CLEAN PRODUCTION IMPLEMENTATION IN

PT. TIRA AUSTENITE

SUPPLY CHAIN DEPARTMENT (production)

1Imo Lolona Boangmanalu

FACULTY OF PRODUCTION AND INDUSTRIAL TECHNOLOGY

SUMATRA INSTITUTE OF TECHNOLOGY

1. Clean Product Definition

The definition of clean production according to UNEP (United Nations

Environment Program, 1990) is the ongoing application of integrated
environmental strategies to processes, products and services to increase efficiency
and reduce risks to people and the environment.

According to KLH (Ministry of Environment, 2002), clean production is an

environmental strategy that is preventive, integrated and applied continuously in
every production process, product and service to increase efficiency so as to reduce
the impact on humans and the environment.

2. Clean Product Concept

Initially, the concept of end-of-pipe treatment was used, which focused on waste
treatment and disposal. On the other hand, this concept is not entirely effective for
solving environmental problems. The constraints of this concept include:

a. A new approach is taken after the waste is formed.

b. Treatment of liquid, solid or gaseous waste risks causing the transfer of
pollutants from one media to another.
c. High investment and operating costs.
d. It requires various regulations, availability of costs and reliable human
resources for supervision but social control is weak and the number of
facilities and infrastructure is limited.
 Due to various constraints of the end-of-pipe treatment concept, the concept of
clean production for environmental management emerged. Clean production aims
to prevent and minimize waste or pollutants that are discharged into the
environment. There are two advantages derived from this clean production concept.
First, environmental sustainability is maintained because the formation of waste can
be reduced. Second, there is efficiency in the production process so that production
costs can be reduced. The principles in net production known as the 4Rs include:

a. Reuse or reuse is a technology that allows waste to be reused without

undergoing physical, chemical, biological treatment
b. Reduce or reduce waste at the source. For example, replacing B3 material
with non-B3
c. Recovery or recycling is separating materials or energy from waste with or
without treatment
d. Recycling or recycling is processing waste with treatment to return to the
original process. For example, plastic waste made by plastic pellets which
aims as raw material for other products (KLI, 2003).

Analysis related to the application of clean production in one of

the production sectors, energy saving, raw material recovery
and others.

PT. TIRTA AUSTENITE

SUPPLY CHAIN DEPARTMENT (production)

PT. Tira Austenite is currently a company that has two strategic business
units. Both include Industrial Products imported from abroad such as various types
of special steel, welding wire and welding machines, and Industrial Gases, namely
industrial gases, medical gases and special gases.
The supply chain (production) department is one part of the strategic
business unit of industrial products. This section produces its own industrial
products, such as bronze for industrial machines and welding wire with
specifications according to consumer demand. Consumers of these products are
generally industries that require replacement of parts on their production machines.
In the foundry industry, there are various hazards that can affect human
health. In the metal casting work environment there are hazards including: high
temperatures, hot metal splashes, combustion dust and metal material fragments
(Ireng, 2010).
While in the welding wire production process there are also factors that
affect health. According to research by Paran ko, et al (1992), these factors include:
noise and manganese in the form of acrosol flying in the air in high concentrations.
The health impact of these substances is the possibility of being toxic to the blood,
lungs, brain, central nervous system as well as organ damage if exposed for a long
time (Science Lab, 2013)
In the production process of welding wire and bronze at PT. Tira Austenite
is characterized by various outputs, both products and non-products, non-product
outputs can be reused for the production process, and some become waste. Some of
these wastes are directly disposed of into the environment and some are sold to
collectors. On the other hand, during the production process there are also things
that affect human health and the surrounding environment. In addition, fuel for
bronze smelting furnaces uses LNG which is more environmentally friendly than
similar industries that use coke and diesel.

1. WELDING WIRE PRODUCTION

The process of making welding wire in general, starting from beginning to end
is the same, the difference is mixing time, coating thickness. humidity during the
drying stage, heating time and temperature in the oven and stamping according to
the product name. At the time of observation and interview on February 24, 2014,
the welding wire being produced was MG-NOX 29. In general, the production of
welding wire consists of several stages. Here is a flow chart of the welding wire
production process.
 Chart 1. Welding Wire Production

• Application of 3R Principle Based on Welding Wire Production

Stages
The welding wire production process at IT Lira Austenite in the application
of clean production principles, namely 3R has applied 2 principles
including, namely Reduce and Reuse.

o When washing never in the welding wire production process only

water and brushes are used Soap is only used when there are workers
who wash their hands or clean certain tools.
o Reuse of welding powder that contains defective welding wire
during the pressing process .
Based on the identification of inefficiencies at each stage of
production discussed earlier, there are various kinds of non-product outputs
or waste from each process. The waste produced in the welding wire
production process includes the remaining welding powder carried in the
production machine and in the water used for washing mixers, bent core
wire, finished products of welding wire that have irreparable defects.
The source of liquid waste for welding wire production comes from
the washing process of mixers as well as workers in the welding wire
production section who wash their hands with laundry soap. While solid
waste comes from welding powder flakes used as core wire coatings. These
flakes are thought to pollute the air although the rest of the use can be reused
for the production process as long as they have not been welded wire
inserted in the drying chamber. Air pollution is also thought to come from
smoke drains in ovens used to reduce moisture content in welding wires.
Based on observations of the surrounding environment, there is no
significant influence on animals and plants living around it due to welding
wire production waste. Water vapor that comes out of the air channel also
does not greatly affect the condition of the surrounding environment. The
only visible effect is a change in water quality due to the mixer washing
 process The change can be seen from the difference in water turbidity as
previously described. Water that comes out of the reservoir to the outside
environment also does not affect the surrounding environment because the
amount is very small (5-10 liters). The risk of disease that is very likely to
occur is in the welding wire production section
is respiratory problems and irritation of the treatment and other parts of the
body. The disease can arise due to inhalation of welding powder from the
welding wire production process. In the production process of making
welding wire, workers are very susceptible to exposure to dust from welding
powder During the mixing process by the mixer, some of the powder flies
when pouring into the mixer. Workers who serve powder use masks. But
other workers do not use masks so that flying dust can be inhaled.

2. BRONZE PRODUCTION (BRONZE)

The process of making waiters starts from several stages, namely
inserting melting raw materials. Quality control, and after that it is divided
into three types of printing processes such as centrifuge, continuous and
sandcasting.

Chart 2. Bronze Production (Bronze)

• Application of the 3R principle based on the stages of bronze
production
 Bronze production process at PT. Tira Austenite in the application of
clean production principles, has applied all 3R principles, including:

• Reduce, The use of fuel for melting furnaces and holding furnaces that
currently use LNG gas which is more environmentally friendly than the
previous few years that used diesel.
• Reuse, which is the remelting of remaining raw materials and defective
materials from previous production. I
• Recycle is to smelt raw materials obtained from companies that collect
goods made from aluminum, copper, tin, lead and nickel.

The identification of inefficiencies in the production process is also seen in

the use of energy. The foundry uses two kinds of energy, namely electricity and
liquefied natural gas. The following electricity consumption is seen from the
average usage in one month. In this case, it is seen from the use of electricity
which is included in the LWBP category. The average amount of electricity
consumption in the foundry section in one month is 714 Kwh The amount of
electricity consumption in the foundry comes from the office area and the use
of lights, cranes, lathes and welding machines that take place every working
day.

References

http://www.menlh.go.id/kebijaksanaan-produksi-bersih-di-indonesia/
 http://digilib.its.ac.id/public/ITS-Undergraduate-7206-2703100021-
bab2.pdf

http://www.esdm.go.id/berita/migas/40-migas/5896-pertamina-rintis-
pemanfaatan-lng-untuk-transportasi-dan-rumah-tangga.html

http://www.menlh.go.id/kebijaksanaan-produksi-bersih-di-indonesia/