CPA in Cupcake Processing

[Type text] CLEANER PRODUCTION ASSESSMENTOF Dr. A.
Culaba
A CUPCAKE PRODUCTION LINE 2nd Term

2010
Introduction
Cleaner Production is defined as the continuous application of an integrated, preventive,

environmental strategy applied to processes, products, and services to increase overall
efficiency and reduce risks to humans and the environment. It is different to the traditional
‘pollution control’ approach to environmental management. Where pollution control is an after-
the-event, ‘react and treat’ approach, Cleaner Production is a proactive, ‘anticipate and prevent’
philosophy (COWI Consulting Engineers and Planners AS).
Cleaner Production has most commonly been applied to production processes, by bringing
about the conservation of resources, the elimination of toxic raw materials, and the reduction of
wastes and emissions. However it can also be applied throughout the life cycle of a product,
from the initial design phase, through to the consumption and disposal phase. Techniques for
implementing Cleaner Production include improved housekeeping practices, process
optimization, raw material substitution, new technology or new product design (COWI
Consulting Engineers and planners AS).
Cleaner Production assessment
A Cleaner Production assessment is a methodology for identifying areas of inefficient use of

resources and poor management of wastes, by focusing on the environmental aspects and thus
the impacts of industrial processes for developing Cleaner production options.
Phase I: Planning and Organization
1. Management Commitment
As part of the company’s mission statement:

Villarosa, J., Buena, J. Page 1
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“In conducting business, we will work to maintain close relations with all our partners and
suppliers. We will be a steadfast in the search for better technology and better opportunities.”
The company is aiming to be on top in the industry that uses the state of the art technology that
would enhance its production rate, increase the efficiency of the resources, and boost the
morale of the employees while continuing to be an environmental friendly food producing
company.
2. Project team
The project team is composed of two mechanical engineers with the support of a chemical
engineer and an industrial engineer of the plant.
3. Environmental policy, objectives and targets
Environment Policy
The company has no formal environmental policy. However, in search for better technology, the
company’s guidelines focus on how to maximize their resources and how to reduce wastes and
emissions.
Objectives and targets
General Objectives:
This cleaner production assessment (CPA) aims to minimize the waste generation and pollution
emission in a cup-cake producing company.
Targets:

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1. To eliminate or minimize oil leak in gear-motors and thermal-oil system by maintaining

excellent working condition for all equipment and practicing good housekeeping.
2. To identify faulty design of the equipment that would contaminate the product and
correct unsafe practices in accordance to food safety and environmental aspect.
3. To check the flue gas emission of the oil heater and steam boiler in compliance with the
Department of Environment and Natural Resources (DENR) standards.
4. Plan the cleaner production assessment
The project team decided to focus on the largest cup-cake producing line of the company.
Since this is the production line that uses most of the raw materials, it has the most number
of mechanical, electrical and electronics wastes generated, it houses the biggest thermal oil
system of the company. The following steps were decided upon:
Week Week Week Week Week Week Week Week Week Week
Activity 1 2 3 4 5 6 7 8 9 10
Ocular Visit
Obtain Company
commitment
Obtain a company
organizational chart,
Mission-Vision
Obtain process flow chart
of each production lines
Obtain a focus
Determine the process
description

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Determine technical
specification of machine
used
Collection of qualitative
data
Material Balance
Identify cleaner production
opportunities
Evaluate CP options
Select Viable Options
Phase II – Pre-assessment
II.1 Company Description
The Company Logo
Lemon Square is one of the top Filipino brands that were given the prestigious Superbrands
Award by the Superbrands Asia organization.
Lemon Square has been accorded this distinction thrice since 2004 in recognition of the
company's formidable success in marketing and brand-building.

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Over the years, Lemon Square products have become staples in Filipino meriendas, parties,
picnics and other special occasions. Filipino kids love to have Lemon Square goodies in their
lunch boxes. Parents regularly take home Lemon Square cakes and pastries as pasalubong.
Lemon Square's owner Dulce had always dreamed of producing the best-tasting and the
highest-quality cupcakes in the Philippines, and to make these available to millions of Filipinos
at a very reasonable price.
Lemon Square had its humble beginnings in 1985 when it started to offer local communities a
small selection of homemade-style baked goods. Then newly-married Dulce began baking
cakes to sell to her friends. Word-of-mouth soon became the primary driving force for her cakes
as demand went through the roof.
She and her husband Errol soon had to buy more cake-making machines, hire more people,
increase production and enhance its variety to keep up with demand and to cater to the
preferences of the market.
In 1991, Lemon Square had to build a larger building to accommodate its booming operation.
In 1995, Lemon Square had to thoroughly modernize its operations to keep up with the times. It
did so by acquiring a state-of-the-art baking system that enhanced its production and efficiency.
Lemon Square also adopted the latest packaging techniques used by bakers the world over.
II.2 Organizational Chart

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Please see appendix.
II.3 Walk-Through Inspection
The company has a four-storey production building. Situated in the ground floor are
receiving area, warehouse, and dispatching area. Also, located in the ground floor are
the pre-mix sections where the raw ingredients for different production lines are pre-
weigh. On the second floor, four different production lines are installed. On the third floor
of the building is situated the biggest production line of the company. While on the fourth
floor is located the production line intended for reprocess products.
During the walk-in inspection, listed below are the observation taken.
1. Poor Housekeeping. The strainer that should be installed in the drainage system
was left on top of the motor housing.

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2. Material loss due to leak and emission. The black portion in the oil heating
chamber is the result of the soot that comes out from the leak on the chamber.
3. Material storage. Pre-weighed raw materials for producing cupcakes are stored in
an air-conditioned room. Next to it is the mixing room where these ingredients are
mixed.

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4. Waste and emission from process equipment. Products on the floor caused by
missed pick-up of the robot will be considered as reject.

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5. Emergency Equipment. Fire-extinguishers are placed in a strategic location where

everyone can see and has an easy access. Every fire-extinguisher is labeled just
above the located where it is visible.
II.4 Establish a focus
For a food manufacturing company, the main environmental issues are the high consumption of
energy and high volume of effluent.

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Based on the figures, we decided to have our cleaner production assessment on line 5
production area which is the cupcake frostings production line. The line has the most number of
machines and consumes the largest energy resources of the company. It is the biggest
production line of the company that generates significant volume of effluent containing high
organic.. also, it has the highest consumption of gear-oil for gearbox and thermal oil for heat
transfer wherein if not manage correctly would create significant effect to the environment.
II. 5 Process overview
A frosting is an excellent delicacy for us Filipinos who love sweet foods. It is composed of the
base cake that satisfies our hunger for soft and puffy cake. There’s the cream filling inside the
cake that determines the flavor of the frostings. And also, the chocolate coating of the cake that
indulge us to a heavenly sweet craving. Not also to forget the crisp and sweet taste of candy
through the vermicelli sprinkled on top of the frosting.
Usually the processes involve in making cupcake frostings are mixing, aerating, depositing,
baking, cream injection, chocolate depositing, and cooling of the chocolate coating.

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Fig1. Product flow diagram of Cupcake Frosting
All the ingredients are pre-weighed and set ready for each batter premix batch. These
ingredients are feed into the pre-mixer at a predefined mixing rate and sequence. Once the
batch is pre-mixed, the transport pump will automatically pump the whole batch into the buffer
tank. Underneath the buffer tank is the main pump that transfer cake batter to mixing head to
undergo aeration process. The aerated mixture (slurry) is then deposited in a baking cup with
the right amount of volume and density. It is then baked in an oven at a predetermined
temperature and cooled down for certain time (25minutes) before the cream filling is injected. A
melted chocolate is then deposited on top of the base cake and sprinkles with vermicelli (crispy
candy) to add more pleasure for the taste as well as for the eyes. The frosting is then chilled at
a low temperature to crystallize the chocolate topping.

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Fig 2. Process flow of Cupcake Frosting production
Slurry Mixing Process (Pre-mixer Tank)
All the ingredients will be pre-weighed and set ready for handling at each batter premix batch.
After starting the pre-mixer, all the ingredients will be manually fed into the pre-mixer at a rate
and sequence as required for the specific recipe.
Once the batch is pre-mixed the valve underneath the tank will open automatically and the
transport pump will start. The transport pump will pump the whole batch into the buffer tank and
stops automatically if an empty signal is received from the pre-mixer. Now the valve underneath
the pre-mixer will close again and a signal is given “pre-mixer ready for next batch”.

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Process description : This tank has been designed to plasticize and mix different
creams, consisting of fat (liquid fat or fat blocks with a temperature
of 20 degrees) which have to be mixed homogeneously with dry
ingredients, to a paste like consistency. The different ingredients
can be added manually or automatically depending on the design.
Buffer Tank
In the buffer tank the cream is kept in motion to avoid sacking of ingredients thus maintaining a
homogeneous mass throughout the production. Directly underneath the buffer tank the main
pump is placed which will pump the cream at the required capacity through the mixing head.
Process description : This tank has been designed for buffering of viscous products to
be able to go from intermittent to a continuous process. The
stirring avoids sinking of heaving ingredients. The stirring work
also has a light mixing function. However, the stirrer has not been
designed to mix different ingredients. Depending on the design the
tank can filled manually or automatically.
The Aerator
The aerator has been designed for mixing foaming products. The air, synchronized with the
main pump, is injected into the mixing head at a rate as set from the control panel. In the mixing
head the pins of both the rotor and the stator see to it that the air is homogeneously mixed with
the slurry down to the required density and structure. The cutting action of the pins of the stator
and the rotor ensure a regular distribution of air or another gas in the product.
The air/gas dosing system has been designed to reduce the density of products by injecting air
or gas. The air/gas dosing system is to be used for this purpose. The mixing head pressure is
controlled, irrespective of the length and diameter of the discharge pipe, by the mixinghead

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pressure regulator. From the mixing head the aerated cake is discharged towards the slurry
depositor.
Depositor
From the hopper (1), the product will be deposited

through the piston (2) and the nozzles (3). The volume
that will be deposited depends on the hit length of the
pistons (B).
Due to the spring mechanism in the nozzles, the out

flow will be closed after the deposit hit. This way
leaking will be prevented.
With the sensor there will be checked if there is

enough slurry in the hopper. The head of the unit can
move up and down with the transport system.
Fig 3. Section view of the slurry depositor
Oven-Thermal heating system
The system consists of two basic circuits entitled Primary and Secondary. The Primary circuit
feeds two separate secondary circuits, one servicing the Thermal Oven heating plates, and one
servicing the Pan Wash Unit water-heating requirements.
Primary

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Thermal oil is re-circulated around the primary side of the system by the primary re-circulation
pump. Oil; returning from the secondary circuit manifold is transferred via the primary pump to a
heat exchanger. A gas burner mounted to the heat exchanger maintains primary oil temperature
at a pre-determined set point en-route to the secondary circuit/s, thus completing the cycle.
Secondary circuit manifolds, pumps and control valves are situated in a cabinet/s adjacent to
the oven and pan wash.
As the thermal oil heats up and cools down during normal production phases it is allowed to
expand and contract accordingly via a system of tanks and expansion lines. A drain tank and
pump allows for overflow from the expansion tank to be contained and re-introduced into the
system should replenishment of thermal oil be required. The draining tank and pump is also
used during initial filling and priming of the system.
Secondary, Oven Heating (Zone 1 to 4)
The oven is heated by re-circulated hot thermal oil pumped continuously through heat exchange
plates mounted within the oven chamber. The layers of heat exchange plates in the oven are
divided into four separate zones of heating. The four separating zones are each serviced by an
individual secondary circuit pump which re-circulates thermal oil through respective radiator
plates. The radiator plates, located below the pan pass on each level, enable a rising bottom
heat transfer ideally suited for muffin and cake products. An extra plate above the last (top) pan
pass in the 4th zone has the ability to influence the final bake top color.
Thermal oil in the radiator plates is maintained at a set temperature via independently controlled
Baelz modulating valves, which mix incoming “hot” oil from the primary circuit supply line with
existing “cold” oil from the secondary circuits. These valves which are incorporated into the

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secondary circuit govern the mix ratio between hot primary oil and re-circulated secondary oil,
depending on heat loads and selected zone temperatures. Thermocouple sensors are installed
at strategic points along the primary and secondary loops which feedback oil temperature
information to the PLC. As primary oil temperature varies due to heat loads, an on-board PLC
initiates the primary circuit burner to fire, maintaining temperature within an acceptable range.
Likewise, the secondary circuit temperatures are held at set points by PLC initiation of electric
actuators mounted directly to the modulating valves. Each zone has its own Baelz modulating
valve.
Adapted from Autobake Serpentine Thermal baking oven “Operation and Maintenance Manual”
Fig 4. Process flow of the Thermal Oil System
Cream Injector

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From the hopper (1), the product will be deposited

through the piston (2) and the needles (3). The
volume that will be deposited depends on the hit
length of the pistons.
Due to the spring mechanism in the nozzles, the

out flow will be closed after the deposit hit. This
way leaking will be prevented. With the sensor
there will be checked if there is enough cream in
the hopper. The head of the unit can move up and
down with the transport system.
Fig.5 Section view of the Cream Injector
Cream Processing
Application : Cream and Mallow

Production capacity : Min. 200 kg/hr. and max. 500 kg/hr.
Incoming density : 1.1 kg/ltr. (depending on product)
Outgoing density : 0.7-0.8 kg/ltr. (depending on product)
Process description
The process starts with the open bath cooker. This cooker will be manually fed with ingredients.
After cooking the batch is dumped into the cooling tank. When the slurry has been mixed and
the correct temperature has been reached it will be pumped towards the premixer or buffer tank,
depending on the product which will be produced (Cream or Mallow).
After starting the pre-mixer, all the ingredients will be manually fed into the pre-mixer at a rate
and sequence as required for the specific recipe.

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Once the batch is pre-mixed the valve underneath the tank will open automatically and the
transport pump will start. The transport pump will pump the whole batch into the buffer tank and
stops automatically if an empty signal is received from the pre-mixer. Now the valve underneath
the pre-mixer will close again and a signal is given “pre-mixer ready for next batch”.
In the buffer tank the cream is kept in motion to avoid sacking of ingredients thus maintaining a
homogeneous mass throughout the production. Directly underneath the buffer tank the main
pump is placed which will pump the cream at the required capacity through the mixing head.
The air, synchronized with the main pump, is injected into the mixing head at a rate as set from
the control panel. In the mixing head the pins of both the rotor and the stator see to it that the air
is homogeneously mixed with the cream down to the required density and structure.
Fig 6. Process flow of Cream Processing

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The Pick-and-Place Robot
This robot transfers baked cupcake from the continuous tray to a conveyor system. The robot
has depanner which has needles designed to pick-up 75 cupcakes at a time. This place-and-
place sequence also helped the ease of production because it maintains the alignment of
cupcakes which is essential for the next processes.
Chocolate Depositor
The chocolate filling masses prepared by the cooking machine or tempers are fed into the tank
of the depositor head via a manifold distributor. Distribution of the compounds across the tank
width is thus automatic. The compound level in the tank is recorded by a filling level sensor.
The piston is operated volumetrically, i.e. a defined compound volume is dosed by the dosing
pistons from the mass hopper through the nozzle bed and the nozzles during each working
stroke.
The dosing pistons are driven by an eccentric shaft. The piston stroke can be set via the control
system by a servo drive simultaneously for all pistons. Individual adjustment of the pistons is
also available.
During the depositing process, the whole depositor head moves together with the transport belt.
This follow-up movement is transmitted to the depositor head via a programmable servo drive.
The follow-up movement is adapted to the speed of the transport belt.

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Fig 7. Overview of the Chocolate depositor
Cooling Tunnel
The air cooling tunnel serves to cool the warm bakery and sweet products which are transferred
from an upstream installation on to the transport conveyor of the cooling tunnel.
The LK-type air cooling tunnel is designed for cooling of all types of fat coatings as well as
cooling of pastry, praline or bar fillings. The bottom (contact cooling) and top cooling (convection
cooling) is achieved by cold air in least two cooling zones.

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Packaging System
The packaging system of the production line is a fully automated conveying system. It is
composed of a Product Distribution System (PDS) which distributes the individual rows out of
product flow and to the four packaging machines.
Continuous distribution of the product to the packaging machine is made possible through the
aligner, dumping system and the distribution units. Undistributed rows of product are recovered
through the recycling belt.
Fig 8. Product Distribution System with two Packaging Machines

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Table 1. Average weight of utilized raw materials for each cupcake frostings
Percentage of Finished
Weight (g) product
Finished product 35 100
Paper cups 0.1 0.2857
BaseCake 21 60.0000
Cream 4 11.4286
Chocolate 8 22.8571
Vermicelli 0.9 2.5714
Packaging Material 1 2.8571
Reject Processing
Feed mill
Rejected products, contaminated raw materials and faulty-mixture of raw materials are transfer
to other plant for feed mill processing. Every day there is a truck assigned to transport these
resources for feed mill.
Toasting
Products which are about to reach their shelf life (two weeks before expiration date) are return
to the factory as “back-order” (BO). These products are reprocess as toasted products and are
sold at lower prices through “in-house sale”.

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Other products such as under-baked over-baked but not burnt and trimmings are reprocessed
as toasted products.
II.6 Environmental Aspects
As for many other food processing operations, the main environmental aspects associated with
cupcake processing activities are the high consumption of water, the discharge of effluent with
high organic loads and the consumption of energy.
Water Consumption
Cupcake processing characteristically requires very large quantities of fresh water. Water is used
primarily for cleaning process equipment and work areas to maintain hygiene standards. Production
facilities like chillers, boilers and air compressors use water for their cooling system.
Table 2 shows the water consumption of each machine in a typical Clean-In-Place of the production area.
It gives an indication of the extent to which each area contributes to overall water use.
Table 2. Consumption of cleaning water for the CIP of the production line
Mixing tank 4400 kg

Depositing 750 kg
Cream mixing tank 2400 kg
Cream Injector 800 kg
Chocolate
depositor 50 kg
Packaging 25 kg
Effluent Discharge
The dominant environmental aspect caused by cupcake processing is the discharge of large quantities of
liquid effluent. Cupcake processing effluents generally have high organic load due to the presence of milk

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components. They exhibit fluctuations in pH due to the presence of caustic and acidic cleaning agents
and other chemicals. Figure 9 shows percentage of the effluent generated by each process.
Fig 9. Waste water generation in cupcake frosting production

Energy Consumption
Energy is used at cupcake processing plants for running electric motors on process equipment, for
heating, evaporating and drying, for cooling and refrigeration, and for the generation of compressed air.
Thermal energy, in the form of steam, is used for heating and cleaning.
Approximately 50 percent of electrical consumption of the plant are generated for cooling the
water needed in the process and ventilation and refrigeration.

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Fig 10. Electrical Consumption of Process Equipment
Table 3. Actual wattage of Process Equipment

watt 7.621 kwh
Mixer 7621 s
watt 8.231 kwh
Aerator 8231 s
watt 11.523
Slurry Depositor 11523 s kwh
watt 36.581
Baking (Oven) 36581 s kwh
watt 11.584
Cream Injector 11584 s kwh
watt 12.194
Chocolate Depositor 12194 s kwh
watt 24.387
Cooling 24387 s kwh
watt 24.387
Packaging 24387 s kwh
watt 15.242
Burner 15242 s kwh

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watt 78.497
Chiller 78497 s kwh
watt 70.113
ACCU 70113 s kwh
Solid Waste
Raw materials for cupcake production like flour, skimmed milk, whey, and cocoa powder are
packed in multi-layered craft paper sack. Liquid raw materials are delivered in pails and plastic
containers.
Pre-weight raw materials for processing are packed in individual plastic as ready for batch. Final
product, cupcake frostings are individually packed in a fully automated packaging machine.
Low-density polypropylene is used for packaging the product. Packaging mistakes cannot be
totally avoided. Improperly packaged product can often be returned for reprocessing; however
the packaging material is generally discarded.
Emission to air
Emissions to air from cupcake processing plants are caused by the high levels of energy
consumption necessary for production. Hot water, which is generally used in jacket pipe of
chocolate and for cleaning of equipment, is generally produced in on-site boilers, and electricity
used for cooling and equipment operation is purchased from the grid. Thermal oil system of the
oven is heated using a burner which utilizes diesel as fuel.
Air pollutants, including oxides of nitrogen and sulfur and suspended particulate matter, are
formed from the combustion of fossil fuels, which are used to produce both these energy
sources.
Refrigerant

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Old refrigeration systems based on chlorofluorocarbons (CFCs), the fugitive loss of these gases to the
atmosphere is an important environmental consideration, since CFCs are recognized to be a cause of
ozone depletion in the atmosphere. For such operations, the replacement of CFC-based systems with
non- or reduced-CFC systems is thus an important issue.
Hazardous waste
Hazardous wastes consist of oily sludge from gearboxes of moving machines, laboratory waste, cooling
agents, oily paper filters, batteries, paint cans etc. Preventive maintenance program of the process
equipment requires monthly lubrication for reliable operation. Both unplanned and planned replacement of
gearbox parts requires replacement of gear-oil once the gearbox is exposed and contaminated. Table 4
shows the average consumption of these lubricants per year.
During repair works of the thermal oil system of the oven, thermal oil at the lowest part of the pipes are
drained. This drained oil even if it goes to the drain pan cannot be introduced again to the system. They
are considered contaminated.
Table 4. Average annual consumption of lubricants
Liters of lubricant
(gear-oil, grease, Percenta
Machine chain oil) ge %
Mixing motor 16 2.83
Transport
pump 6 1.06
Buffer Tank 12 2.12
Transport
pump 6 1.06
Aerator 20 3.53
Depositor 2 0.35
Oven 404 71.38
Injector 2 0.35
Robot 50 8.83
Packaging 48 8.48
Phase III – Assessment

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III. 1 Material Balance
1. Mixing and product transfer (Slurry and Cream)
All the pre-weight ingredients for each batch (slurry and cream) are manually dump
into the pre-mixing tank. It is then mixed at a pre-set time, rate of spin and sequence.
The motor with installed gearbox that is located at the bottom of the tank mixes the
first set of ingredients at low speed and pre-defined time. After the first sequence, the
remaining ingredients are dumped into the tank and mix for a predefined time at a
faster speed of mixing. This switching of speed is occurring simultaneously through
the aid of the PLC and the frequency converter installed.
Once the batch is pre-mixed the transport pump automatically transfer the product in
a buffer tank at a synchronous speed. This is possible because of the stator design
that maintains the accurately the pre-set speed of the pump.
a. Inputs-outputs

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Fig. Inputs and outputs of Mixing process
b. Environmental issue
Water is used in cleaning and sanitizing the mixing tank, buffer tank and transfer lines.
The resulting effluent from cleaning and rinsing contains pre-mixed product and cleaning
agents which has high organic load.
c. Cleaner production opportunities
Cleaner production opportunities related to this area are related to reducing the amount
of pre-mixed product that stays in the mixing tank, buffer tank and transfer lines. Ways of
achieving this includes:

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• Collecting the remaining product along the sides of the tanks
• Using compressed air to push the remaining product in the pipeline for recovery
2. Aeration – The pre-mixed product from the buffer tank is injected with clean
compressed air to reduce the density of the product. The air, synchronized with the
main pump, is injected into the mixing head at a pre-defined rate. In the mixing head
the pins of both the rotor and the stator see to it that the air is homogeneously mixed
with the slurry down to the required density and structure. The mixing head is double
walled wherein cooling water continuously stabilized the foaming of the product.
a. Inputs-outputs

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The main environmental issue associated with aeration of the slurry is the high level s of
energy consumed for cooling the slurry as well as the generation of compressed air for
air injection.
In addition, machine components like pump and mixing stator, silicon hose and electrical
components are damaged because of faulty operation and poor maintenance.
Cleaner production opportunities in this area focus on improving energy efficiency. Ways
of achieving this includes:
• Installation of a centralized chilled water system for the whole plant and
the existing chiller will only be used as back-up chiller especially during
summer season.
• Replacement of old piping insulation of the chilled water pipeline
• Routine check and replacement of mixing head jacket
• Execute routine maintenance of machines and comply with standard

operating procedures
3. Slurry and cream depositing
Slurry and cream depositor are two different machines; however they have the same
operating concept. Before the slurry/cream is transported to the hopper the density of
the slurry/cream must be determined first. After obtaining the correct density, the
hopper will be filled with slurry/cream and ready for depositing.

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After the operation, the slurry and cream depositor are detached from the production
line and transferred to the washing area for cleaning and sanitizing. Hot water
around 60C is utilized in cleaning and sanitizing. The hose that is connected in the
hot water line is being covered with a finger at the end to increase the pressure of
the water.
a. Inputs-outputs
The environmental issue specific for the depositing process is the large volume of hot
water for the cleaning and sanitizing the hopper and the depositing mechanism.
The hose used should have a pressurized gun installed at the end to increase the
pressure of the hot water to reduce the consumption of hot water.

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4. Baking (Thermal oil Oven)
The oven is operating at 300°C through a thermal oil system which has a primary
and secondary oil circuit. The thermal oil used was changed from synthetic oil to
mineral-based thermal oil due to price variation.
The oven consists of four (4) different zones where individual temperatures can be
assigned and dynamically modulated by the motorized control valve. The hot air
circuit is being maintained by the fresh-exhaust air system. The exhaust air from the
oven is around 175°C.
a. Inputs-outputs
The specific environmental issue in baking process is the excess heat (175°C) that is
rejected to the environment.
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The hot air that the exhaust system of the oven introduces to the environment can be
a valuable resource for a heat-recovery system.
5. Cooling Tunnel
Melted chocolate generally crystallized at 20-30 degrees Celsius. For commercial

chocolate production, it is being chilled to a temperature of 5-10°C in a continuous
transport conveyor.
a. Inputs-outputs
The main environment issue associated with cooling of cupcake with chocolate coating
is the energy consumed for the chiller and the potential loss of refrigerant in the
atmosphere.

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Cleaner production opportunities in this area focus on improving the energy efficiency of
the chiller. Ways of achieving this includes:
• Ensuring that the insulation are undamaged
• Re-designing the air-conditioned space to a smaller space to utilize the

cold room as a pre-cooling system
• Undertaking regular maintenance of the refrigeration system
6. Packaging
Final product, cupcake frostings are individually packed in a fully automated

packaging machine. Low-density polypropylene is used for packaging the product.
An out-feed conveyor manages the distribution of the product for outer-packaging
(10pcs/pack) and simultaneously box for distribution.
a. Inputs-outputs

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The major waste from packaging of cupcake products are solid wastes, including
rejected cupcakes, machine cut cupcakes, and damaged packaging materials.
In addition there liquid discharges from cleaning of packaging machines, work surfaces
and conveyors.
All rejected cupcakes should be collected separately from other waste and either sold for
in-house sale at lower price or sold as animal feed.
Damaged packaging materials can be sold as scrap materials.
Liquid waste should be treated together with other effluent streams.
7. Ancilliary operations

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7.1 Compressed air
Air is compressed in a higher pressure by an air compressor and distributed

throughout the plant in a pressurized pipe. The compressor is driven by electricity and
cooled by air. The compressed air then passed to a desiccant dryer to eliminate
moisture in the air.
a. Inputs-outputs
Small holes that causes air leak in the compressed air system can lost significant
volume of compressed air. This results to a waste of electricity because the compressor
has to run more than is necessary.

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Air compressors are usually noisy causing serious risk of hearing damage to the workers
in the area.
Compressor oil is changed periodically. If the changed oil is not collected, re-used or
sold, it can cause serious pollution of soil and water.
It is very important to check the compressed air system frequently. The best time to
check the system is during no production to easily detect leaks.
Maintenance and keeping of accurate log-books will often help identify the accurate time
of changing compressor oil and eliminate unnecessary repairs.
7.2 Thermal oil System
The thermal oil system has generally two oil circuit, primary and secondary circuit.
The primary circuit is heated in the oil heater which uses fuel to heat the thermal oil.
The primary pump transports the heated thermal oil to the secondary circuit. In the
secondary circuit, five (5) pumps are individually transporting thermal oil to the plate
heat-exchanger of the oven in different zones. The thermal oils are re-circulated to
the primary circuit for reheating and ready to heat the oven again.
a. Inputs-outputs

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Inefficiencies of boilers or oil heaters lead to the waste of valuable fuel resources as well as
additional operating costs. Combustion of fuel oil results in emissions of carbon dioxide (CO2),
sulfur dioxide (SO2), nitrogen oxides (NOX) and polycyclic aromatic hydrocarbons (PAHs). Some
fuel oils contain 3–5% sulfur and result in sulfur dioxide emissions of 50–85 kg per 1000 liters of
fuel oil.
Sulfur dioxide converts to sulfuric acid in the atmosphere, resulting in the formation of acid rain.
Nitrogen oxides contribute to smog and can cause lung irritation. If the combustion is not
adjusted properly, and if the air-fuel ratio is too low, there are high emissions of soot from the
burners. Soot regularly contains PAHs that are carcinogenic. (UNEP, 1996)

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Thermal oil often spills during repair or maintenance of thermal oil system. When conducting
repair of pumps, about 10kg of thermal oil is wasted because of the volume that stays in the
pipe (4” diameter).
Instead of using fuel oil with high sulfur content, it is advantageous to change to a fuel oil with
low sulfur content (less than 1%). This increases the efficiency of the boiler and reduces sulfur
dioxide emissions.
It is essential to avoid oil spills and, if they occur, to clean them up properly and either reuse or
sell the oil. A procedure for handling oil and oil spills should be instituted and followed.
A recovery pipe that is installed in the lowest part of the pump system and connected to the oil
storage will minimize oil spills during maintenance work. Also, a filtration system for the thermal
oil will increase the thermal transfer efficiency and prolong the life of the thermal oil.
III. 2 Summary of identified Cleaner production Opportunities

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Problem type Problem description Cleaner Production Options
Wastewater CIP of Mixing tank of cream - Collecting the

and slurry and transfer remaining products
pipeline produces high that can be recovered
organic load because along the side of the
remaining products in the tank
pipelines and tanks goes with
- Using compressed air
the effluent
to push the remaining
product in the pipeline
for recovery
- The hose used should

Cleaning of depositor and
have a pressurized
Injector - Large volume of hot
gun installed at the
water for the cleaning and
end to increase the
sanitizing the hopper and the
pressure of the hot
depositing mechanism.
water to reduce the
consumption of hot
water.
Energy Consumption During aeration process, - Installation of a

chilled water is used to centralized chilled
stabilize the process. water system for the
Individual chillers are used for whole plant and the
each aerator. existing chiller will only
be used as back-up
chiller especially
during summer

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2010
season.
- Replacement of old
piping insulation of the
chilled water pipeline
- Routine check and

replacement of mixing
head jacket
- Re-designing the air-

conditioned space to a
The current cooling space is smaller space to utilize
not suitable for the existing the cold room as a pre-
systems since the cooling system
replacement of machine
Heat rejected to the In baking process, the excess The exhaust air from the oven
environment heat (175°C) that is rejected can be used in the proofing
to the environment can be a process (90C) of the dough for
good source for heat recovery the bread processing
system
Thermal oil spill When conducting repair of - A recovery pipe that is

pumps, about 10kg of thermal installed in the lowest
oil spill and wasted because part of the pump
of the volume that stays in the system and connected
pipe (4” diameter). to the oil storage will
minimize oil spills
during maintenance
work.
- A filtering system for

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2010
the thermal oil will

increase the thermal
transfer efficiency and
prolong the life of the
thermal oil.
Phase IV – Evaluation and Feasibility study
IV.1 Technical Evaluation
Wastewater
PROCESS Option Technical Evaluation
CIP of mixing tanks (cream Collecting the remaining The use of plastic scraper
and slurry) products that can be would not affect the quality of
recovered along the side of the product although it would
the tank by using a long take a longer time to finish the
plastic scraper CIP of the machine. The
recovered product can be
used for further process.
This option would not require

additional personnel to do the
job although supervision must
be taken to ensure the safety

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2010
of the personnel and machine

components like level sensor.
Using compressed air to push

the remaining product in the The injection of compressed
pipeline for recovery air in the product would not
affect the quality of the
product. Strategic location of
the input air should be located
to ensure effectiveness.
Proper handling of the
recovered product should be
observed to assure food
safety because the recovered
product can be re-processed.
This option would not require

additional personnel but a
proper training of the
operation must be taken.
Cleaning of Depositor and Install pressure gun at the end The installation of the
Injector of the hose used for cleaning pressure gun would not
the machine require specialized personnel
outside the company. The
technical personnel of the
company can do the job.
The pressure gun must not

corrode. It must be made from
brass, aluminum, stainless
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2010
and alike.
Energy Consumption
Process Options Technical Evaluation
Cooling process of Slurry and - Installation of a The installation of the

cream during aeration centralized chilled centralized system with a
water system for the back-up would ensure a
whole plant and the sufficient chilled water supply
existing chiller will only for the whole line, assuring a
be used as back-up stable aeration process even
chiller especially during summer season.
during summer
It would require the expertise
season.
of contractors in HVAC
- Replacement of old system and proper training of
piping insulation of the the personnel assigned to
chilled water pipeline operate the new system.
The piping insulation cladding

must be of aluminum/stainless
steel.
- Routine check and
Replacement of the mixing
replacement of mixing
head jacket would not affect
head jacket
the product or the process.
The replacement jacket must
always ensure food safety
requirements (Food grade

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2010
material).
Cooling of the processing Re-designing the air- Reducing the air conditioned
area. The current cooling conditioned space to a smaller space would not affect the
space is not suitable for the space to utilize the cold room process flow of the product. It
existing systems since the as a pre-cooling system would not restrict the
replacement of machine. movement of the personnel in
the processing area.
The conditioned air would not

contaminate the product since
the ductings to be installed are
made of stainless.
It would require the expertise

of contractors in HVAC
system and proper training of
the personnel assigned.
Recovery system
Process Options Technical Evaluation
Heat rejected by the oven The exhaust air (175C) from The option would not affect
exhaust to the Environment the oven can be used in the the process flow of the
proofing process (40C at product.
relative humidity of 70-80 %)
There is enough space for the
of the dough for the bread
installation of the heat
processing through the use of
exchanger system.
heat exchanger
The exhaust air (175C) is

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2010
enough to produce the

necessary heat of 40C.
This would require the

expertise of contractors in
heat pipe heat exchanger.
With the case study of

Buttercup Bakery in Australia,
they developed a heat pipe
heat exchanger with good
heat transfer characteristics,
compactness, no moving parts
and no cross-contamination
between fluid streams.
Oil spill during repair works - A recovery pipe that is The recovery pipe will not
installed in the lowest affect the process flow of the
part of the pump thermal oil system since it will
system and connected be closed during normal
to the oil storage will operation.
minimize oil spills
The installation would require
during maintenance
the expertise of contractors in
work.
piping system.
The installation might require

a shut-down of the operation
to isolate the thermal oil in the
installation spot.
The filtering system will not

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2010
affect the process flow of the

- A filtering system for thermal oil system since it is
the thermal oil will installed in the storage tank. A
maintain the thermal portion of the system where
transfer efficiency and there is not much activity.
prolong the life of the
The installation will be done
thermal oil.
during the total change oil
period of the system.
There is enough space for the

additional system.
The installation will require the

expertise of contractors in oil
piping system, filter tank and
proper training on the new
system.
IV.2 Economic Evaluation
Wastewater
Payback
Process Option Investment Benefit peroid
Collecting the remaining Fabrication of
products that can be long scraper 10 kg of
recovered along the side made of recovered
CIP of mixing tanks of the tank by using a plastic = Php product = Php Less than a
(cream and slurry) long plastic scraper 2000 500 month

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2010
Fifty percent
savings of hot
water
consumption
Using compressed air to Installation of 20kg of
push the remaining compressed recovered
product in the pipeline for air line = Php product = Php Less than two
recovery 3000 1000 months
Cost of Fifty percent
compressed savings of hot
air per CIP = water
Php 124.00 consumption
Cleaning of Install pressure gun at 75 percent
Depositor and the end of the hose used savings in hot
Injector for cleaning the machine water
Pressure gun consumption Less than 1
= Php 800 for cleaning week
Energy Consumption
Payback
Process Option Investment Benefit peroid
Cooling process of Installation of a A centralized 30 percent
Slurry and cream centralized chilled water chilled water savings on
during aeration system for the whole system for the energy
plant and the existing 3 aerators consumption
chiller will only be used chilled water including
as back-up chiller system would electricity,
especially during cost Php refrigerant,
summer season. 1,500,000 of water

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2010
Replacement of old labor and

consumption
piping insulation of the materials
and
chilled water pipeline including the
consumables
new unit
- Routine check and Fabrication of
replacement of mixing a replacement
head jacket mixing head
jacket = Php
1,800
Cooling of the Cost of labor
processing area. and materials
The current cooling Re-designing the air- for the re-
50 percent
space is not conditioned space to a location of the
savings on
suitable for the smaller space to utilize ACU, re-sizing
energy
existing systems the cold room as a pre- of air-
consumption
since the cooling system conditioned
replacement of space = Php
machine. 300 000
Recovery System
Process Option Investment Benefit Payback period

Heat rejected to The exhaust air from the oven Installation of Replacing the If the company
the environment can be used in the proofing heat pipe heat water heater would just
process (90C) of the dough for exchanger = (8pcs) to operate for 8
the bread processing Php 500,000 generate heat hours per day,
in the the payback
proofing area period would be
would save as long as
Php 11years
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2010
45,000/year
Oil spill during Installation of Eliminate the

repair works recovery piping oil spill during
A recovery pipe that is installed system would repair works
in the lowest part of the pump cost Php 30,000 that nearly
system and connected to the oil cost Php
storage will minimize oil spills 4,500 every
during maintenance work. repair work.
A filtering system for the thermal Installation of
oil will maintain the thermal filtering system
transfer efficiency and prolong would cost Php
the life of the thermal oil. 50,000
Thermal Initial cost Operating Years - Cost Total Cost

Oil Therm Investm
System al oil ent 1 2 3 4 5 6 7 8 9 10
Filtered 990 37700
oil 99000 80000 0 0 0 0 00 0 0 0 0 99000 0
Un-
filtered 990 990 9900 39600
oil 99000 0 0 00 0 0 00 0 0 0 0 0
IV. 3 Environmental Evaluation
Waste Water
Environmental Evaluation
Process Option
Positive Negative

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2010
CIP of Mixing tank of

cream and slurry and Reduce the amount of
transfer pipeline organic load by almost
Collecting the remaining
produces high organic 50%
products that can be
load because
recovered along the side of
remaining products in
the tank
the pipelines and
tanks goes with the
effluent
Reduce hot water Minimal
consumption by 50% increase in
therefore saving energy the operating
Using compressed air to push cost for
the remaining product in the compressed
pipeline for recovery air
The hose used should have a
pressurized gun installed at
Cleaning of Slurry Reduce in the
the end to increase the
Depositor and Cream consumption of hot
pressure of the hot water to
Injector water up to 75%
reduce the consumption of
hot water.
Energy Consumption
Process Option Environmental Evaluation
Positive Negative
During aeration process, Installation of a centralized
chilled water is used to chilled water system for the Reduction of refrigerant
stabilize the process. whole plant and the existing emission to air by 33%.
Individual chillers are chiller will only be used as (From 3 chillers (R22) to
used for each aerator. back-up chiller especially one chiller-R134a)
during summer season.
Replacement of old piping

insulation of the chilled water Reduction in energy Generate
pipeline consumption solid waste
Routine check and
replacement of mixing head Reduction in energy Generate
jacket consumption solid waste

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2010
Re-designing the air- Refrigerant

conditioned space to a emission
The current cooling space
smaller space to utilize the (R22) when
is not suitable for the Reduction of energy
cold room as a pre-cooling discharging
existing systems since the consumption
system refrigerant as
replacement of machine
needed for
installation
Recovery System
Environmental Evaluation
Process Option
Positive Negative
The exhaust air (175C) from

the oven can be used in the Reduction of heat in the
Heat rejected by the oven proofing process (40C at environment by up to
exhaust to the relative humidity of 70-80 %) 50%
Environment of the dough for the bread
processing through the use of
heat exchanger
Reduction of energy
consumption
Oil spill during repair A recovery pipe that is
works installed in the lowest part of
the pump system and Reduction of used oil
connected to the oil storage generation
will minimize oil spills during
maintenance work.
A filtering system for the
thermal oil will maintain the Extending the life span
thermal transfer efficiency of the thermal oil
and prolong the life of the therefore reducing
thermal oil. thermal oil usage

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2010
IV. 4 Select Viable options
Water Consumption
With the result of the comparative ranking analysis, it is recommended to practice first the
scraping of the remaining product on the side of the tank compared with the other options to
reduce water consumption. Obviously, the installation of pressure a gun at the end of the hose
would be very easy to implement and effective way to reduce water consumption, therefore, can
be done simultaneously.
Energy Consumption

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2010
The result of the comparative ranking analysis suggests that a routine check and in-time
replacement of mixing head jacket can be the initial action to reduce the energy consumption of
the factory. For major renovation, the installation of the centralized chilled water system is
suggested to be done.
Recovery System

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2010
For the suggested recovery systems, the installation of the filtering system of the thermal oil is
strongly suggested as the result of the comparative ranking analysis. Next to it, is the installation
of the recovery pipe from the drain port to the storage of the thermal to eliminate the spill during
repair works.
Using exhaust air for dough proofing got the lowest rank in the analysis. The main reasons for
having a low score are the high investment of the system and a low return of investment rate.
The breadline section which uses the dough proofing is only operating on an 8-hour operation
per day for 6days in a week.
Conclusion
Cleaner Production assessment (CPA) is an effective technique for reducing wastes and
effective use of resources without compromising the environmental aspects.

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2010
CPA in a cupcake producing company identifies that the main environmental issues are the high
energy consumption for the machineries and operations; and high volume of effluent generated
from cleaning of the machines. Reduction of energy consumption can be done through effective
maintenance of the machine to ensure high efficiency and reliability of the operation. Installing
appropriate recovery system saves the company a lot of resources through effective use and full
utilization.
High volume of effluent can be reduced effectively through an attitude change of the personnel
involve in the process. From the comparative ranking analysis, a simple act of removing the
remaining product that can be recovered from the system is the best way of reducing the water
consumption as well as the discharge of effluent.
References
COWI Consulting Engineers and Planners AS, 1992. Cleaner Production Opportunities in
Dairy Processing
COWI Consulting Engineers and Planners AS, 1992. Cleaner Production Opportunities in
Meat Processing
Recycling of hydraulic oil at a factory in the automotive industry.

Retrieved in www.cprac.og
Cleaner production in production of bakery and cake products. Retrieved in
www.cprac.org

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[Type text] CLEANER PRODUCTION ASSESSMENTOF Dr. A.

A CUPCAKE PRODUCTION LINE 2nd Term

Cleaner Production is defined as the continuous application of an integrated, preventive,

Cleaner Production assessment

A Cleaner Production assessment is a methodology for identifying areas of inefficient use of

Phase I: Planning and Organization

As part of the company’s mission statement:

A CUPCAKE PRODUCTION LINE 2nd Term

3. Environmental policy, objectives and targets

Objectives and targets

Villarosa, J., Buena, J. Page 2

A CUPCAKE PRODUCTION LINE 2nd Term

1. To eliminate or minimize oil leak in gear-motors and thermal-oil system by maintaining

4. Plan the cleaner production assessment

Villarosa, J., Buena, J. Page 3

A CUPCAKE PRODUCTION LINE 2nd Term

II.1 Company Description

The Company Logo

Villarosa, J., Buena, J. Page 4

A CUPCAKE PRODUCTION LINE 2nd Term

II.2 Organizational Chart

Villarosa, J., Buena, J. Page 5

A CUPCAKE PRODUCTION LINE 2nd Term

Please see appendix.

II.3 Walk-Through Inspection

Villarosa, J., Buena, J. Page 6

A CUPCAKE PRODUCTION LINE 2nd Term

Villarosa, J., Buena, J. Page 7

A CUPCAKE PRODUCTION LINE 2nd Term

Villarosa, J., Buena, J. Page 8

A CUPCAKE PRODUCTION LINE 2nd Term

5. Emergency Equipment. Fire-extinguishers are placed in a strategic location where

II.4 Establish a focus

Villarosa, J., Buena, J. Page 9

A CUPCAKE PRODUCTION LINE 2nd Term

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A CUPCAKE PRODUCTION LINE 2nd Term

II. 5 Process overview

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A CUPCAKE PRODUCTION LINE 2nd Term

Fig1. Product flow diagram of Cupcake Frosting

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A CUPCAKE PRODUCTION LINE 2nd Term

Fig 2. Process flow of Cupcake Frosting production

Slurry Mixing Process (Pre-mixer Tank)

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A CUPCAKE PRODUCTION LINE 2nd Term

Villarosa, J., Buena, J. Page 14

A CUPCAKE PRODUCTION LINE 2nd Term

From the hopper (1), the product will be deposited

Due to the spring mechanism in the nozzles, the out

With the sensor there will be checked if there is

Fig 3. Section view of the slurry depositor

Oven-Thermal heating system

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A CUPCAKE PRODUCTION LINE 2nd Term

Secondary, Oven Heating (Zone 1 to 4)

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A CUPCAKE PRODUCTION LINE 2nd Term

Fig 4. Process flow of the Thermal Oil System

Villarosa, J., Buena, J. Page 17

A CUPCAKE PRODUCTION LINE 2nd Term