United Nations Earth Summit+5 Success Stories - Cleaner production at a toddy distillery

EARTH SUMMIT+5
Special Session of the General Assembly to Review and Appraise
the Implementation of Agenda 21
New York, 23-27 June 1997
SUCCESS STORIES FROM ASIA AND THE PACIFIC

Cleaner production at a toddy distillery

Location Colombo, Sri Lanka

Responsible organization(s) Central Environment Authority in cooperation with Seeduwa Distillery, which is part of Distilleries Company of Sri Lanka Ltd., and the United Nations Industrial Development Organization (UNIDO).

Description The production of coconut arrack harnesses the natural formation of alcohol in the nectar of the coconut flower. In the traditional manner, toddy tappers climb the coconut trees to collect toddy in coconut plantations along the tropical shores of the India Ocean. Toddy is lowered to the ground, placed into traditional wooden barrels and transported to the distillery. The fermentation occurs due to naturally occurring yeasts that find their way into the toddy. By the time the toddy arrives at the distillery, the fermentation is complete.
At the distillery, toddy is stored until enough is gathered to feed in one of a range of stills depending on the quality and quantity of product required. Following distillation, the alcohol is aged in wooden vats to improve its flavour. Some high quality alcohol products require a double distillation. After, ageing the product is blended and filtered prior to bottling and sale.
The cleaner production initiative came at the time when the Seeduwa Distillery's owners were reflecting the most optimistic outlook for profits by improved production efficiency. A cleaner production study of the distillery and bottling hall highlighted the benefits of a number of potential changes, including improvements to the continuous French patent still, heat recovery from effluent and more efficient bottle washing. Soon after, the Seeduwa Distillery/UNIDO joint cleaner production project team analyzed the production process and prepared a survey of the equipment. A four-step approach was agreed upon to develop modifications and implement them without severely disturbing the production process:
* In the first phase, the operating practices and equipment were examined in detail. Designs were drawn up and implemented for upgrading the stainless steel still and optimizing its process parameters.
* In the second and third phases, the French patent still was further upgraded, including more new equipment.
* In the fourth phase, an effluent treatment facility was built. The biogas produced in this facility replaced part of the fuel.

Issues addressed The project has addressed issues, that caused some of the negative environmental effects.

Objectives By introducing cleaner production to the distillery: to attain more efficient production, to improve the quality of products; and to reduce energy costs, wastage and pollution.

Results achieved On the fuel savings of 22 per cent, which has also led to a similar reduction in SO2 and CO2 emissions, the distillery saved approximately US$ 25,000. Reductions of 95 per cent in alcohol loss to the drain saved US$ 34,000 worth of recovered alcohol, and reductions in breakage during bottling and loading saved US$ 22,600 annually. In addition, major quality improvements in the produced alcohol, which reduce the required ageing time by two years, will result in US$ 70,000 in savings on interest payments. By avoiding the breakage of bottles, both resource requirements in terms of glass and the volume of solid waste were also reduced.

Lessons learned The cleaner production audit had generated a number of options that showed potential economic benefits. These have been prioritized and incorporated in other projects.

Financing The United Nations Development Programme (UNDP) funds

Contact Mr. Grant Ramsay, Chemical Industries Branch,
UNIDO Vienna International Centre
P.O. Box 400 A-1400 Vienna Austria
Telephone: (+43 1) 21131 - 3774

Copyright © United Nations
Department of Economic and Social Affairs
Comments and suggestions: esa@un.org
1 November 1997

	Cleaner production at a toddy distillery
	Location	Colombo, Sri Lanka
	Responsible organization(s)	Central Environment Authority in cooperation with Seeduwa Distillery, which is part of Distilleries Company of Sri Lanka Ltd., and the United Nations Industrial Development Organization (UNIDO).
	Description	The production of coconut arrack harnesses the natural formation of alcohol in the nectar of the coconut flower. In the traditional manner, toddy tappers climb the coconut trees to collect toddy in coconut plantations along the tropical shores of the India Ocean. Toddy is lowered to the ground, placed into traditional wooden barrels and transported to the distillery. The fermentation occurs due to naturally occurring yeasts that find their way into the toddy. By the time the toddy arrives at the distillery, the fermentation is complete. At the distillery, toddy is stored until enough is gathered to feed in one of a range of stills depending on the quality and quantity of product required. Following distillation, the alcohol is aged in wooden vats to improve its flavour. Some high quality alcohol products require a double distillation. After, ageing the product is blended and filtered prior to bottling and sale. The cleaner production initiative came at the time when the Seeduwa Distillery's owners were reflecting the most optimistic outlook for profits by improved production efficiency. A cleaner production study of the distillery and bottling hall highlighted the benefits of a number of potential changes, including improvements to the continuous French patent still, heat recovery from effluent and more efficient bottle washing. Soon after, the Seeduwa Distillery/UNIDO joint cleaner production project team analyzed the production process and prepared a survey of the equipment. A four-step approach was agreed upon to develop modifications and implement them without severely disturbing the production process: * In the first phase, the operating practices and equipment were examined in detail. Designs were drawn up and implemented for upgrading the stainless steel still and optimizing its process parameters. * In the second and third phases, the French patent still was further upgraded, including more new equipment. * In the fourth phase, an effluent treatment facility was built. The biogas produced in this facility replaced part of the fuel.
	Issues addressed	The project has addressed issues, that caused some of the negative environmental effects.
	Objectives	By introducing cleaner production to the distillery: to attain more efficient production, to improve the quality of products; and to reduce energy costs, wastage and pollution.
	Results achieved	On the fuel savings of 22 per cent, which has also led to a similar reduction in SO2 and CO2 emissions, the distillery saved approximately US$ 25,000. Reductions of 95 per cent in alcohol loss to the drain saved US$ 34,000 worth of recovered alcohol, and reductions in breakage during bottling and loading saved US$ 22,600 annually. In addition, major quality improvements in the produced alcohol, which reduce the required ageing time by two years, will result in US$ 70,000 in savings on interest payments. By avoiding the breakage of bottles, both resource requirements in terms of glass and the volume of solid waste were also reduced.
	Lessons learned	The cleaner production audit had generated a number of options that showed potential economic benefits. These have been prioritized and incorporated in other projects.
	Financing	The United Nations Development Programme (UNDP) funds
	Contact	Mr. Grant Ramsay, Chemical Industries Branch, UNIDO Vienna International Centre P.O. Box 400 A-1400 Vienna Austria Telephone: (+43 1) 21131 - 3774