makers
Female members of the household

Stove Materials
There is no special foundation. The stove is very simple, made of six bricks and clay. Bricks cost Rp. 10.80.

Stove Utensils

• Aluminum pan (2 feet diameter)
• Pot (to boil honey)
• Coconut shell spoon

Stove/Industry capacity
At present the head of the household obtains sweet toddy from three palm trees. He gets 24 bottles in the morning and 15 bottles in the evening. From these 24 bottles, he can obtain 5 bottles of honey after four hours of boiling.

Fuel Consumption
Approx. 0,2 square yard of wood per day.

Ergonomics
There is no heavy lifting required.

Stove Maintenance
Cow dung or clay is applied to the surface of the stove every three weeks. Ashes are removed from the stove every day.

Stove Durability
Approximately 2–3 years

Flow Chart of Stove Operation

String Hopper Industry

Typical of stove used in string hoppers industry

Profile of String Hoppers Industry
String hoppers are made from rice flour, wheat flour or murukku flour. String hoppers can be eaten with any curry or coconut honey mixture (called Lavaria).

The flour is boiled in water for about two hours. Then, it is mixed with hot water and salt to make a batter. The batter is cut into strings with a special hand-held utensil. The utensil may be made of wood or plastic. It is circular and is approximately 12 cm diameter. Water is then boiled and the string hoppers are steamed in a special vessel for five minutes. String hoppers are then removed from the vessel and from the plastic/wooden utensil. Twenty string hoppers can be steamed at a time.

The stove is an important part of this industry because the process requires both boiling and steaming.

Scale of Industry
Household industry with only owner working, sometimes his daughter helps Working space is (8 × 6) feet

Fuel Type
Fire wood

Size of Stove
(2,5 × 2 × 1) feet

Stove Makers
Local masons

Stove Materials
Foundation:

• Cement slab

Body:

• Bricks: 15 pcs
• Clay
• Sand
• Cow dung

Stove Utensils

• 2 Aluminum pans
• Steam pan

Stove/Industry capacity
7 kg flour is boiled with steam. It takes 5 lt water and 2 hours. When the string hoppers are prepared, it should boil about 5 minutes. 20–25 string hoppers/time are produced. The entire process takes 7–8 hours.

Fuel Consumption
1 cwt wood to cook 7 kg flour. (1 cwt = 50 kg)

Exchange rate : US $ 1 = Rp. 77.1

Ergonomics
No heavy lifting nor bending are required during the process.

Stove Maintenance
Maintenance done regularly. The ash in the stove is removed every day and clay and cow dung are applied to the stove body every week.

Stove Durability
10–12 years

Flow Chart of Stove Operation

Yogurt Industry

Typical of stove used in Yoghurt industry

Profile of Yoghurt Industry
Yoghurt is a famous and widely consumed milk product in Sri Lanka. It is semi-solid sour curd prepared from milk and fermented by adding bacteria. It is very popular amongst children who eat it as a cool dessert. The stove is an important part of the yoghurt industry because the milk used to make the yoghurt must be boiled for a long time.

Scale of Industry
Small scale industry with 2 laborers. Working space is 2 rooms, (10 × 12) feet each

Fuel Type
Fire wood

Size of Stove
(3 × 2,5 × 1) feet

Stove Makers
The foundation, structure and chimney were built by masons. A simple stove was built by household members.

Stove materials
Foundation:

• Concrete slab: 2.5 ft. above floor level

Body:

• Stone, bricks, clay

Chimney:

• Bricks

Cost of stove Rp. 8,000

Stove Utensils
4 Aluminum sauce pans

Stove/Industry capacity
Produce 800 containers of yoghurt/ time (8 hours)

Fuel Consumption
Approx. 1/8 sq. yd. of fire wood/time

Exchange rate: US $ 1 = Rp. 77.1

Flow Chart of Stove Operation

Ergonomics
Heavy lifting is required during the process

Stove Maintenance
Ash is removed every day. Every 4–5 months, clay is applied.

Stove Durability
Approx. 5 years

VIETNAM

Cane Sugar Industry

Sugar cane moulds made from wooden boards	Typical stove used in cane sugar industry

Profile
In rural areas of Vietnam we could still easily see cane sugar produced with traditional method. The cane sugar comes in the forms of disc or block and is usually used in food industry and in confectionery. The cane sugar production involves simple processes. Initially, fresh canes are pressed for the juice. The juice is boiled till a thick brown liquid is formed. The liquid is then put in a mould and left to cool and harden. For a home based industry with an average production of 150 kgs of cane sugar per day, approximately 1500 kg of fresh canes is required.

Stove has an important role in cane sugar industry. It is needed during the boiling of cane juice. A relatively long period time and a substantial amount of fuel are needed to reach the desired liquid thickness before it is cooled to form cane sugar.

Scale of Industry
Cottage industry with 4 labors. Space required is about (6 × 9) sq.m.

Fuel Type
Coal

Size
(140 × 120 × 100)cm.

Stove Makers
Users

Stove Materials
Body:

• Brick
• Clay
• Cement and Sand

• Iron bar 3/4 inch dia.

Cost per stove : 160.000 VND

Stove Utensils

• Shape : Parabolic and cylindric tube
• Size : 110 cm diameter (for wok), 80 cm diameter for cylindrical tube
• Material : Alloyed cast iron and sheet metal
• Amount : 2 pieces

Stove/Industry Capacity
From 1.500 kg of raw sugar, in average they can obtain around 150 kg of cane sugar per day through 5 batches of boiling process. They use 2 stoves, one stove has 3 batches, the other 2 batches. Time needed for single batch is around 3 hours and yielded around 30 kg of cane sugar per stove/batch. For good quality of sugar cane they will get around 180 kg of sugar through 6 batches of boiling process (3 batches each stove/day).

Fuel Consumption
300 kg of coal are required in a day.

Stove Operation
The fire is started with the aid of kerosene or twigs or dry leaves. Once the fire starts, the work is put on the stove and cane juice is poured up to 4/5 of the wok's volume (about 130 L). A metal cylinder is immersed in the wok to prevent the overflowing of foam from the boiling of cane juice. During the process, the fire needs to be kept strong to enable the evaporation of water from the cane juice. After an hour of boiling, when the volume decrease and the liquid starts to thicken, more juice is added. Dirts and foams will rise to the top and are scooped with a wooden spoon. When the volume decreases again, more juice is added, and so the process is repeated until the total volume of juice in a batch is approximately 200 litres. After 2.5 hours, when the liquid gets thicker, the cylinder is removed. At this stage, stirring needs to be done continuously to prevent burning. When the liquid reaches certain thickness, the work is removed from the fire and the liquid is transferred to moulds. The moulds are made of wooden board, each measuring 20×10×7 cm. 12 pieces of sugar cane blocks, each weighing 2.5. kgs, could be produced in a batch. The process continues, the next batch starts; the wok is cleaned, more coal is added to the stove, fresh cane juice is added to the wok and the whole steps are repeated.

Flow Chart of Stove Operation

Fresh canes are pressed for the juice

Ergonomic
The work is quite large (110 cm in diameter), and the shifting and transferring of liquid in the wok to the moulds requires the strength of two adult males. Another activity that could be considered demanding, is, the continuous stirring of liquid at the stage when it starts to thicken so that it will not burn.

Stove Maintenance
There is no meaningful damages during more than 6 years. Small cracks can be repair using clay or mud mix with ash.

Stove Durability
It is assumed that stove will last up to next 5 years.

Transferring the cane juice after pressing

Dormitory Canteen Stove

	Typical of stove and utensils used in the dormitory

Profile
Hanoi Architectural University is located at the periphery of Hanoi city. Right besides the campus, there is a dormitory which houses about 300 students. A canteen is contained within the dormitory complex, and is located at the ground floor. The canteen caters for both the students in the dormitory and the general public. Food preparation is done in a relatively large kitchen which is divided into two sections. Each section is equipped with a rack for storing food ingredients, a table, a washing place and a stove with two fire holes. Additionally there are two portable stoves, used when preparing food in small quantities. The kitchen staff consists of 2 chefs and 5 assistants.

Profile Scale
Serve at least 300 students for breakfast, lunch and dinner. For lunch time usually serve up to 400–500 customer.

Fuel Type
Coal

Size
(250 × 110 × 60) cm.

Stove Makers
Users/locally available

Stove Materials
Foundation :

• Stone

Body:

• Bricks
• Cement
• Sand

Grate :

• Iron bar dia. 3/4 inch

Cost per stove : 1.015.000 VND
Exchange rate: US $ 1 =14.500 VND

Stove Utensils

• Shape : Parabolic, Cylindrical, etc.
• Size : Variable (diameter ranging from 35–50 cm)
• Material : Alloyed cast iron and Alluminum

Stove/Industry Capacity
The average customer per meal time is around 300–350 person. They cook 3 times a day, for breakfast, lunch and dinner; but especially for lunch the have to cook more.

The daily menu are rice and 4 other items such as vegetable, meat, soup, etc. Besides they have to boil a lot of water for drinking.

Fuel Consumption
In average per fire hole requires around 3 kg of coal per meal time; thus 4×3 kg = 12 kg coal per meal time or 3×12 = 36 kg of coal per day. Plus 2 portable stove which consume 4 kg per day/stove, thus the total fuel consumption is about 40 kg of coal/ day.

Stove Operation
Cooking time is start in the early morning, around 5 o'clock a.m. For first ignition usually they put some kerosene on the coal then burn. For better air circulation they put on a small fan in front of air hole. The first activity is boiling water while they prepare materials for breakfast meal.

Flow Chart of Stove Operation

As soon as water boiled, they replace the pan and start to cook. At 6.30 am the meals are ready, meanwhile they utilize the leftover heat for heating meat, water or other materials as preparation for lunch meal. At 10.30 am they start to prepare for lunch meal, and for dinner they usually start to cook at 17.00.

The ash should be removed every morning before ignition. The total cooking time is about 8 hours per day.

Ergonomic
Practically there is no lifting of heavy load required during the cooking process. Although the stove is about 60 cm high, no hefty cooking utensil is used (the biggest pot has a diameter of only 50 cm), hence lifting and moving of the utensils could be done easily.

Stove Maintenance There is no special maintenance required for the stoves surveyed. Minor repairs are usually done on the stoves' corners, which experience cracks due to bumping with cooking utensils.

Stove Durability
The stoves are estimated to have 10 year lifetime.

Kindergarten Stove

Stove at a local kindergarten

Profile
Children at 5 to 6 years old are already entering pre-school or what is usually called kindergarten. School time for kindergarten is usually from 8.30 in the morning to 16.00 in the afternoon. Due to the long school hours, the school has to provide lunch and light meals for the children. One of kindergartens in Hanoi, has a wood stove in its kitchen that prepares lunch, drinking water and light meals for 250 children daily.

Scale
Serve 250 kids and 8 teachers for lunch and sometime light meals in the afternoon.

Fuel Type
Fire wood

Size
(135×128×42) cm.

Stove Makers
Users/locally available

Stove Materials
Foundation:

• Stone

Body:

• Bricks
• Cement
• Sand

Grate:

• Iron Bar

Chimney:

• Bricks, cement and sand

Total cost per stove : 800.000 VND
Exchange rate: US $ 1 = 14.500 VND

Stove Utensils

• Shape: Parabolic, Cylindrical, etc.
• Size: Variable (diameter ranging from 30–55 cm)
• Material: Alloyed cast iron and Alluminium

Stove/Industry Capacity
The average rice cooked is 10 kg/ day, together with vegetable, soup, etc. to serve 250 kids and 8 teachers. The light meals such as pooridge, bean soup, etc. is cooked in the same time. Cooking time is 1,5 – 2 hours per day.

Fuel Consumption
In average the stove requires around 5 kg of fire wood per day.

Stove Operation
The stove has 3 fire holes and one chimney. Cooking time is start usually at 10.30 pm. For ignition they usually put some kerosene on the wood, then burn. The first activity is boiling water while they prepare materials to cook. As soon as water boiled, they replace the pan and start to cook. At 11.30 am the meals are ready, meanwhile they utilize the leftover heat for heating afternoon meal. Cooking time is 1,5 – 2 hours per day. The ash is removed every 3 days or if it looks full in the bottom of the stove.

Flow Chart of Stove Operation

A classroom in the kindergarten

Ergonomic
There is no lifting of heavy load during the cooking process.

Stove Maintenance The stove surveyed is quite new, not more than a year. The maintenance required consists only of cleaning and removing of ash.

Stove Durability
The stove is estimated to last for 10 years

Tea Industry

Loading tea leaves to the stove

Profile of the Industry
Tea drinking is a tradition of the Vietnamese people. Both urban as well as rural Vietnamese are fond of tea drinking, whether in a guest serving occasion or as something they have daily with rice or cakes. Tea trees could be grown in cool places at certain altitude. An example is in the district of Pho Yen in Thai Nguyen province (about 100 km from Hanoi), a region suitable for tea plantation. Most of the community members in Pho Yen district, about 80 households altogether, are involved in tea processing which is a home based industry. The people of Pho Yen use a conical drum heated with either wood or coal to process fresh tea leaves. The drum which is set horizontally, sits permanently and rotates on its axle above a stove. The drum is rotated either by an electric motor or manual turning. Fresh tea leaves go through repeated heating in the process; the first heating is quick, and serves to wilt the leaves, the second heating produces dry tea leaves ready for the market.

Scale of Industry
Cottage industry with 2–3 labourers. The space required for the tea processing is about 5m×4m

Fuel Type
Fuel wood or coal

Size
(135 × 105 × 115) cm.

Stove Makers
Users/masons while the drum for roasting is locally made.

Stove Materials
Foundation:

• Stone

Body:

• Brick
• Clay
• Cement and Sand

Total cost per stove: 300.000 VND

Stove Utensils
Drum for roasting the tea leaves:

a) Shape:
Double cones which are connected on its base. There is a height difference between the two connected cones. The drum is set horizontally and sits permanently above the stove. The inner surface of the drum has grooves which sits at an angle. While at the mouth of the drum, there are three blades present. An iron axle rotates the drum, at one end its end there is a connection to an electric motor and a regulator which maintain the rotation up to 80 rpm, while a crank is attacched at other end of the axle for manual turning.

b) Dimension:
The cone each has a base which is 80 cm in diameter
The upper part of cone A is 60 cm in diameter
The upper part of cone B is 45 cm in diameter
The cone is 135 cm long each
The cost per drum is 500,000 VND

Stove/Industry Capacity
Tea production varies from time to time. Tea could be picked for eight months in a year, with the peak production season from June till August. On average, 10 kilograms (kgs) of tea could be produced from 50 kgs of fresh tea leaves. At first the fresh tea leaves are roasted in roasting/oven drum; the drum is rotated for 5 minutes. The roasted leaves are drawn out of the drum, and is squeezed manually into smaller pieces and is left to cool. Then the leaves are roasted for the second time. The second roasting requires 25–30 minutes with drum rotation maintained constantly at 80 rpm, aided by a 0.5 hp electric motor. Afterwards, the tea leaves are drawn out, left to cool, packed and are ready for the market. The production of 10 kgs of dried tea leaves require about 4 hours and 0.1 m3 of wood as the fuel. If coal is used instead of wood, the end product will be of inferior quality.

Fresh tea leaves are processed in the drum which acts as an oven. The drum can be rotated on its axle by hand or with an electric motor

Fuel Consumption
0,1 m3 of wood are required to process 50 kg of fresh tea leaves to 10 kg of dried tea; or 10 kg of coal are needed for obtain 10 kg of dried tea.

Exchange rate: US $ 1 = 14.500 VND

Stove Operation
Tea is usually picked twice a day, at 7.00 am in the morning and at 2.00 PM in the afternoon. The stove fire is lit at about 2.00 PM. After sufficient heat is obtained, fresh tea leaves are processed in the drum which acts as an oven. The drum rotates on its axle with the aid of an electric motor. The first heating needs only 5 minutes untill the leaves wilt. The leaves are drawn out, put on a bamboo tray, pressed by hands into small pieces. A cutting machine could also be used to produce small leaf pieces. The drum is again filled with fresh tea leaves, and the process is repeated. The dried leaves which are already pressed into small pieces are heated again. The second heating requires a longer time of 25–30 minutes. For the second roasting, the drum rotates at a constant rotation of 80 rpm. At this stage, the fire also needs to be stable. The leaves are drawn out, left to cool an is ready for consumption/ market.

Flow Chart of Stove Operation

Constructing the drum

Ergonomic
In the process of tea production in small scale, workers are not required to lift any heavy object

Stove Maintenance
The drum should be replaced every three years. The upper part of the stove have to break to take the drum out then replaced with new one. The upper part of stove then rebuild again by plastering with mortar. For the lower part of the stove, there is no meaningful damages during over than 6 years. Small cracks can be repair easily using clay or mud mix with ash.

Stove Durability
About 10 years

Tofu Industry

Typical of stove used in Tofu industry

Profile of Tofu Industry
Tofu is a famous and widely consumed food in almost any part of Vietnam. It is no surprise that tofu is produced everywhere in Vietnam, with production ranges in scale from small to large. The raw materials used in tofu industry is soy bean. The beans are ground to produce paste, from which milk is extracted. The milk is boiled and precipitated with the aid of acid. The thick soy extract is then filtered with a cloth, put in a mould and allowed to harden. Tofu is the hardened soy extract.

Scale of Industry
Cottage industry with 2 labors. Space required is about (6 × 8) sq.m.

Fuel Type
Coal

Size
(100×100×35) cm. Single fire hole

Stove Makers
Users

Stove Materials
Body:

• Brick
• Clay
• Cement and Sand

Grate:

• Iron bar 3/4 inch dia.

Total cost per stove : 35.000 VND

Stove Utensils

• Shape : Parabolic
• Size : 50 cm diameter
• Material : Alloyed cast iron
• Amount : 2 pieces

Stove/Industry Capacity
In average 25 kg of soy bean can be processed per day. The cooking time is 1,5 hours per batch, and one day thay have to cook 3 batches continuously. From 25 kg of soy bean can be made to about 400 pieces of tofu of (10×5×4) cm size

Fuel Consumption
15–18 kg of coal are required to process 25 kg of soy bean in a day.

Exchange rate: US $ 1= 14.500 VND

Stove Operation
The wok is filled with water half full before ignition. The warm up the water inside the wok up to 60°C and during the period, the workers grind the soya beans into fine particles which then ispourred into the water. Keep on stirring the solution in order to keep from burnt. Once the solution gets thicker and the temperature raising up to 110–125(C they take out the solution and screen with fine cloth to separate the coarse particles. The fire is reduced to avoid empty wok from crack due to over heating.

Flow Chart of Stove Operation

The same process is repeated again depend on the amount to be processed.

Grinding the beans to produce paste, from which milk is extracted

Ergonomic
In small scale tofu production, there is no heavy load lifting required during the process. A grinding machine is used to grind soy beans. Meanwhile small sized pans are used in the boiling process.

Stove Maintenance
There is no meaningful damages during more than 4 years. Small cracks can be repair using clay or mud mix with ash.

Stove Durability
About 10 years

Flow Chart of Stove Operation