Industrial Institutional Food Non-Food
Stove used in Bakpia industry
Profile
Bakpia is a snack which is quite well
known in Indonesia. It originated from
China. There are several types of
bakpia with various fillings such as
chocolate, beans, pork, fruits, etc.
In Yogyakarta there is one very famous
bakpia industry with
mungbean filling. This snack which
is made from mung beans is a popular
souvenir item that domestic Indonesia
tourists take home with them.
Although it is located in the urban center of Yogyakarta, wood stove is still used. According to the producer, the use of wood stove is maintained as it imports a certain flavour to the cake, which is made of mixture of mungbean and sugar. This is then wrapped within a flour-egg dough and placed on a stainless steel sheet and baked in an oven.
Scale of Industry
Household industry with 15 laborers.
Fuel Type
Wood for the stove to cook the dough
Charcoal for the oven to bake the
bakpia
Size of Stove
Stove: (150 × 170 × 70) cm
Oven: (105 × 135 × 200) cm
Stove Makers
Masons, locally available
Stove Materials
Stove
Foundation :
Body:
Chimney:
Cost/stove : Rp. 150,000
Oven
Foundation:
Body:
Chimney:
Cost/oven : Rp. 600,000
Exchange rate US $ 1 = Rp. 8,350,-
Stove Utensils
Stove/Industry capacity
Stove: 25 kg mung bean mixture to
make approximately 5,000 bakpia
Oven: 2,500 pieces of bakpia/batch
Fuel Consumption
Stove: 2 bundles of firewood (18–20
kg)
Oven: 1 sack of charcoal (25 kg)
Stove Operation
The pan is 75% filled with water
which is then boiled in preparation
for steaming the mung bean paste.
When the water begins to boil, the
mung beans which have been mixed
with sugar, are placed in the wok.
At the same time, the flour-egg
dough is prepared. The mung bean
paste is wrapped in the dough,
shaped into cakes and placed on the
tray, which is then placed in the oven.
The Bakpia are arranged in the tray then placed in the oven
The charcoal are used to bake the cakes. The oven is preheated while the bakpia are being prepared. After approximately 15 minutes, the bakpia are turned over then baked until done.
Ergonomic
No heavy lifting nor bending are required
during the process.
Stove Maintenance
Stove: Ashes are cleared away every
morning before use. If there are
any cracks in the work, they must be
repaired immediately with a mixture
of cement and sand. The chimney
is cleaned when necessary, usually
every six months.
Oven: The ashes are always cleared away before use. If the oven is damaged, it is repaired with cement and sand, by widening the crack and plastering it with cement and water.
Stove Durability
10 years in operation
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Boiling coconut milk |
Profile of Coconut Oil Industry
Cooking oil made from coconut primarily
serves the traditional market.
The price of the oil is very much influenced
by the price of factory-produced
cooking oil.
The coconut are grated using simple grating machine. This flesh is then mix with water, and squeezed to obtain coconut milk. The coconut milk then boiled under continuous and strong fire before sieved to separate oil and waste (blondo) which can be eaten.
The stove is very important in this industry because it cooks the coconut milk for approximately 2 hours until all the oil is extracted.
Scale of Industry
Household industry with 4 laborers.
Fuel Type
Coconut shell and wood
Size of Stove
(150 × 50 × 30) cm
Stove Makers
Brick layer (locally available)
Stove Materials
Body :
Cost/stove: Rp. 150,000
Stove Utensils
Wok: 3 pieces-diameter 60 cm, permanently
fixed on the stove and
tightly sealed with clay
Stove/Industry capacity
30–35 lt. coconut oil from 300 coconuts
are produced daily
Fuel Consumption
300 coconut shells (from those used
for processing),
Fire wood: 25 kg for 3 days of work.
Financial Calculation
Expenditures | |
Coconuts: 300 pcs | =Rp. 90.000 |
Labor: 4 people | =Rp. 56.000 |
Firewood | =Rp. 10.000 |
Diminishing | =Rp. 25.000 |
TOTAL COSTS | =Rp. 175.000 |
Income | |
Oil: 35 lt | =Rp. 210.000 |
Blondo | =Rp. 30.000 |
TOTAL INCOME | =Rp. 240.000 |
Profit/day | =Rp. 65.000 |
Exchange rate: US $ 1 = Rp. 8.350 |
Add some water to grated coconut
Coconut is grated using a simple grating machine
Stove Operation
The three woks are filled with coconut
milk and the fire is ignited. Within
15 minutes, the coconut milk in the
first wok starts to boil. The milk must
be stirred constantly to avoid any
sticking to the wok. After two hours,
the milk in the first wok has become
oil and is sieved to separate oil and
the waste (blondo). The milk in the
second wok which is already hot is
then transferred to the first wok.
Stove used in coconut oil industry
Ergonomic
Convenient for cooking because no
bending is necessary as the stove is
high enough.
Stove Maintenance
Routinely cleaned. Ashes are always
removed prior to use. Any damage
to the body is immediately repaired
by local masons.
Stove Durability
Approximately 5 years
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Profile of Geplak Industry
Geplak is made from coconut and
sugar. This snack, characteristic of
the Bantul regency of Yogyakarta
province, is produced by a family industry
which continues to thrive because
the demand for geplak continues
to increase, not only in Yogya
and the surrounding area, but
throughout the country.
The stove is used in the cooking of the young coconut and sugar mixture.
Scale of Industry
Household industry with 15 laborers.
Fuel Type
Coconut shell.
Firewood can be used in needed in
addition to the coconut shell and if
easily available.
Size of Stove
(90 × 70 × 25) cm
Stove Makers
Users, locally available
Stove Material
Body:
Chimney:
Cost of stove: Rp. 100.000
Stove Utensils
Stove/Industry capacity
There are 5 stoves; each stove can
cook approximately 20 batches/day
which produce 8 kg of geplak/batch.
Fuel Consumption
Each stove cooking 15–20 batches/day uses approximately 2 sacks of
coconut shells (50 kg) and 3 bundles
of firewood (15 kg)
Financial Calculation
Expenditures | |
Young coconut 1.000 pcs | = Rp. 2.500.000 |
Granulated sugar 900 k | = Rp. 3.600.000 |
Coloring | = Rp. 5.000 |
Flavoring | = Rp. 10.000 |
Labor: 15 people | = Rp. 125.000 |
Diminishing | = Rp. 100.000 |
TOTAL COSTS | = Rp. 6.340.000 |
Income | |
800 kg @ Rp. 9.000 | = Rp. 7.200.000 |
Profit/day = Rp. 860.000 | |
Exchange rate: US $ 1 = Rp. 8.350 |
Stove Operation
Shredded coconut and sugar are
mixed while heating on the stove. If
the mixture no longer sticks to the
pan, add flavoring and coloring. After
30 minutes on the stove, the
geplak is cooked.
Flow Chart of Stove Operation
Ergonomic
No heavy lifting is required, but the
cook need to bend or sit during the
process because the stove is low.
Stove Maintenance
Ashes are removed every morning.
If there is any damage to the stove
opening, it must be repaired immediately
with a mixture of sand and
clay. The chimney is cleaned every
3 months.
Stove Durability
Approximately 5 years
A typical stove used in Geplak industry
Industrial Institutional Food Non-Food
Single pothole stove | The three pothole stove is used in Gudeg making |
Profile of Gudeg Restaurant
One of the food items which Yogya
is famous for is gudeg, a dish made
from young jackfruit stewed in coconut
milk. Gudeg can be found in almost
every restuarant in Yogya.
The stove which uses firewood is important for retaining the characteristics flavor of gudeg while it is boiling the young jackfruit, chicken, tofu, tempe, and sambal krecek, a side dish made with beef rind. In order to get best taste, the gudeg made one day should be consumed the next day. Fried chicken, often served as a side dish, must also be cooked using a wood burning stove for flavor.
Scale of Industry
Household industry with 20 laborers
Fuel Type
Fire wood
Size of Stove
(100 × 100 × 50) cm for 1-hole stove
(160 × 80 × 40) cm for 2-hole stove
(180 × 75 × 40) cm for 3-hole stove
Stove Makers
Brick layers (locally available)
Stove Materials
2- and 3-hole stoves:
Single hole stove:
Stove Utensils
Stove/Industry capacity
Each day (4 am – 8 pm):
Fuel Consumption
Approximately 2 m3 firewood/day
Financial Calculation
Expenditures | |
Whole chicken: 100 pcs | = Rp. 1.800.000 |
Eggs: 3,000 pcs | = Rp. 2.400.000 |
Young jackfruit: 2 kwintal | = Rp. 150.000 |
Tempe: 120 pcs | = Rp. 60.000 |
Tofu: 100 pcs | = Rp. 100.000 |
Chili | = Rp. 250.000 |
Beef rind: 5 kg. | = Rp. 100.000 |
Coconut: 25 pcs | = Rp. 50.000 |
Spices | = Rp. 100.000 |
Oil: 2 cans | = Rp. 240.000 |
Rice: 0.5 kwintal | = Rp. 150.000 |
Labor | = Rp. 100.000 |
TOTAL COSTS | = Rp. 5.650.000 |
Income | |
Average income/day | = Rp. 7.500.000 |
Profit/day | = Rp. 1.850.000 |
Exchange rate: US $ 1 = Rp. 8,350,- |
The three pothole stove | The two pothole stove |
Stove Operation
The stove is ignited at 4 a.m. and
kept in operation until 8 p.m. The heat
should be kept low in order to obtain
the specific taste of gudeg.
Ergonomic
No heavy lifting nor bending are required
during the process.
Stove Maintenance
Ash and charcoal are removed daily.
If any stove is damaged, it is repaired
immediately and left to dry for one
day.
Stove Durability
Approximately 10 years
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Stove for frying in beef rind industry | A typical stove for boiling |
Profile of Beef Rind Chips Industry
Kerupuk rambak (beef rind chips) are
made from buffalo or beef rind. This
family industry has been in existence
for more than 20 years, and continues
to thrive in response to a high
demand for the product. This high
protein food is used in sambal
krecek, a side dish that is served
with gudeg, as well as with Padang-style
food (from West Sumatra), and
also by itself as a snack food.
The stove is used to boil the raw rind so that it can be easily cleaned, and also to fry the dry rind.
Scale of Industry
Household industry with 20 laborers.
Fuel Type
Hard wood (for frying), wood shavings
or firewood (for boiling)
Size of Stove
Stove Makers
Brick layers (locally available)
Stove Materials
Stove for boiling:
Cost/stove: Rp. 100.000
3-hole stove for frying:
Cost/stove: Rp. 350.000
Stove Utensils
Wok: diameter 100 cm, iron, 4 pcs
Stove/Industry capacity
Each day (7 am – 4 pm): 100 kg of
raw rind are boiled. The 2-holes of
the 3-hole stove is used for the first
frying process; each time fries 50 kg
for about 3 hours frying time. One of
the holes of the 3-hole stove is used
for the last stage, which needs a
higher flame because the oil must be
maintained at boiling temperature.
The average production is 600 kg dry
beef rind/day.
Fuel Consumption
1,500 kg dry wood + 20 kg sacks
wood shavings/day
Financial Calculation
Expenditures | |
Raw rind: 100 kg | = Rp. 1.500.000 |
Cooking oil | = Rp. 400.000 |
Labor: 20 people | = Rp. 180.000 |
Fuel wood | = Rp. 102.500 |
Diminishing | = Rp. 50.000 |
TOTAL COSTS | = Rp. 2.232.500 |
Income | = Rp. 2.500.000 |
Profit/day | = Rp. 267.500 |
Exchange rate: US $ 1 = Rp. 8,350,- |
Stove Operation
The wok on the single hole stove
which is used to boil the raw rind is
half-filled with water which is then
heated until boiling. The raw rind
which has been cut into squares (20
× 20) cm is added to the boiling water.
When it is soft, it is removed
from the fire and cooled. Then, the
hair and underskin are removed. The
rind then sliced into smaller pieces
(1,5 × 5 cm) before frying.
Two of the woks on the 3-hole stove
are prepared for the first stage of frying. They are half-filled with cooking
oil and then heated until boiling. After
the oil boils, the firewood is reduced,
then the raw rind is added.
The third hole (in the middle of the
stove) is used for the final frying
proceess. For this stage, the oil
must boil constantly and the firewood
must be centered under the pot.
Ergonomic
No heavy lifting nor bending are required
during the process.
Stove Maintenance
Ash is removed every day before use.
If the stove is full of ash at mid-day,
the ash must be cleared away so that
the fire can burn well. If there is any
damage to the stove, it must be repaired
immediately.
Stove Durability
More than 5 years.
The rinds are sliced into smaller pieces before frying |
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Typical stove used for steaming in tapioca chip industry |
Profile of Tapioca Chip Industry
Tapioca chips, or as they are often
called, krupuk terung Bandung (because
most of these industries were
originally in Bandung, West Java), is
a popular snack. It is very inexpensive
and can be eaten with any meal.
One can easily find one of these industries
in every town in Indonesia,
so it can be said that it serves as the
livelihood of thousands of families.
For instance, in samll towns like Cepu
and Padangan, Central Java, there
are 35 tapioca chip industries, each
employing an average of 5 – 12
people.
The stove functions to cook the dough and spices and also to fry the dried chips.
Scale of Industry
Household industry with 6 laborers.
Fuel Type
Dry rice husk (for cooking dough)
Wood & rice husk (for frying chips)
Size of Stove
Stove Makers
Masons, locally available
Stove Materials
Foundation:
Single-hole stove:
Body:
Chimney:
Double-hole stove:
Body:
Chimney:
Stove Utensils
Stove/Industry capacity
Fuel Consumption
Average: 100 sticks firewood + 15
sacks rice husk (8 kg each)
Financial Calculation
Expenditures | |
Tapioca flour: 50 kg | = Rp. 220.000 |
Gaplek flour: 50 kg | = Rp. 150.000 |
Wheat flour: 50 kg | = Rp. 325.000 |
Spices | = Rp. 20.000 |
Firewood | = Rp. 12.500 |
Rice husk | = Rp. 8.000 |
Cooking oil: 3 gal/60 kg | = Rp. 360.000 |
Labor (5 peoples) | = Rp. 73.000 |
Overhead | = Rp. 100.000 |
Distribution | = Rp. 150.000 |
TOTAL COSTS | = Rp. 1,418.500 |
Income | |
Chips: 24,000 chips | = Rp. 1,800.000 |
Profit/day | = Rp. 381.500 |
Exchange rate: US $ 1 = Rp. 8,350,- |
Packaging the tapioca chips
Stove Operation
The single-hole stove is ignited at
5:30 am. The wok is filled 75% with
water and heated. The initial firing
uses teak wood until the flame is
considered sufficient, then it is fed
with rice husk to maintain boiling temperature.
The chip ingredients are
mixed, then placed above the boiling
water. The pan is covered with an
aluminum cover until the contents are
cooked, then the cooked batter is
quickly cut to size and dried in the
sun.
The dried chips are then ready to be
fried on the double-hole stove. This
is done at 3 p.m., so that the chips
will be fresh for distribution early the
next morning. The stove is initially
ignited with dry firewood and later
with a combination of wood and rice
husk to control the heat of the cooking
oil. The back pot (medium hot)
is used for the first frying and the front
pot (over the central fire) is used for
the final frying.
Ergonomics
No heavy lefting nor bending are required
during the process.
Stove Maintenance
Ash is removed every morning. If
there is any damage to the stove, it
must be repaired with clay and water
before being used again.
Stove Durability
The two stoves in use are 10 years
old
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Grinding the soybean | Boiling the soy porridge |
Profile of Tofu Industry
Tofu is a famous and widely consumed
food in almost any part of Indonesia
and in many other countries
in Asia. It is considered as a good
source of protein. Tofu is made from
soya beans which is finely grounded
and extracted into a kind of milk. The
milk is then boiled for a few hours
until it becomes thick. The thick fluid
is sieved with fine cloth to get fine
grade of solution. The solution is then
mixed with some acetic acid that
functions as coagulant for the protein
in the solution. Once it settled,
the water is removed and the white
soft part is collected and pressed
until it becomes hard, and cut into
small pieces called tofu.
Stove is an important part of tofu industry
because it needs long time
boiling of large quantity solution.
There are two methods of heating the soy porridge in the process of making tofu: by cooking over heat and by steaming.
Scale of Industry
Household industry with 10 laborers.
Fuel Type
Primarily residue from eucalyptus
leaves obtained from the eucalyptus
oil industry in the region. If continuous
rain dampens the residue, then
rice husks are used.
Size of Stove
Stove: (120 × 45 × 45) cm
Steamer: (120 × 60 × 55) cm
Stove Makers
Owner with the Department of Industry,
Gunung Kidul regency,
Yogyakarta Special Province
Stove Materials
For Direct Boling Stove
Foundation:
Body:
Fire box:
Grate:
Chimney:
Cost/stove: Rp. 250,000
For Steamer Stove
Foundation:
Body:
Grate:
Chimney:
Cost of stove: Rp.8.500.000,-
Heating the soy porridge with steam | A typical of steamer stove |
Stove Utensils
Stove/Industry capacity
Each day (7 am – 3 pm) 3.5quintal
of soybeans are processed.
Fuel Consumption
4 m3 eucalyptus leaf residue to cook
10 quintal soybeans (3 days)
Financial Calculation
(For Steamer Stove)
Expenditures | |
Soy beans: 3.5 qt | = Rp. 1.400.000 |
Vinegar: 300 lt | = Rp. 15.000 |
Fuel | = Rp. 30.000 |
Labor: 8 people | = Rp. 40.000 |
Diminishing | = Rp. 150.000 |
TOTAL COSTS | = Rp. 1.635.000 |
Income | = Rp. 1.818.000 |
Profit/day | = Rp. 183.000 |
Exchange rate: US $ 1 = Rp. 8,350,- |
Stove Operation
Fire is ignited with eucalyptus leaf
residue which burns easily. The water
in the pans begins to boil approximately
30 minutes later. At the same
time, the soy beans which have been
soaking in water are ground with a
machine, then taken to the pans. The
steam cooks the soy porridge.
It takes approximately 7 minutes after boiling for the tofu to agglomerate. The agglomeration is strained through a thin cloth screen to get the primary ingredient of tofu. It is then pressed into square molds.
Ergonomics
It need strong man to stir porridge
continuously.
Stove Maintenance
Ash from the previous day is always
cleaned away in the morning. When
the water begins to boil, the steam
pipes are checked for obstruction.
The steam pipe connections are examined
every 6 months. The ash in
the chimney is cleaned once every
year.
Stove Durability
Approximately 10 years
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Loading the Wingko into the oven | The racks are placed near the flame |
Profile of Wingko Industry
This wingko industry is a family business
which has been passed down
through several generations. Because
this snack food industry originated
in Babat village in Lamongan,
East Java, it has come to be known
as Wingko Babat. The shelf life of
this snack is one week, so the demand
for it is high, especially with
the growth of the tourist industry, as
tourists will choose wingko to take
home with them.
The stove serves to bake the dough of glutinous rice flour, grated coconut and granulated sugar.
Scale of Industry
Household industry with 4 laborers.
Fuel Type
Coconut shell (initial stage), teak
wood (final stages)
Size of Stove
(250 × 200 × 150) cm
Stove Makers
Owner, Skilled people
Stove Materials
Foundation:
Body:
Chimney:
Stove Utensils
Stove/Industry capacity
Every day: usually 200 trays backed
in 2 ovens. If baked too long, the
wingko tastes sour.
Fuel Consumption
180 sticks of teak wood (40 cm long,
6 cm diameter)
Financial Calculation
Expenditures | ||
Rice flour: 20 kg | = Rp. | 76.000 |
Coconut: 35 pcs | = Rp. | 122.500 |
Sugar: 15 kg | = Rp. | 60.000 |
Teak wood | = Rp. | 15.000 |
Labor: 4 persons | = Rp. | 50.000 |
Overhead | = Rp. | 25.000 |
TOTAL COSTS | = Rp. | 348.500 |
Income | ||
Wingko: 200pcs | = Rp. | 450.000 |
Profit/day | = Rp. | 102.000 |
Exchange rate: US $ 1 = Rp. 8,350,- |
Coconuts should be cleaned before grating | The Wingko: fresh from the oven |
Stove Operation
35 coconuts are cleaned and grated,
mixed with one bucket (15 kg) of
granulated sugar, and let to sit for 12
hours. The next day, the coconut-sugar
is mixed with hot water and
20 kg glutinous rice flour. This dough
is placed on the trays.
While the coconut and rice flour mixture is being prepared, the ovens are ignited with coconut shells in the left corner of the stove. When the shells have begun to burn, the teak wood is added.
Six trays are arranged on 1 rack and are placed near the flame. After 10 minutes, the rack is moved every few minutes until the dough is baked evenly.
Ergonomic
No heavy lifting nor bending are required,
but the cook is exposed to
heat during the process.
Stove Maintenance
Ash is removed and the stove is
swept clean every morning. The
chimney is also swept with a long
handled broom. If there are any
cracks on the walls of the stove/oven,
they are repaired with a mixture of
cement, sand and palm sugar/sugar
cane liquid. Maintenance is done by
the baker who has been trained by
the oven makers.
Stove Durability
One stove has been in operation for
15 years. This is a plan to rehabilitate
next year
The other stove has been in operation for 5 years, and should last another 20 years
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
A typical of stove used in the cane sugar industry
Profile
In rural areas in northern Laos around
Luang Prabhang province -
there are still plenty of villagers producing
cane sugar using traditional
methods. Fresh cane juice is first obtained
using a simple pressing tool.
The juice is then boiled for 2 to 3
hours until a thick dark brown liquid
is obtained. This liquid is then transferred
to moulds. When the liquid has
hardened, it forms blocks of cane
sugar. The cane sugar blocks are
lifted from the moulds and are ready
for consumption or to be marketed.
The cane sugar is usually produced by farmers, who have done it for generations. It supplements their main occupation as rice farmers. While rice needs irrigation, sugar cane can be grown on dry land.
The stove is a crucial element in cane sugar production, used during the process of boiling cane juice into thick brown liquid which then cools to form cane sugar.
Scale of Industry
Cottage industry with 3 laborers.
Space required is about (5×8) m for
boiling and moulding; and (6×6) m for
pressing raw sugar cane to get the
juice.
Fuel Type
Fuel wood and bagasse
Stove Size
(290 × 100 × 30)cm. A long stove with
four fireholes.
Stove Makers
Users, locally available
Stove Materials
Body:
Stove Utensils
Stove/Industry Capacity
On average 30 kg. of cane sugar are
produced daily. Although there are
4 fire holes in a stove, only two or
three holes are used regularly. The
amount of raw materials and the operator
capacity are sufficient to work
only on two to three holes. Cane
sugar is only produced during the dry
season (March, April, June). At other
times the cane sugar produced is of
low quality. The harvest from 0.6
hectare of sugar cane plantation will
be completely processed into cane
sugar within 30 days.
Fuel Consumption
For every batch, a stove will consume
3 logs of wood measuring 1.5 m and
a diamater of 12 cm. Therefore if two
batches are done per day, and two
stoves are operated, the fuel consumption
will be 2×2×3 logs = 12
logs
Financial Calculation
Expenditures | ||
Sugar cane | = | 35.000 Kip |
Fuel wood | = | 12.000 Kip |
Labor | = | 30.000 Kip |
Rent a buffalo | = | 5.000 Kip |
Income | ||
Cane sugar 30 kg @ 3.500 Kip | = | 105.000 Kip |
Profit/day | = | 23.000 Kip |
Exchange rate : US $ 1 = 7.400 Kip |
When the liquid reaches the appropriate consistancy, the wok is lifted and the lmixture is transferred to moulds.
Stove Operation
Fresh canes are harvested early in
the morning and is immediately processed
using a simple pressing machine.
The machine is operated using
a buffalo which can be rented for
5000 kip per day. For the first batch
fresh canes are pressed until approximately
75 litres of cane juice are obtained.
This amount of liquid is then
divided into two woks. The two woks
are then heated simultaneously on a
strong fire for two hours. As the liquid
boils, foam and dirt rises to the
top and are then periodically removed
with a wooden spoon. To prevent an
overflow of the foam during boiling, a
bamboo cylinder, 40 cm in diameter,
is immersed in the wok. After 2 hours,
the liquid starts to thicken and is dark
brown in colour. At this stage, the
cane juice needs to be stirred continuously
to prevent burning. When
the desired thickness of the liquid is
obtained, the wok is lifted and the
liquid is transferred to moulds. The
liquid is then left to cool and harden,
forming cane sugar blocks. The
blocks of cane sugar are then taken
out of the mould. The cane sugar is
now ready to be marketed.
The fire is extinguished by pulling out the remaining burning wood. The whole process is repeated for the next batch. The second batch is usually completed at 5.00 in the afternoon. At the end of the day, the burning wood in the stove, is left undisturbed until it dies out. The total working time in a day is between 6–7 hours.
Ergonomics
Generally the process does not require
the lifting of any heavy load. The
activity which appears most taxing,
is, the continuous stirring of cane
juice when it starts to thicken.
Stove Maintenance
The stoves surveyed do not require
special maintenance. If cracks occur,
they can be mended with a clay and ash mixture
Left the liquid to cool and harden, forming sugar cane blocks
Stove Durability
The stoves are 4 years old and are
still functioning well. The stoves are
estimated to last for another 5 years.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
The rice flour paste is steamed layer by layer in a steaming pot
Profile of Noodle Industry
Noodle is a popular food throughout
Laos. It is eaten at all times, for
breakfast, lunch or dinner. There are
two types of noodle, one is made
from wheat and is usually yellow in
colour and the other made of rice flour
and is white in colour. In Laos, noodle
is usually produced by home based
industry. The producers usually sell
the noodle directly or supply restaurants.
The main ingridient is rice
which is made into flour and soaked
overnight. A small amount of cassava
flour is added to improve the noodle
elasticity. On the following day, the
rice flour paste is steamed layer by
layer in a steaming pot. Noodle thickness
depends on preference but is
usually 2mm. Some of the noodles
are sold fresh/wet while othrs are sold
in dry form. In noodle production, wood fueled stoves are used during
the steaming process.
Scale of Industry
Cottage industry with 3 laborers.
Space required is about (8 × 6) m for
grinding and slicing; another (6 × 10)
m for steaming and drying.
Fuel Type
Fuel wood
Stove Size
(140 × 85 × 30) cm with 2 fire holes
(360 × 100 × 35) cm with 4 fire holes
Stove Makers
Users/locally available
Stove Materials
Body:
Labor: 125.000 Kip
Total cost per stove: 280.000 Kip (for
2 fire hole stove)
Total cost for 4 fire hole stove is 70.000 Kip because of the additional chimney.
Stove Utensils
Stove/Industry Capacity
The production of noodle is mainly
depends on the orders, but on average
100 kg of rice per day produces
50 kg dried noodle, 60 kg wet noodle
and 15 kg of crackers.
Fuel Consumption
The 2 fire hole stove requires 4–5
pieces of wood , 1,5 m long and
about 20 cm diameter, for 2–3 hours
working time.
For 4 fire hole stove requires 11–12
pieces of wood for 3 hours working
time.
Financial Calculation
Expenditures | ||
Rice - 100 kg | = | 200,000 Kip |
Cassava - 1 | = | 12,000 Kip |
Fire wood 12 pc | = | 24,000 Kip |
Labor - 3 person | = | 60,000 Kip |
Rent/Power/Depreciation/Misc. | = | 100,000 Kip |
TOTAL COST | = | 39,000 Kip |
Income | ||
50 kg dried noodle | = | 200,000 Kip |
60 kg wet noodle | = | 150,000 Kip |
15 kg crackers | = | 195,000 Kip |
TOTAL INCOME | = | 500,000 Kip |
Profit/day | = | 149,000 Kip |
Exchange rate US $ 1 = 7,450 Kip |
A two pothole stove used in the noodle industry | The noodle sheets are sliced using a simple slicer machine |
Stove Operation
The stove is usually lit at 5.30 in the
morning. Pots are half-filled with water.
A round frame with cloth attached
on its upper part is immersed in the
pan. Once the water boils, rice flour
which has been soaked overnight, is
put in the pot, on the cloth. It is put
in a spoon at a time until it forms a
circle and is about 1–2 mm thick. The
lid of the pot is put on for 2–3 minutes.
After the rice paste is cooked,
a new batch is put in and the process
is repeated. Meanwhile the fire
needs to be kept strong, to keep the
water boiling so that steaming takes
place.
To produce dry noodles, the rice paste is dried until it is dehydrated. While for the production of fresh/wet noodle, the rice paste is sliced and is immidiately ready for consumption. Flavouring such as sugar, salt etc are added to the left over pasta which is fried and made into crackers
Ergonomics
In general, there is no lifting or energy
expanding activities required in
the noodle production industry surveyed.
Stove Maintenance
The stove is now 4 year old. During
the time, there has been no major
breakdowns.
Stove Durability
It is assumed that stove will be last
for another 10 years.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Spreading the fibres evenly on the mould
Profile of Paper Industry
Banxang Khon, a village 10 km from
Luang Prabang, is famous for its paper
making industry. The majority of
Banxang Khon residents are involved
in hand-made paper production. The
hide of jute plant is used as the raw
material in the paper production. The
jute is first soaked in water containing
a bleaching agent, followed by
boiling. Next, the fibres are separated
by beating the softened jute with
a wooden mallet. The paper porridge
is then molded on a plastic
screen and allowed to dry. Flowers
or leaves can be added to decorate
the paper. When dry, it is lifted from
the screen.
Stove is an important component in paper making. The jute hide needs to be boiled and then maintained at constant temperatures between 60–70°C for twelve hours.
The paper produced could either be bound into a book, painted or sold as it is, as a souvenier.
Scale of Industry
Home industry with 5 labors. Space
required is 6×8 m for stove and moulding,
and another 5×4 m for drying.
Fuel Type
Fuel wood
Stove Size
(15 × 95 × 50)cm
Stove Makers
Users, locally available
Stove Materials
Body:
Chimney:
Stove Utensils
This container sits on the hole of the stove permanently, the narrow gap between stove and container is then sealed with clay and ash.
Industry Capacity
On average 100 sheets of paper
(each measuring 55×80 cm) are produced
daily. Some of these are plain
sheets while others have flower/leaf
decorations on them. For the production
of 100 sheets of papers, 20 kgs
of dry jute are required.
Fuel Consumption
6–8 pieces of woods each 1,5 m long
and about 15 cm diameter are needed
for a single batch.
Financial Calculation
Expenditures | ||
Jute 20 kg @ 3000 Kip | = | 60.000 Kip |
Chemical | = | 18.000 Kip |
Fire wood | = | 9.000 Kip |
Labor 5 persons | = | 100.000 Kip |
Rent/Power/Depreciation/Misc | = | 250.000 Kip |
TOTAL EXPENDITURES | = | 429.000 Kip |
Income | ||
100 sheets @ 7.000 kip | = | 700.000 Kip |
Profit/day | = | 271.000 Kip |
Exchange rate: US $ 1= 7.450 Kip |
Stove and boiling container used in the Jute paper industry |
Stove Operation
20 kg. of jute are soaked overnight
and then washed with detergent. The
jute is then put in water containing
bleaching agent and is stirred. Afterwards,
the jute is transferred to another
container for boiling. 20 kg. of
ash is added to the water used for
boiling the jute. It takes between 45–60 minutes to reach the boiling stage,
after which the jute is simmered on
a steady fire, with the temperature
maintained at between 60–70°C for
12 hours. The softened jute is then
beaten with a wooden mallet until the
fibres are separated. The beating continues
till the jute breaks into fine
strands of fibres. Before being put into
mold the jute needs to be weighed.
On average 5 sheets of paper can be
produced from a kilogram of jute
fibres. If thicker sheets of paper are
to be produced, more jute is added.
The jute fibres are put in a tray filled
with water. The mould is then immersed
in the tray and the fibres are
spread evenly on the mould. The
mould is lifted from the tray and is
dried in the sun.
The mould is a wooden rectangular frame, (55 × 80 × 3)cm. A plastic mosquito net is nailed to the frame. When the jute has been put on the moulds, the boiling container is cleaned. The next batch of jute which has been soaked, is ready for processing.
Ergonomics
There is no lifting of any heavy load
during the process as small amount
of jute fibres are taken each time.
Stove Maintenance
Avoiding boiling water from overflowing
onto the stove will ensure that no
major damage occurs. Small cracks
can easily be repaired with sand and
cement or clay and ash mixture.
Stove Durability
The stove surveyed was made in
1990, and it has been rebuilt twice.
However by preventive maintenance,
i.e. avoiding boiling water overflow,
the stove is estimated to last for another
5 years.
Scrubbing the paper surface | Expose to the sun |
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
The salt crystals are taken out using a wooden spoon
Profile
Usually salt is obtained by evaporating
by seawater. However, since
there is no sea in Laos, salt is obtained
from inland salt mines. Firstly,
groundwater has to be mined from
depths between 200–400 meteres.
The groundwater from the depths
contains somewhere between 25–35% salt (NaCl). This salt water is
then evaporated by boiling on a pair
of stoves to produce crystal salts.
Eventhough solar energy could be
used to evaporate the salt water, the
boiling process produces better quality
salt.
Scale of Industry
Small scale industry with 50 – 200
laborers. Space required is about
20.000 sq.m.
Fuel Type
Saw dust
Size
(265 × 150 × 50) cm
Stove Makers
Users, locally available
Stove Materials
Body:
Cost per stove : 60.000 Kips
Stove Utensils
Stove/Industry Capacity
The average production of raw salt
per pair of stove is 60 kg per batch.
Boiling time is about 10 hours. Thus
per day they only prepare 2 batches.
The factory has 130 pairs of stoves.
If it works at full capacity the total
production is 15.6 tons of raw salt
per day.
To obtain the final product iodine (45 ppm.) is added using simple mixer machine.
Fuel Consumption
0,15 m3 of saw dust are required to
produce 60 kg of raw salt in a day.
Financial Calculation
Expenditures | ||
Iodine (for 15 tons/day) | = | 85.000 Kip |
Electricity | = | 150.000 Kip |
Depreciation (building) | = | 400.000 Kip |
Depreciation (machinery, equipment) | = | 500.000 Kip |
Misc | = | 850.000 Kip |
Labor equipments | = | 400.000 Kip |
Raw salt 15 tons/day | = | 1,250.000 Kip |
TOTAL COSTS | = | 3.135.000 Kip |
Income | ||
Raw salt (for industry purposes) - 7 tons @ 150 Kip/kg | ||
= | 1.050.000 Kip | |
Iodine Salt - 8 tons @ 400 Kip/kg | = | 3.200.000 Kip |
Total gross income/day | = | 4.250.000 Kip |
Profit/day | = | 615.000 Kip |
Exchange rate: US $ 1 = 7.450 Kip |
Stove Operation
At first a round wooden log, 10 cm in
diameter and 175 long, is placed horizontally
at the base of the stove. Saw
dust is then poured until it covers the
log, (about 15–20 cm thick). Then, 3
wooden sticks are placed vertically
on the log at a distance of about 50
cm from one another. The stove
chamber is then filled with saw dust
which is made firm by repeatedly
stepping on it. The wooden sticks and
the log are then slowly taken out.
Hence air channel are created, one
horizontal at the stove base and the
other three vertical.
Saw dust is used as fuel in the salt industry | Pouring the saw dust into the stove chamber |
The stove is lit from the vertical holes made earlier. An iron container is used to hold salt water. The salt water is filled almost to the brim, leaving only about 2 cm. to the container's lip. When the salt water becomes concentrated, it crytallises at the bottom of the container. When enough salt crystals are formed, the salt is taken out using a wooden spoon. More salt water is added when the water level in the container is low. The process is repeated until the salt water is completely evaporated and at about the same time, the saw dust is completely burnt. A batch of salt processing will take between 8–10 hours. Between 50–60 kgs of raw salt could be obtained from 200 litres of salt water. When a batch is completed, the iron container is lifted out, and the combustion chamber is cleaned. The same process is repeated for the next batch.
A wooden log is placed horizontally at the base of the stove; three wooden sticks are also placed vertically; then saw dust is poured into the stove chamber.
Ergonomics
Salt crystals collected in a bamboo
basket needs to be transported to a
storage area. Transporting it needs
considerable strength as a basket full
of salt can weigh up to 60 kgs. Another
physically demanding job is the
lifting up of the iron container, which
needs to be cleaned at the base and
then replaced on the stove. While
other activities are not as physically
demanding as these two.
Stove maintenance
The stove is made of layered bricks
and plastered with mud, ash and clay.
Sometimes some cracks appear
which needs to be repaired with a
mixture of mud and small amount of
ash.
Stove durability
A stove last one year, while the iron
container last about 6 months.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
The boiler requires a large amount of fuel wood to produce steam continuously |
Profile of Sauna Stove
The sauna industry is sponsored by
the Laos Red Cross Society. All
materials for the sauna (drum, stove,
sauna room, etc.) are the provided
by the Red Cross; and all income
goes to the Red Cross. There is one
employee who is responsible for
cleaning the rooms, firing the stove,
putting the herbs in, etc.
The sauna only open in the evening from 6–9 PM.
The equipment used to produce
steam consists of:
A boiler made of a used tank with a
volume of about 200 L. The upper part
has two outlets which channel steam
by means of metal pipes to two
steam rooms (one for woman, the
other for men) which have wooden walls with a capacity of 5 persons
per room. The water in the drum is
first mixed with various types of herbs
and leaves; more than 20 types of
herbs and leaves are put in the mixture
and are replaced every two days.
The stove used has two fireholes and is wood fueled. One hole is used to heat the water in the drum which sits tightly on the stove's lip. The gaps between the drum and the stove's lip are filled with clay mixed with ash. Another hole is 40 cm in diameter is used to boil water for making herb drinks for the visitors. A chimney is also present and is made of a metal pipe, 6 inches in diameter.
Scale of Industry
Household activity with one worker.
A space of (4 × 3) m is needed for
ground level where the stove is situated
and (10 × 8) m is needed for the
upper level where there are two sauna
rooms and a rest and waiting area.
Massage rooms (5 rooms) are beside
the sauna room.
Fuel Type
Fuel wood
Size
(150 × 97 × 40) cm.
Stove Makers
Users, locally available
Stove Materials
Foundation:
Body:
Grate:
Chimney:
Cost of stove: 400.000 Kip
Stove Utensils
Stove/Industry Capacity
The service hours for the sauna is 3
hours/day, starting at 18.00 up to
21.00 in the evening. The stove is ignited
at around 5.30. The drum fill up with the water up to ⅓ part of the
height (60–70 liter only). The herbs
and some kind of leaves are then put
into the drum. The fire should be kept
big to boil the water and produce the
stream. At 21.00 the fire is dimed by
pulling out the wood from the stove,
and then some water is splashed on
the fire to extinguish it.
Fuel Consumption
10 pieces of fire wood with 1,5–2 m.
long and 10 – 12 cm. diameter are
consumed every evening.
Financial Calculation
Expenditures | ||
Equipments: | ||
Stove | = | 400.000 Kip |
Drum & pipe | = | 270.000 Kip |
Pipe for chimney | = | 80.000 Kip |
Sauna rooms, bath room, etc. | = | 2.500.000 Kip |
Operational: | ||
Fuel wood/day | = | 15.000 Kip |
Labor/month | = | 160.000 Kip |
Herbs, tea, soap etc./day | = | 30.000 Kip |
Exchange rate US $ 1 = 7.450 Kip |
Ergonomics
Generally there is no heavy load that
needs to be carried. The drum needs
only to be cleaned once in a while or
when it appears very dirty.
Stove maintenance
There is no special maintenance requirements
for the stove. Cracks can
be repaired with a clay and ash mixture.
Stove durability
The stove is now 2 years and is still
functioning well. It is estimated that
the stove will last for five years.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Profile
In Kepong, Kuala Lumpur, there are
plenty of sidewalk food vendors.
These eating places are jammed with
custumers during lunch hour. Most
of those frequenting the places are
office workers from the surrounding
Kepong. Many vendors still use wood
charcoal. It is believed that the food
cooked with charcoal taste better.
Food is often served, on small portable
stoves, known as anglo. Fish
soup, seafood and vegetables will
become more delicious if served hot,
maintained hot with the anglo. Some
types of food are first cooked with
gas stove, and then served on charcoal
anglo which keeps the food hot.
For some food types, clay wok is used instead of metal or alumunium one. The anglo used is usually tiny, with a diameter of about 25 cm. The anglo could easily be purchased in markets costing between 10–16 RM. For big restaurants, they serve food on more than 50 anglos at once.
Scale
Restaurant with 10–12 labors. Space
required is about (8 × 10) m.
Fuel Type
Gass and/or charcoal
Size
25 cm height and 27 cm diameter
(top); 17 cm diameter (bottom)
Stove Makers
Stove producer
Stove Materials
Body:
Grate:
Total cost per stove: 14.50 RM
Stove Utensils
Capacity
The restaurant surveyed has 12 round
tables with each table accomodating
6 chairs. There are 50 anglos and 6
bigger cooking stoves in the
restaurant. According to the owner,
they serve on average between 200–250 customers per day. Working hour
is between 11.30–20.00. And they
cater for more than 15 food items in
the restaurant.
Fuel Consumption
Depend on how frequent the stove
being used, but in average 1 kg of
charcoal are required per portable
stove per day.
Stove Operation
For cooking, the restaurant uses either
gas stoves or charcoal fueled
cooking stoves. The portable stoves
are placed, ready on the tables; when
there is an order for food items which
require the use of anglos, the anglos
are loaded with glowing charcoal.
Food is then ready for serving on the
anglos.
Ergonomic
In the process, in terms of ergonomic,
there is no need to lift heavy
materials.
Stove Maintenance
There are no maintenance needed
exept cleaning dirt and ash regularly.
If cracks occur the stove just throw
away and replace with new one.
Stove Durability
About 0,5 – 1 years
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
Tofu sheet is taken out piece by piece, arrange in the pan then sold as fresh tofu sheet |
Profile of Tofu Sheet Industry
Tofu sheet is a widely consumed food
in Malaysia, especially in Chinese as
well as vegetarian restaurants. There
are also many Malays who enjoy the
food. Tofu sheet is versatile and can
be prepared with vegetable, beef,
chicken or other dishes.
Tofu sheet comes in two forms, in
fresh or dry forms, in the market. The
raw material in tofu sheet production
is soy beans. The beans are soaked
overnight and ground into porridge.
Water and acetic acid are added to
the mixture. The mixture is heated
at a temperature between 60–70°C.
The sheet will form steadily on the
surface of the mixture. At a thickness
of 2 mm, the sheet is taken out and
drained. More tofu sheets will be
formed at the surface. However the
interval of the sheet formation gets
longer as the mixture gets less concentrated.
Stove is an important part of this industry
required to heat up the tofu
solution. Firewood is used as the fuel.
Saw dust, rice husk or agricultural
wastes are not used because they
produce too much smoke and dust
which will affect the quality of the tofu
sheet.
Scale of Industry
Cottage industry with 3 laborers. The
space required is about (6×18)m for
the boiling room with 10 stoves; and
a (6×6)m space is required for washing
and grinding.
Fuel Type
Fuel wood
Size of Stove
(370 × 120 × 60) cm; a long single
fire hole
Stove Makers
Masons; locally available
Stove Materials
Body:
Chimney:
Total cost per stove: 300 RM
Stove Utensils
Stove/Industry Capacity
On average 25 kg of soy bean can
be processed per stove in a day.
Cooking is carried out continuously
for 12 hours per day. 25 kg of soy bean could yield about 17 kg of dried
tofu sheet. The producer has 10 operating
stoves and on average 250
kg of soy bean can be processed
per day.
Tofu sheets are hanged for air dried; sold as dried tofu sheet
Fuel Consumption
Each stove require 0.5 m3 of wood
to process 25 kg of soy bean in a
day.
Financial Calculation
Expenditures | ||
Soy bean | = RM | 388 |
Fire wood | = RM | 170 |
Labor 3 persons @ 20 RM/person/day | = RM | 60 |
Rent/Power/Depreciation/Misc. | = RM | 25 |
TOTAL EXPENDITURES | = RM | 643 |
Income: | ||
175 kg of tofu sheet @ 4 RM/kg | = RM | 700 |
Profit/day: | = RM | 57 |
Exchange rate: US $ 1 = 3.79 RM |
Stove Operation
Soy which has been soaked overnight
is ground into porridge. 250 liter of
water is added to 25 kg of soy porridge.
Acetic acid is added next and
the mixture is stirred till all parts obtain
uniform viscosity. The stoves are
lit at about 6 o'clock in the morning.
The soy mixture is then heated to a constant temperature of 60–70°C. Tofu sheet will be formed at the surface of the mixture and will get thicker with time. When the sheet reaches certain thickness (± 2 mm), it is then sliced and drained. More tofu sheets will be formed, each formation stage will take longer as the mixture gets less concentrated. The stove is doused in the late afternoon at about 17.00 hours. The leftover mixture is thrown away.
Ergonomic
The process of tofu making does not
require the lifting of heavy loads.
Stove Maintenance
There is no significant damage during
the stove lifetime of more than 4
years. Small cracks could be repaired
using clay or mud mix with ash.
Stove Durability
About 10 years
Loading fuel wood
Flow Chart of Stove Operation