Industrial Institutional Food Non-Food
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
Stove Utensils
Stove/Industry capacity
5 kg ashmee/day
Fuel Consumption
0,25 square yard of wood/day
Typical of stove used in Ashmee industry
Financial Calculation
Expenditures | |||
Rice: 1.5 kg | = Rp. | 36 | |
Wheat four: 750 gr | = Rp. | 15 | |
Coconut oil: 3.5 bottles | = Rp. | 220 | |
Coconut: 1 pc | = Rp. | 13 | |
Salt | = Rp. | 20 | |
Coloring | = Rp. | 20 | |
Sugar: 3 kg | = Rp. | 90 | |
Fire wood | = Rp. | 25 | |
Labor | = Rp. | 160 | |
TOTAL COSTS | = Rp. | 580 | |
Income | |||
Ashmee: 5 kg | = Rp. | 750 | |
Profit/day | = Rp. | 70 | |
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
Industrial Institutional Food Non-Food
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
Stove Makers
Masons, trained people
Stove Materials
Foundation:
Body:
Chimney: (for oven)
Cost of stove: | |
Iron and metal sheets | :Rp. 50,000 |
Labor: | Rp. 10,000 |
Total cost: | Rp. 60,000 |
Stove Utensils
Stove/Industry capacity
72 loaves bread/baking
400 loaves bread/day (10 hours)
Financial Calculation
Expenditures | |||
Wheat Flour: 125 kg | = Rp. | 1,800 | |
Haiko: 1.5 kg | = Rp. | 100 | |
Yeast: 1 p kg | = Rp. | 100 | |
Sugar: 2.5 kg | = Rp. | 75 | |
Salt: 2 kg | = Rp. | 20 | |
Rice husks | = Rp. | 20 | |
Labor | = Rp. | 345 | |
Electricity | = Rp. | 20 | |
TOTAL COSTS | = Rp. | 2,480 | |
Income | |||
Bread: 400 loaves @ Rp. 7.50 | = Rp. | 3,000 | |
Profit/day | = Rp. | 520 | |
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
Industrial Institutional Food Non-Food
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:
Body:
Stove Utensils
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
Financial Calculation
Expenditures | |
Wheat Flour: 20 kg @ Rp. 19 | = Rp. 380 |
Peanuts: 5 kg | = Rp. 390 |
Grams: 1 kg | = Rp. 70 |
Salt | = Rp. 5 |
Coloring | = Rp. 12 |
Coconut oil | = Rp. 476 |
Labor | = Rp. 150 |
Selling expenditures | = Rp. 550 |
TOTAL COSTS | = Rp. 2,133 |
Income | |
Murukku | = Rp. 3,920 |
Profit/day | = Rp. 1,787 |
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.
Industrial Institutional Food Non-Food
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:
Body:
Stove Utensils
Stove/Industry capacity
65 kg or raw noodles can be boiled
at a time in each stove
Fuel Consumption
Financial Calculation
Expenditures | |
Wheat Flour: 1 gunny bag (65 kg) | = Rp. 1,850 |
Transport | = Rp. 50 |
0.25 yard of wood | = Rp. 50 |
Saw dust | = Rp. 25 |
Labor | = Rp. 650 |
Electricity | = Rp. 166 |
Water | = Rp. 17 |
TOTAL COSTS | = Rp. 2,808 |
Income | |
Noodles: 22 packets | = Rp. 7,820 |
Profit/day | = Rp. 5,012 |
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
Industrial Institutional Food Non-Food
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
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.
Financial Calculation
Expenditures | ||
Wood | =Rp. | 10 |
Labor: 2 people | =Rp. | 175 |
TOTAL COSTS | =Rp. | 185 |
Income | ||
Sweet toddy: 5 bottles @ Rp. 100 | =Rp. | 500 |
Profit/day | =Rp. | 315 |
Exchange rate: US $ 1 | =Rp. | 77.1 |
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
Industrial Institutional Food Non-Food
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:
Body:
Stove Utensils
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)
Financial Calculation
Expenditures | ||
Flour: 7 kg | = Rp. | 135 |
Salt: 350 gr | = Rp. | 3 |
Coconuts: 6 | = Rp. | 60 |
Sugar: 1 kg (or honey) | = Rp. | 30 |
Wood | = Rp. | 30 |
TOTAL COSTS | = Rp. | 258 |
Income | ||
String hoppers | = Rp. | 635 |
Profit/day | = Rp. | 377 |
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
Industrial Institutional Food Non-Food
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:
Body:
Chimney:
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
Financial Calculation
Expenditures | |
Milk powder: 6 kg @ Rp. 190 | = Rp. 960 |
Sugar: 9 kg @ Rp. 30 | = Rp. 270 |
Gelatin: 200 g | = Rp. 80 |
Culture for yoghurt | = Rp. 50 |
Coloring & condiments | = Rp. 25 |
Plastic containers | = Rp. 1,200 |
Labor: 2 people @ Rp. 100 | = Rp. 200 |
Electricity | = Rp. 30 |
Water | = Rp. 3 |
TOTAL | = Rp. 2,818 |
Expiry rate of whole production = 5% | |
5% of 800 containers | = 40 |
Cost of production of one yoghurt | = Rp. 3.52 |
Expiry rate of 800 containers: 40 × Rp. 3.52 | = Rp. 140 |
TOTAL COSTS: Rp.2,818+Rp. 140 | = Rp. 2.958 |
Income | |
Yoghurt: 800 containers @ Rp. 6.50 | = Rp. 5,200 |
Profit/day | = Rp. 2,242 |
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
Industrial Institutional Food Non-Food
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 :
Grate:
Cost per stove: 160.000 VND
Stove Utensils
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.
Financial Calculation
Expenditure : | |
Sugar cane 1.500 kg | = 200.000 |
VND | |
Coal 300 kg | = 80.000 |
VND | |
Labor: 4 persons | = 60.000 |
VND | |
Rent/Power/Depreciation/Misc. | = 10.000 |
VND | |
Total expenditure | = 350.000 |
VND | |
Income: | |
150 kg of cane sugar | = 525.000 |
VND | |
Profit/day | = 175.000 |
VND | |
Exchange rate: US $ 1 = 14.500 VND |
Stove Operation
The fire is started with the aid of kerosene
or twigs or dry leaves. Once the
fire starts, the wok 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 wok 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.
Fresh canes are pressed for the juice
Ergonomic
The wok 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.
Flow Chart of Stove Operation
Transferring the cane juice after pressing
Industrial Institutional Food Non-Food
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:
Body :
Grate:
Cost per stove: 1.015.000 VND
Exchange rate: US $ 1 =14.500 VND
Stove Utensils
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. 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.
Flow Chart of Stove Operation
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.
Industrial Institutional Food Non-Food
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 :
Body :
Grate :
Chimney :
Total cost per stove : 800.000 VND
Exchange rate: US $ 1 = 14.500 VND
Stove Utensils
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.
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
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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:
Body:
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.
Financial Calculation
Expenditures | |
Fresh tea leaves 50 kg | = 100.000 VND |
Wood | = 15.000 VND |
Labor | = 40.000 VND |
Rent/Power/Depreciation/Misc. | = 4.000 VND |
Total expenditures = 164.000 VND | |
Income | |
10 kg of dried tea @ 25.000 VND/kg | |
= 250.000 VND | |
Profit/day: | = 86.000 VND |
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.
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
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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:
Grate:
Total cost per stove: 35.000 VND
Stove Utensils
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.
Financial Calculation
Expenditures | |
Soy bean | = 120.000 VND |
Coal | = 4.800 VND |
Labor 2 persons | = 40.000 VND |
Rent/Power/Depreciation/Misc | = 3.000 VND |
Total expenditure | = 187.800 VND |
Income | |
400 pieces of tofu @ 500 VND each | |
= 200.000 VND | |
Profit/day | = 33.200 VND |
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.
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