PENERAPAN

KONSEP PRODUKSI BERSIH

ANAS M FAUZI
DEPARTEMEN TEKNOLOGI INDUSTRI PERTANIAN
FATETA IPB
 ? LIFE CYCLE

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BAHAN
PRODUK
BAKU

4 Basic concerns of ? agroindustrial enterprises

(1) efficiency
(2) quality
(3) convenience
(4) innovation
Industrial Sustainability
Industrial sustainability is the continuous innovation,
improvement and use of clean technology to reduce
pollution levels and consumption of resources (OECD)
Keywords : clean, efficient

In practical terms, Industrial sustainability means employing

Technology and know-how to:
- lessen material and energy input
- maximizing renewable resources and biodegradable substances as input
- minimizing pollutants during products manufacturing and use
- produce recyclable or biodegradable products
Eco-efficiency
Doing more with less – using environmental resources
more efficiently in economic processes (WBCSD)
‘Production value’ divided by ‘production of damage’
during a production step or over the whole production
of goods and services.
7 COMPONENTS
Reduce material intensity
Reduce energy intensity
Reduce toxin dispersion
Enhance material recyclability
Maximize sustainable use of renewable resourcs
Extend product durability
Increase the service intensity
Technologies that
(1) extract and use natural resources as efficient
as possible in all stage of their lives;
(2) generate products with reduced or no
potentially harmful components;
(3) minimize releases to air, water and soil
during fabrication and use of the product;
(4) produce durable products which can be
recovered or recycled as far as possible;
(5) are energy-efficient
Source: OECD (1995)
Pengukuran kuantitas limbah

• Kunjungan ke pabrik / lihat laporan

• Wawancara dengan kontraktor & pemasok
• Inspeksi on - site
• Pencatatan bahan baku dan produk
• Data pembuangandan pengolahan limbah
• Data di asosiasi industri
• Wawancara dengan staf inspektor/pejabat
pemda
• Survai
 WASTE MANAGEMENT HIERARCHY
SOURCE REDUCTION
POLLUTION WASTE
PREVENTION IN-PROCESS RECYCLING MINIMIZATION

OTHER RECYCLING

TREATMENT POLLUTION
CONTROL
DISPOSAL
 ZERO WASTE :
To maximize transformation of NPO to PO
 Industry tree
 Value added
 Industrial Networking (cluster approach)

To Reduce wastes to disposed of

 3R : Reduce, Reuse & Recycle

To improve process efficiency

 process technology, product durability
 house keeping (management)

The ultimate goal of cleaner production is zero waste

MEAT & BONE
UTILIZATION
KENDALA IMPLEMENTASI DI INDONESIA
(1) Subsidi terhadap harga energi dan bahan baku
---> kurang mendorong upaya efisiensi dan
minimisasi limbah

(2) Terbatasnya informasi dan ketersediaan fasilitas

kredit komersial untuk investasi produksi bersih

(3) Sebagian besar merupakan IKM

(sekitar 88 % di Indonesia)

(4) Terbatasnya akses informasi terhadap BAT

(best available technology) untuk produksi bersih
----> perlu networking
KENDALA
Finansial (30%)
Teknis (10%)
ketersediaan, ketrampilan & pengalaman

Politis (60%)
organisasi, peraturan
KENDALA POLITIS
Kurang berani mengambil resiko penerapan inovasi (unproven)
Komitmen perusahaan terhadap lingkungan kurang
Penegakan hukum lemah

KENDALA EKONOMI & FINANSIAL

Umumnya industri sudah dilengkapi dengan fasilitas EOP
Investasi jangka pendek lebih disukai oleh industri
Intangible benefits (tidak kuantitatif) kurang dihargai

KENDALA TEKNIS
Diseminasi teknologi (BAT) secara rinci
Biaya transfer teknologi
Ketrampilan SDM
Policy tools and instruments :
Regulatory instruments (command
and control)

Economic (market based) instruments

Information-based strategies
What is a “policy instrument” ?
A Policy instrument is a tool or a mechanism
used as a means to accomplish a specific
goal.

A strategy is a plan for attacking a problem,

and policy instruments are a means to carry
out that attack.
 Informal Regulation Market as Regulation
Citizens Consumers
Plants
Plants
Community Markets
Elements Elements
• Power NGO • Reputation Investors
• Social norms • Credit
• Negotiations • Profits

The New Model

Government

Source: The Greening Industry (WB, 2000)

Range of policy instruments
Policy instruments
 Regulatory instruments - which require or
mandate specific behaviour, e.g. determine what
is prohibited, what is allowed, and how to carry
out certain activities
 Economic Instruments, which create incentives or
disincentives for specific behaviours, by changing
related economic conditions
 Information-based strategies , which seek to
change behaviour by providing information. The
underlying assumption is that the actors do not
take optimal or correct decisions for lack of
information or know-how
Regulatory instruments
 Environmental norms and regulations /
“command and control”
 Raw materials depletion quota
 Liability assignment
 Extended producer’s responsibility and product
take-back schemes
 Facility operation standards / permits
Market-based instruments
 Emission fees and non-compliance fines
 Grants, subsidies and financial assistance for CP
 Marketable permits
 Deposits and product charges
 Demand-side management
 Harmful subsidy removal
 Green procurement guidelines
 Reduction in taxes, duties and fees
Economic instruments - taxes
 Argentina: reduction of waste generation
taxes for companies with a recycling
programme
 Mexico: environmental taxes on gasoline
depending on the lead content
 Argentina: favourable taxes to promote the
use of natural gas instead of gasoline
 Lithuania: acelerated depreciation
 Belgium: eco-tax on beer if the producer does
not use to 95% recycled bottles / packaging
Information-based strategies
 Establishment of a national CP Program
 Waste prevention targets
 Public recognition and awards
 Product labelling (eco-labels , CFC-free products)
 Pollutant Release and Transfer Registers (PRTR) and
public access to environmental information
 Public environmental reporting
 Information clearinghouse and technical assistance
 Industry codes of practice
 Voluntary pollution prevention agreements
 Public education campaigns (energy efficiency and
water savings campaign)
 Manfaat Lingkungan

Manfaat Ekonomis
PERHITUNGAN KELAYAKAN FINANSIAL

Biaya investasi dan operasional murah

 Pay back period = Total investasi/extra cash flow

Biaya investasi dan operasional mahal

 Perlu ditambah : IRR, NPV

n

NPV = 
t =0
Bt – Ct
(1+i)t
i = bunga modal
t = umur proyek
IRR = internal rate of return
NPV1 NPV = net present value
IRR = i1 + (i2-i1)
NPV1 – NPV2
IRR = i pada NPV=0
 CONTOH-CONTOH MANFAAT PENERAPAN
MINIMISASI LIMBAH
Pabrik Kelapa Sawit (PKS)
Limbah organik (COD > 30.000 ppm)
Pilihan penerapan CP:
1. Konservasi air
 ‘reuse’ air pendingin, kondensat, overflow dari vacuum dryer
2. Pengurangan beban limbah
 penggunaan ‘oil trap’
3. Modifikasi proses klarifikasi
 penggunaan saringan getar untuk pemisahan padatan
4. Pemanfaatan limbah
 bungkil, cangkang, serat, lumpur (mengandung N,K,Mg),
metana, tandan kosong
PENINGKATAN EFISIENSI PROSES
PRODUKSI PULP & KERTAS
Bahan baku : jerami gandum
Produksi : 18.000 ton/th

Pilihan CP :
(1) Perubahan proses dengan peningkatan suhu pemasakan
(2) Peningkatan kekuatan vakum pada ‘drum washer’
(3) Perubahan ukuran saringan pada proses pencucian

Manfaat Lingkungan :
(1) Penurunan beban COD > 900 ton/th
(2) Peningkatan rendemen pulp 45 – 51%
(3) Pengurangan konsumsi NaOH 230 ton/th
(4) Efisiensi penggunaan air

Manfaat finansial :
Total penghematan = peningkatan keuntungan = US$ 85,000/th
INDUSTRI PULP & KERTAS
 Efisiensi penggunaan air

Kondisi saat ini :

Penggunaan air = 7500 m3/hari (air sungai), pajak Rp 100,-/m3
200 m3/hari (air sumur), pajak Rp. 300,-/m3

Program CP :
(1) Penggunaan kembali kondensat = 8,6 m3/hari
(2) Penggunaan ‘level control’, mengurangi overflow = 15 m3/hari
(3) Perbaikan ‘valve’, mengurangi bocor = 15 L/menit
(4) Penggunaan ‘pressurized sprayer’ pada selang pembersih, hemat 12 m3/hari
(5) Perbaikan saluran air, mengurangi bocor = 3 m3/hari

Total penghematan air sekitar 500 m3/hari

Biaya implementasi CP = Rp. 20.375.000,-
Penghematan = Rp. 27.852.000 (di luar hemat energi pompa)

PBP = (20.375.000)/(27.852.000) x 12 bl = 8 bl
 ASUMSI – ASUMSI :
Pengadaan air bersih
Pengambilan air sungai = Rp. 100,-/m3 (dari pajak)
Pengolahan air = Rp. 55/m3 (bahan kimia)
Pengambilan air sumur = Rp. 300,-/m3 (pajak)

Jumlah penghematan air sungai

= 20.745 L/jam x 24 jam/hari x Rp 155,-/m3 = Rp. 77.500,-/hari
Jumlah penghematan air sumur
= (kondensat) + (overflow) = 23 m3/hari x Rp. 300,-
= Rp. 6.900,-/hari
Total penghematan = Rp.(77.500 + 6.900) x 330 hari/th
= Rp. 27.852.000,-/th

Biaya penerapan :
(1) Spray = 50 unit x Rp. 22.500,- = Rp. 1.125.000,-
(2) Level controller = 2 unit x Rp. 3.375.000,- = Rp. 6.750.000,-
(3) Tenaga kerja (upah) = Rp. 12.500.000,-/th
 Total biaya = Rp. 20.375.000,-/th
PENERAPAN MINIMISASI LIMBAH

INDUSTRI KULIT (CONTOH-1)

(CONTOH-2)
(CONTOH-3)

BUDIDAYA PADI
PENGOLAHAN CPO
INDUSTRI KECIL TAHU
INDUSTRI TAPIOKA
INDUSTRI NATA DE COCO
CUKA APEL GULA
PULP & KERTAS
Faktor penentu minimisasi limbah

Peraturan dan kebijakan pemerintah

Kelayakan teknologi
Manfaat ekonomis
Komitmen dan dukungan manajemen
Enforcement

LEGISLATION FACILITIES

SUPPORT
ENFORCEMENT SERVICES
 Strategi untuk UKM
UKM dapat :
 dikecualikan dari peraturan
 diikutkan langsung
 diikutkan bertahap
 diberikan insentif
 diatur tersendiri
7 ASPEK PENERAPAN PB di UKM
Pengendalian limbah terpadu
Penghematan energi
Studi banding (benchmarking)
Keterkaitan aktor internal (pemilik, pekerja, teknokrat) dan
eksternal (lembaga pembiayaan, mass media, dll.)
Pengembangan kelembagaan  pelatihan
Pengembangan dan transfer teknologi  local-based technology
Paket finansial  pinjaman lunak (bunga, grace period, dll.)
subsidi
pengurangan pajak
CP award, dll.
ENVIRONMENTAL MANAGEMENT
SYSTEM (EMS)

(1) ISO 14000 series  ISO product

(2) Eco Management and Audit System (EMAS)
 EU standard

(1) & (2)  Tools to achieving CP

ENVIRONMENTAL MANAGEMENT
SYSTEM (EMS)
The organizational structure,
responsibilities, practices,
procedures, processes and resources
for implementing and managing an
organization’s environmental affairs
while ensuring conformity to its
policies, standards and stakeholders’
expectations
The foundation of an EMS includes:
Purpose – an organization should have an identifiable purpose,
which is usually stated as its goals and objectives and
encapsulated in the organization’s environmental policy

Commitment – there should be a sense of commitment and

accountability among the people in the organization with respect
to taking the appropriate action in support of the EMS

Capability – the organization should have the necessary

resources (human, physical and financial) as well as the
knowledge and skills to achieve the organization’s environmental
policy

Learning – the organization should strive to continuously learn

to improve its own management and learning processes through
monitoring and measurement of environmental performance,
efficient internal and external communication as well as review
of the EMS by senior management
ISO 14000 Consists of :
(1) EMS
(2) EA&RI (Env. Auditing & Related Investigation)
(3) EL (Env. Labels and Declaration)
(4) EPE (Env. Performance Evaluation)
(5) LCA (Life Cycle Assessment)
(6) T & D (Terms & Definition)
EMAS covers:
(1) Compliance with all relevant env. Regulation
(2) Prevention pollution
(3) Achieving continuous improvement in
environmental performance

PROPER
TUJUAN DAN SASARAN PROPER
TUJUAN
Mendorong terwujudnya pembangunan berkelanjutan;
Meningkatkan komitmen para stakeholder dalam upaya pelestarian lingkungan;
Meningkatkan kinerja pengelolaan lingkungan secara berkelanjutan;
Meningkatkan kesadaran para pelaku usaha/kegiatan untuk menaati
peraturan perundang-undangan di bidang lingkungan;
Meningkatkan penaatan dalam pengendalian dampak lingkungan melalui
peran aktif masyarakat;
Mengurangi dampak negatif kegiatan perusahaan terhadap lingkungan

SASARAN
Mendorong perusahaan untuk menaati peraturan perundang-undangan
melalui instrumen insentif dan disinsentif reputasi;
Mendorong perusahaan yang sudah baik kinerja lingkungannya untuk
menerapkan produksi bersih (cleaner production).

PERINGKAT
ISO 19011  Guideline for auditing
(1) General priciple of auditing
(2) Management of audit program
(3) Auditing activities
(4) Competence auditors
AUDITING :
Systematic, independent, and documented
process for obtaining audit
evidence and evaluating it objectively
to determine the extent to which the
audit criteria are fulfilled
THREE PRINCIPLES OF
AUDITORS
 Ethical conduct  foundation of
professionalism

 Fair presentation  report truthfully

 Due professional care  the application of

dilligent & jugment in auditing
QUALITY & ENVIRONMENT
MANAGEMENT SYSTEMS

Plan Do  Check  Action

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