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Improving Productivity and Product Quality in Buko Juice Manufacturing

Through Cleaner Production

Technical Report · February 2008

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 Improving Productivity and Product Quality in Buko Juice Manufacturing
Through Cleaner Production
Maria Isabel R. Dumlao1, Roselyn V. Arellano2, Stephen G. Cubar3, Christine D. Olairez4, Narvinso S.
Tan2
1
Chemical Engineering Department,
Xavier University, Cagayan de Oro City
m.dumlao@xu.edu.ph
2
DOST Region 10, Cagayan de Oro City
3
Lourdes College, Cagayan de Oro City
4
DOST IPCT-ITDI, Manila

Fresh buko juice is the pure coconut water natural obtained from young coconuts. It
is an isotonic beverage often with added bits of coconut meat. It contains potassium and
magnesium, as well substantial levels of vitamin B such as thiamin. It is often served or sold
in its natural shell or in white plastic cups. A local fresh buko juice manufacturer
experienced income losses from returned products such as back-orders, empty and broken
cups. The buko juice has an estimated shelf life of 3-5 days. A cleaner production
assessment was conducted to improve the product quality by increasing the shelf life of the
buko juice, and to increase the company’s productivity by reducing the number of returned
products. The assessment includes the evaluation of the operations and practices at each
process. Buko juice production starts from the washing the coconuts, cracking young
coconuts and decanting the coconut water, straining the coconut water together with sugar,
mixing of the coconut water and coconut meat, and filling up of cups. Prior to the
assessment, of the total produced cups in a month, the company has 3.03% returned cups
mainly because of spoilage, breakage and empty. Cleaner production options initially
implemented included training of all personnel in Good Manufacturing Practices, proper
sanitation and rinsing of coconuts, standardization of chlorination procedures for washing
and cleaning, installation of footbath, use of crusher for slicing of coconut meat,
standardization of mixing proportions, and use of a plastic dispenser for the filling process.
Environmental benefits experienced by the manufacturer include reduced solid wastes by
88,000 kg/year, reduced wasted buko juice by 116 m3/year. Cleaner production also resulted
to an increase in number of produced cups per coconut by 19%, and a reduction in returned
cups per production by 45%.

Keywords: cleaner production, buko juice, coconut water

INTRODUCTION This paper summarizes the information gathered

Cleaner production (CP) assessment is an integral
component of a Cleaner Production program that
may eventually serve as the foundation for the
establishment of an environmental management
system within a facility.
in relation to the CP assessment of a fresh buko
juice manufacturing company. The paper
includes the following sections: Product
Overview, Facility Description, CP Goals and
Objectives, Driving and Restraining Forces, CP
Assessment Findings, Recommendations, and
Monitoring Program.

*Note: This was presented during the PIChE National Convention last February 28, 2008.
 5. Mixing with Coconut Meat
CLEANER PRODUCTION ASSESSMENT Coconut meat and coconut water are
mixed together and stirred.
2.1 Product Overview
6. Filling of Cups
The mixture of coconut water and meat is
Fresh buko juice is the pure natural coconut poured into cups. The cups are then
water obtained from young coconuts. It is an covered, capped and sealed.
isotonic beverage often with added bits of
coconut meat. It is often served or sold in its
COCONUTS
natural shell or in white plastic cups. A
particular local fresh buko juice manufacturer
(1)
experienced income losses from returned WATER WASHING WASTEWATER
products such as back-orders, empty and
broken cups. The buko juice has an estimated
shelf life of 3-5 days.

2.2 Facility Description

(2)
UNUSED
CRACKING
The company is engaged in the manufacture of AND
COCONUT
fresh buko juice. Fresh buko juices are DECANTING
manufactured at an average rate of 50,000 BUKO COCONUT MEAT
cups/month. The plant has concerns about the JUICE
short shelf-life of the buko juice product. EMPTY
(4) (3) COCONUT
STRAINING SCRAPING SHELLS
The processes carried out in the production of the AND UNUSED
fresh buko juice are shown in Figure 1. CHOPPING COCONUT MEAT

1. Washing of Coconuts and Storage

COCONUT
The coconuts received from suppliers and MEAT
IMPURITIES
heaped on the ground outside the
production area are washed and sprayed (5)
with water from a hose. MIXING

2. Cracking of the Coconuts and

Decanting of the Coconut water
Whole coconuts are cracked partially by a
production worker using a bolo. The
coconut water is poured out from the
coconut shell into a pail. The coconuts (6)
must be at most 5-day old. FILLING

3. Scraping of the Coconut Meat and

Chopping
The coconut meat is scraped out from the
coconut shell manually by a different
production worker using a spoon. The (7)
meat is then chopped into irregular sizes PACKING
by a separate worker using a knife.
4. Straining
Straining is done to remove the
impurities. Figure 1: Process Flow Diagram of Buko
Juice Production

*Note: This was presented during the PIChE National Convention last February 28, 2008.
The current management practices include the
following:
1. The plant uses water from a deep well
located inside its area. The water in the deep well
is chlorinated regularly. For the water used as raw
material for the product, it is passed through a
simple filtration unit.
2. For Good Manufacturing Practices, the
production workers are reviewed of common
safety and health practices. The workers use a lab
gown, hair cover, mask, gloves and boots when
inside the production area.
3. Utensils and production fabrics and
materials are washed with chlorinated water at the
end of each day and kept dry.
4. The water used for washing the coconuts
heaped on the ground is drained to nearby canals.
Inside the production area, floors and sinks are
washed and rinsed with water after every major
activity. The water flows to nearby drainage at
the sides of the production area.
5. Coconuts that have been used are
collected in a metal crate. These coconuts are
brought and sold to buyers. The unused mature
coconut meat is converted to a by-product copra.
The unused grated coconut meat is sold as buko
strings to local bakeries. The spilled coconut
water is just washed and rinsed with water, and
flows to drainage.
6. Impurities collected during straining of
coconut water are disposed to trash or to canal.
2. 3 CP Goals and Objectives
The management and the assessors have drafted
the following CP objectives:
 Improve product quality and improve
company’s productivity
 Reduce waste products, i.e. returned
products
 Improve production technology and
facilities
 Achieve regulatory compliance
*Note: This was presented during the PIChE National Convention last February 28, 2008.
The following driving forces have been identified:
 Desire for regulatory compliance
 improvement of Public image
 aspiration for competitiveness
The following restraining forces have been
recognized:
 lack of technical know-how
2.4. Priority and Focus Area(s)
In this case, the production of buko juice has been
the priority area. Major problem of the buko juice
production is the significant number of returned
products (Back Orders, empty and breakage)
probably because of limited quality control and
short shelf-life of buko juice.
2.5. Environmental Performance Indicators
(EPI)
The EPI used in the CP assessment of the focus
area and in the monitoring of the success of the
CP activities and whether the CP targets are met is
 Number of returned products per total
number of cups delivered (% returned
products in a week or month)
2.6. CP Target
The main CP target generated out of the identified
CP objectives is
 To reduce the returns of fresh buko
juice cups by 50% within 3-6 months.
ASSESSMENT RESULTS
3.1. Source Inventory – Material and Energy
Balance
The quantity of wastage and losses of the
production was determined by calculating for the
masses of each input and output stream. There
was no available actual measurement of the water
usage from a deep well. Thus, the wastewaters
generated from washing of the coconuts, of sinks
and floors and of utensils were not determined.
For other data needed, actual simple research and
experiment were conducted. For instance, the
estimated volume of coconut water supplied by a
single coconut was determined by going to a local
coconut vendor and pouring the coconut water
into a cup. The estimated volume of waste or
unused coconut water (or the coconut water not
used for production of the fresh buko juice) which
was just discharged to the sinks as practiced by
the company was estimated to be around as high
as 6% only. This was calculated as the difference
between the total volume of coconut water from
coconuts used in the production and the total
volume of coconut water from all cups filled and
packed. The losses and wastage in product sales
were calculated as equal to the total volume of
buko juice from all returned cups. It is estimated
that around 7-8% by volume of fresh buko juice is
wasted due to the returned products (i.e. Back-
orders, breakage).
Energy losses may be incurred during sealing
when the sealer is idle.
3.2. EPI Data
The average number of returned products per total
number of cups delivered or the % returned
products in a month was calculated as 3.03%
3.3. CP Option Generation
Practical CP options that have been identified are
discussed in details below. These options are
recommendations by the CP task force and
assessors.
CP Option 1: Standardize use of Chlorine in
cleaning (Good Housekeeping Practice, Low
Cost/Low Risk))
In order to eliminate possible contamination
during the process, utensils, materials and other
equipment must be washed with chlorinated water
before and after use. The utensils and other
materials must be kept inside a dry cabinet. It is
advised that the company follow the standard
proportion(s) of chlorine and water for washing
and rinsing.
CP Option 2: Elevate the buko seeds during
storage and washing (Good Housekeeping
Practices, Low Cost/Low Risk)
*Note: This was presented during the PIChE National Convention last February 28, 2008.
Again, in order to eliminate possible sources of
contamination during the process, the buko or
coconut seeds must be stored or elevated from the
ground. The coconuts can be placed in carts or on
pallets thus minimizing contact with the soil or
ground. This way, the water can just flow through
beneath the cart or pallet when the coconuts are
being washed, and thus minimizing the contact of
the used water with the other coconuts. The crates
and the pallets should be designed to carry or
store the coconuts.
CP Option 3: Rinse or Wash the Coconut seeds
with chlorinated water, possibly in dipping baths
(Good Housekeeping Practices/Improve
Technology/New Technology, Low Cost/Low
Risk/ For Further Technical and Financial Study)
In another way to eliminate possible
contamination, the seeds must be washed or
sanitized with chlorinated water. If possible, the
seeds shall be kept dry immediately prior to their
use in the process. This can be immediately
implemented by the company.
It is also suggested that instead of using a hose to
spray the coconuts with water, the coconuts can
be washed in dipping baths. The dipping baths
consist of around three tubs in series containing
chlorinated water (from dirtiest to cleanest). The
coconuts are dipped in sequence into the each of
the three tubs. The next cycle of rinsing will have
operation of the tubs in reverse which will have
the last tub as the first dipping tub (corresponding
to dirtiest) and the other two tubs shall be clean.
CP Option 4: Replacement of existing bolo with a
stainless bolo (Improved Technology, Low
Cost/Low Risk)
Since the bolo is in direct contact with the coconut
during the process, it is strongly advised that a
stainless bolo is used during the breaking of the
seeds.
CP Option 5: Replacement of Manual Chopping
of Coconut Meat with a dicer/chopper (New
Technology, For Further Financial Study)
It is recommended that a food processor or
chopper be purchased for use for the chopping of
the coconut meat. This way, possible
contamination of the coconut meat is also
minimized.
CP Option 6: Construct and provide a footbath at
the entrance of the production area (Good
Housekeeping Practices, Low Cost/Low Risk)
As part of good housekeeping practices in a food
processing plant, it is recommended that a
footbath be constructed at the entrance of the
production area. All workers entering the
production area should pass through the footbath.
It is estimated that a reasonable amount is
expected to be spent for the construction of the
footbath.
CP Option 7: Use of a Dispensing Machine,
possibly with an agitator, and Separate Addition
of meat into cups (New Technology/Improved
Technology, For Further Technical and Financial
Study/Low Cost/Low Risk)
For immediate implementation, the meat can be
added separately into the filled cups with
standardized measuring cups. This way, there is
more quality control of the product.
Instead of manual mixing and filling of the
coconut water and coconut meat, a dispensing
machine with a faucet and possibly a small
agitator can be purchased or fabricated. It is also
recommended that the dispensing machine’s
container volume is calibrated. And likewise, the
volume dispensed can also be calibrated. This
way, possible contamination from manual mixing
and the use of pitcher is eliminated.
CP Option 8: Check quality of ice and choose
between the purchase of an ice-maker or
supplying the sellers with chiller (Improved
Technology/New Technology, For Further
Technical and Financial Analysis)
For immediate action, the company can request
for the microbial analysis of ice from the
suppliers. Considering the volume requirement of
ice, the company can also study the potential of
purchasing its own ice-maker or the use of chiller
instead of ice chests.
CP Option 9: Research on sterilization of buko
juice and process conditions (New Technology,
For Further Technical and Financial Study)
*Note: This was presented during the PIChE National Convention last February 28, 2008.
Possible use and formulation of preservatives for
buko juice can be studied in order to increase the
shelf-life of the product. Another option is to
research on available and recent sterilization
processes of coconut water. It is also considered
that there might be an optimum temperature
required for the processing of buko juice (i.e. cold
temperature of environment).
CP Option 10: Conduct quality check of product
(i.e. check if cup is properly covered before
sealing) (Good Housekeeping Practices, Low
Cost/Low Risk)
CP Option 11: Conduct quality check of raw
materials (Good Housekeeping Practices, Low
Cost/Low Risk)
In order to check possible contaminations, raw
materials must be analyzed for microbial analysis.
For example, water used in the process, ice, cups.
CP Option 12: Design and install a juice dripping
rack (New Technology, For Further Technical and
Financial Study)
It is advised to use two workers during the
breaking of coconut and pouring of the coconut
water. One worker is tasked to solely crack a hole
in the coconut seed. A separate worker then is
tasked to pour out and extract the coconut water
from the coconut seed into the sanitized
dispensing container with a strainer already.
For more optimized operation, one worker is
tasked to crack a hole in the coconut seed. The
coconut seeds are then turned over in dipping
racks with catch basins, preferably the dispensing
containers already with the strainer. This dipping
rack shall be designed and fabricated.
CP Option 13: Spray meat with coconut water to
clean it from fibers (Good Housekeeping
Practices, Low Cost/Low Risk)
Instead of using water to rinse the meat, or using
spoon to scrape off fibers from the coconut meat,
it is recommended that coconut water be used and
sprayed into the meat to rinse off the fibers.
CP Option 14: Use of Chlorinated water and Cleaning and washing is Standardized use of coconuts) by
done with water and soap chlorine and 19%
squeegee in cleaning floors and tables (Good only procedure of
Housekeeping Practices, Low Cost/Low Risk) cleaning and  Reduced bad
washing orders/ cups
There is no footbath at Installed footbaths produced by
Instead of using water to rinse the floors and the entrance doors 45%
tables, it is advised to use a squeegee. Manual chopping of Used ice crusher
coconut meat for slicing of  Reduced
coconut meat solid wastes
CP Option 15: Conduct a training on GMP (Good Manual filling of buko Used plastic by 88,000
Housekeeping Practices, Low Cost/Low Risk) juice and meat in cups dispenser and kg/yr
using a pitcher causing standard measuring
spillages of products cup in filling buko  Reduced
A training on GMP can be conducted for the juice and meat in wasted buko
production workers. cups juice by 116
m3/yr

CP Option 16: Research on possible options for

sturdier cups or plastic bottles (New Technology,
For Further Technical and Financial Study)

The use of plastic bottles as the packaging

material can be investigated. Likewise, other
suppliers of sturdier cups can be explored. These
options will potentially improve the quality of the
product.

RECOMMENDATIONS

4.1. CP Recommendations

Table 1 in the next pages shows the recommended

options and how they can be implemented.

MONITORING

Table 2 presents the CP options implemented by

the company for the past 6 months from the time
of the CP Assessment. Continuous monitoring is
done to determine the companies CP
implementation and the realized benefits of the
company.

From an initial EPI of 3.03% returned cups, the

calculated EPI after the implementation of the CP
options was 1.67%. This is higher than the target
EPI of 1.52%.

Table 2: CP Options Implemented

Conditions before CP CP Options Environmental
Benefits
Not all Good Trained all  Improved
Manufacturing Practices personnel on GMP productivity
(GMP) are in-place and implemented (number of
GMP cups
Coconuts are washed Sanitizes and rinses produced per
with water only coconuts

*Note: This was presented during the PIChE National Convention last February 28, 2008.
Table 1: CP Recommendations
CP Options
Findings/Wastes Short-Term Action Long Term Action
(< 6 months) (> 6 months)
No training on GMP Request for in-house GMP

Unstandardized use of chlorine in Standardize use of chlorine in cleaning (before and

cleaning of utensils, tables, gloves after use).
Place utensils, basins in cabinet.

No footbath Provide and install footbath with chlorinated water

Improper storage of buko seeds Elevate the buko seeds (Place in carts or pallets)

Buko seeds not sanitized prior to cutting Rinse and sanitize buko seeds (Use of dipping baths)
Include in plant layout
Standardize use of chlorine and procedure of washing

Bolo used for breaking buko is not Use stainless bolo

stainless

1 worker for breaking and cutting Design and install dripping and juice collecting rack
2 workers for breaking of buko seed and cutting

*Note: This was presented during the PIChE National Convention last February 28, 2008.
 CP Options
Findings/Wastes Short-Term Action Long Term Action
(< 6 months) (> 6 months)
Meat with fibers Check meat if there are fibers. Clean meat by spraying
with coconut juice.

Manual handling and paring of meat Replace with stainless dicer/cutter

Look for fabricators of stainless dicer/cutter

Manual mixing and filling of buko juice Add the buko meat separately to the cup. Use standard Replace with a dispensing machine (buko meat
with pitcher measuring cup for the filling of meat. Use stainless should be well-mixed and will not clog faucet,
dispenser with faucet for the juice. calibrate volume)

3-5 days shelf life Research for appropriate preservatives, formulation

No preservatives
Research on the appropriate working temperature

Research on the pasteurization of buko juice

Poor quality of cups Check for more sturdy cups Replace with plastic bottle

Study proper way of packing in styroboxes. For further feasibility study

Implement right way of packing.
Limited quality check Check if cover is properly placed before sealing.

*Note: This was presented during the PIChE National Convention last February 28, 2008.
 CP Options
Findings/Wastes Short-Term Action Long Term Action
(< 6 months) (> 6 months)
Quality of ice Request for microbiological analysis of ice from the Search for mini ice-maker
suppliers
Provide chiller to customers
Implement proper storage, handling of ice
Check for manufacturer/fabricator of chiller

Calculate payback period (use of chiller vs. ice in

styro)

Savings – ice, styro breakage, diesel

Washing of tables and floors with tap Use chlorinated water and rubberized foam in cleaning
water of tables and floors

Quality of raw materials Check possible contaminations. Analyze microbial

content of water, ice, cups, etc.

*Note: This was presented during the PIChE National Convention last February 28, 2008.
 *Note: This was presented during the PIChE National Convention last February 28, 2008.

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