Chapter 2
INDUSTRIAL AND INSTITUTIONAL STOVES IN ASIA

BANGLADESH

Bread Inustry

◊ Industrial    ◊ Institutional    ◊ Food    ◊ Non-Food

A typical Tondur

Profile of Baking Industry

There are about 5,000 bakery industries in Bangladesh. Traditional bakeries produce bread, buns, cakes, and biscuits. Flour is the major raw ingredient used to produce these products. Other ingredients include eggs, sugar, salt, a leavening agent, a liquid, and shortening. In addition, various other ingredients such as chocolate, nuts, spices, or dried fruits are used for variation.

The bread produced may be divided into two basic categories: 1) quick breads and 2) yeast breads. The chemical leavening agents are used to prepare quick bread dough and are baked immediately after mixing. The making of yeast breads is rather a lengthy process due to the fermentation period required for carbon dioxide production by the yeast. In this case, the temperature must be kept below 46°C. Best results are obtained when the shaped dough, which doubles in volume is placed in a preheated oven.

The steps involved for making biscuits are mixing the ingredients, e.g., wheat flour, sugar, fat, leavening agents, salt, and flavoring, then kneading, sheeting, shaping, and baking.

Dome-shaped ovens localled called tondur are used for baking in all traditional bakery industries.

Scale of Industry
Cottage industry with 5–10 laborers.

Fuel Type
Fuel wood

Size of Stove
(200 × 200 × 80–130) cm,or
(300 × 300 × 100–150) cm

Stove Makers
Brick layers (locally available)

Stove materials
Foundation :

• Bricks 200 pcs
• Clay 0.25m³
• Course sand, salt, broken glass pieces = 0.25m³

Body :

• Bricks 100 – 150 pcs.
• Clay 2 – 3 m³

Grate

• Metal strip 1 pc

Stove Utensils
Trays of different sizes: (26 × 8) cm - (40 × 30) cm

Stove/Industry capacity
15m² to 25m² space required for baking.

If the whole process is done continuously, 80 kg of flour can be baked in 8–9 hours.

Fuel Consumption
120 kg of fuel wood required to bake 80 kg of flour

Loading the Tondur

Profit/day = Tk. 900

Exchange rate: US $ 1 = Tk. 48

Stove Operation
Fuel wood is placed in the oven and burned to heat the oven to temperature around 220° – 230°C. Since the chimney is placed at the front near the door, there is poor circulation of gases. This results in a low temperature in the back portion of the stove. The ashes are pushed to one side and then the molded dough is placed on a tray in the oven. A log is placed on a grate near the door of the oven and is kept burning to keep the temperature above the desired level. Biscuits need lower temperature than breads. Normally biscuits and cakes are baked following the same process after the breads are done. At the end of the process, then fire is reduced and finally extinguished.

Flow Chart of Stove Operation

Ergonomic
The stove and processing system seem to be good, because no heavy lifting is involved. As no bending is required, it hardly produces any ergonomic stress. Loading and unleading the stove cause exposure to heat, which is exhausting for the operator.

Stove Maintenance
Regular maintenance and cleaning of the tondur is done. The ashes in the stove are cleared away weekly. The chimney is cleaned from the top at least once a month. The entire stove is coated every week with muddy water.

Stove Durability
Approximately 10 years

Preheating the Tondur

Girl Hostel (1)

Profile
The Girls Hostel Church of God Lumdonbok Mission is located at district Moulavi Bazar, Kaulara, Bangladesh. The stove is used to cook food and boiling water for 50 girls student every day. There is one cook and one helper employed in cooking in this Hostel.

Scale
One Cook and one helper employed in cooking; space of kitchen is (12 × 12) feet

Fuel Type
Fuel wood

Size of Stove
(6 × 2.5) feet

Stove Makers
NGO worker/trained people

Stove Materials
Foundation/Base:

• Bricks and clay construction

Body:

• Bricks, cement and clay

Grate & Ring:

• Iron sheet for grate and setup on ¼ inch ring rod
• Ring is made by ¼ inch rod
• Stove mouth has a ¼ inch round ring where utensil set

Total cost of stove Tk 2210
Exchange rate : US $ 1 = Tk 48

Stove Utensils
Aluminum wok and pan of different size

Stove Capacity
At once they processed 8 kg rice, 1,5 kg dal, vegetable, meat, fishes, eggs, and hot water. They cook three times a day and 1,5 hour are required to process rice and vegetable at once.

Fuel consumption
25 kg of wood is consumed for one time cooking

Stove Operation
Ignition of stove is done with the help of little kerosene. While they prepare food to cook the put water to boil first. The cooking time is about 1,5 hour, then fire is reduced just enough to keep the water hot and sometime to warm the food.

Flow Chart of Stove Operation

Ergonomic
No heavy lifting nor bending are required during the process

Stove Maintenance
Regular maintenance and cleaning of the stove is done; the ashes is cleaned every day or as soon it seem dirty.

Stove Durability
Approximately 5 years

Girl Hostel (2)

Profile
The Narayantala Girls Hostel is located at district Sunamagong, Bangladesh. The stove is used to cook food and boiling water for 65 girls student every day. There is one female cook and one helper employed in cooking in this Hostel.

Scale
One Cook and one helper employed in cooking; space of kitchen is (14 × 10) feet

Fuel Type
Fuel wood

Size of Stove
(5 × 3 × 2.5) feet

Stove Makers
R.C Hostel/trained people

Stove Materials
Foundation/Base:

• Brick and cement construction

Body:

• Bricks, cement
• Top of stove is 1 inch iron slab 5 feet long, 3 feet wide
• Stove mouth has a ¼ inch round ring where utensil set

Grate:

• Iron sheet

Total cost of stove Tk 5000 Exchange rate :US $ 1 = Tk 48

Stove Utensils
Aluminum wok and pan of different size

Stove Capacity
At once they processed 10–11 kg rice, 1,5 – 2 kg dal, 10 kg vegetable, meat, fishes, eggs, and hot water. They cook three times a day and 1,5 hour are required to process rice and vegetable at once.

Fuel Consumption
15–20 kg of wood is consumed for one time cooking

Stove Operation
Ignition of stove is done with the help of little kerosene. While they prepare food to cook the put water to boil first. The cooking time is about 1,5 hour, then fire is reduced just enough to keep the water hot and sometime to warm the food.

Flow Chart of Stove Operation

Ergonomic
No heavy lifting nor bending are required during the process

Stove Maintenance
Regular maintenance and cleaning of the stove is done; the ashes is cleaned every day or as soon it seem dirty.

Stove Durability
Approximately 6 years.

Kashi Training Institute

Profile
The Training Institute Khashi Mission Bromonbazer is located at district Moulavi Bazar, Bangladesh. The stove is used to cook food and boiling water for 25–30 people every day. There is one cook and one helper employed in cooking in this Institute.

Scale
One Cook and one helper employed in cooking; space of kitchen is (15 × 8) feet

Fuel Type
Fuel wood

Size of Stove
(6 × 2,5) feet

Stove Makers
Brick layers (locally available)

Stove Materials
Foundation/Base:

• Brick and clay construction

Body:

• Bricks and clay

Grate & Ring:

• Iron sheet for grate and cutting oil drum for ring

Total cost of stove Tk 700 Exchange rate:US $ 1 = Tk 48

Stove Utensils
Aluminum work and pan of different size

Stove Capacity
At once they processed 5 kg rice, 1 kg dal, vegetable, meat, fishes, eggs, and hot water. In average 1,5 hour are required to process rice and vegetable, fish, water, etc..

Fuel consumption
12 kg of wood is consumed for one time cooking

Stove Operation
Ignition of stove is done with the help of little kerosene. While they prepare food to cook the put water to boil first. The cooking time is about 1,5 hour, then fire is reduced just enough to keep the water hot and sometime to warm the food.

Flow Chart of Stove Operation

Ergonomic
No heavy lifting nor bending are required during the process

Stove Maintenance
Regular maintenance and cleaning of the stove is done; the ashes is cleaned every day or as soon it seem dirty.

Stove Durability
Approximately 10 years.

Sweetmeat Industry

A typical stove with wok frying sweetmeats in oil

Profile of Sweetmeat Industry
Sweetmeats are a consumed food item throughout Bangladesh. There are about 50,000 sweetmeat shops in Bangladesh. Usually these shops produce a variety of sweetmeat in their own kitchens. The major raw ingredients used for sweetmeat production are cow's milk, sugar, and ghee. The steps involved for making most sweetmeats are: coagulation of cow's milk, agglomeration of the curd with other ingredients, shaping and cooking in syrup or in oil. The cooked sweetmeats are kept in concentrated syrup overnight. The syrup is strained prior to transfer in the shop. The stove is an important part of the sweetmeat industry.

Scale of Industry
Cottage industry with 2–5 laborers.

Fuel Type
Fuel wood

Size of Stove
(140 × 120 × 60) cm

Stove Makers
Brick layers (locally available)

Stove materials

• Bricks 20 pcs
• Clay 1 m³

Stove Utensils
Woks: different sizes from 60 cm – 100 cm, made of cast iron and not set permanently on the stove

Stove/Industry capacity
A medium scale industry can produce 160 kg of sweetmeat per day. The working time is about 8–10 hours. Normally two stoves are required for a single kitchen.

Fuel Consumption
250 kg of fuel wood required to bake
160 kg of sweetmeat

Exchange rate: US $ 1 = Tk. 48

Stove Operation
At first, the wok is placed on the stove and then the milk is poured into it. Using kerosene as a starter, the fire wood is ignited in the stove. The milk should be stirred continuously so that it does not burn. Once it boils, it should be removed from the stove. Required amounts of whey protein are mixed slowly with the milk until it coagulates. After the agglumanation of curd, it is strained through a fine cloth sieve. In the meantime, another wok is put on the stove for making syrup. This is done at a low temperature. The curd is mixed with other ingredients. Within half an hour, the syrup is ready. The mixed ingredients are shaped and boiled in the syrup. In this case, a separate stove is used for frying. At the end of the processing, the fire is reduced and finally extinguished. The ashes in the stove are not fully removed, as they will keep the stove warm until the next day.

Flow Chart of Stove Operation

Cooking sweetmeats in syrup

Ergonomic
The stove itself seems to be good and do not create any ergonomic stress. On the other hand the processing needs a lot of heavy lifting and bending causing ergonomic stress. Another heavy thing to do is the continuous stirring and exposure to heat.

Stove Maintenance
Maintenance of the stove is done regularly. The ashes in the firebox are cleaned by leaving the charcoal in every alternate day. The entire stove is coated every week with muddy water.

Stove Durability
Approximately 5 years.

Tea Stall

A typical stove used in Bismilla Hotel and tea stall, Bangladesh

Profile
The tea stall can be found almost everywhere in the districts in Bangladesh. They serve tea, fries, meat, fish, hot water, dal, rice, vegetables, etc. In average they have around 200 customer per day. Stove is an important part of the stall for cooking food and boiling water as well.

Scale
One Cook and one helper employed in cooking; space of kitchen is 15 × 8 feet

Fuel Type
Briquette (made from rice husk) is used every day

Size of Stove
(6 × 2,5) feet

Stove Makers
Brick layers (locally available)

Stove Materials
Foundation/Base:

• Brick and clay construction

Body:

• Bricks and clay

Grate:

• Iron rod ¼ inches

Total cost of stove Tk. 750

Stove Utensils
Aluminum wok and pan of different size

Stove Capacity
They processed 30 kg rice, 2 kg dal, 10 kg vegetable, meat, fishes, eggs, and 30–40 liter of water every day. They cook twice a day, in the morning and the evening, which 1,5 hour require to processing rice and vegetable at once.

Fuel consumption
15 kg of fuel is consumed for one time cooking

Exchange rate US $ 1 = Tk 48

Stove used in Daya Baba tea stall	Another type of stove used in Kubal Mai tea stall

Stove Operation
Ignition of stove is done in the morning using little kerosene and small pieces of wood. While they prepare food to cook the put water to boil first. The cooking time is about 1,5 hour, then fire is reduced just enough to keep the water hot and sometime to warm the food.

Flow Chart of Stove Operation

Ergonomic
No heavy lifting nor bending are required during the process

Stove Maintenance
Regular maintenance and cleaning of the stove is done; the ashes is cleaned every day or as soon it seem dirty.

Stove Durability
Approximately 10 years

Dipping the yarn into the cauldron

Yarn Twisting and Dyeing Industry

Profile of Yarn Twisting and Dyeing Industry
The loom industry is tradition industry in Bangladesh. Possibly, the first loom industry dates back to more than one thousand years ago. Narayanganj, Dhaka, Tangail, Comilla, Sirajgonj, Badarban, Dhittagong, etc., are some places in Bangladesh that are famous for handloom cloths. Many people have adopted the loom industry as a modest means for earning their living. Yarn and cloths used for producing these handloom articles are dyed.

Sometimes yarn is twisted. Fuel wood is the main source of fuel used for steaming the twisted yarn and for dyeing.

When more than one piece of yarn is spun together, it is called twisting. This may be done manually with a charka or by a machine. The twisted yarns must be steamed for one hour or more, according to the thickness or quality of yarn. The dyeing of yarn occurs when a hot dye solution comes in contact with the yarn. The stove is an important part of this industry because it is involved in boiling a large quantity of water and yarn.

Scale of Industry
Cottage industry with 2–5 laborers.

Fuel Type
Fuel wood

Size of Stove
(130 × 75 × 40) cm

Stove Makers
Masons (locally available)

Stove materials
Body:

• Bricks : 80 pcs
• Mud : 0.25 m3

Grate:

• Iron rod (90 cm length, 1.25 cm diameter)

Stove Utensils
Cauldron made of M.S. sheet: (130×75×50) cm

The cauldron is permanently set on the stove.

Stove/Industry capacity
Single batch: 25 kg of yarn can be dyed on one hour.

Total of 200 kg of yarn can be dyed in one day (aprox. 8–9 continuous hours)

Fuel Consumption
200 kg of fuel wood required to dye 200 kg of yarn

Exchange rate: US $ 1 = Tk. 48

Heating the cauldron

Stove Operation
A large cauldron is filled with water, leaving some space for the addition of the yarn. Then, the cauldron is heated by burning firewood/kerosene. When the temperature of the water rises to about 45°C, the dyes are added to the water. The heating of the cauldron is continued and when the water temperature reaches around 60°C–100°C, the yarn is dropped into the cauldron. The yarn is boiled for about 15 minutes for the light shades; the darker shades require a longer time. The quantity of yarn dyed in one batch may be up to 20 kg. The dyed yarn is removed from the cauldron by means of a handling stick and then dried in sunlight. During the dyeing process the yarn is continuously stirred in order to achieve uniform coloring throughout the yearn. The quality of dying which is mainly judged from the uniformity of coloring and achievement of required darkness depends on the skill of the dyer and quality of dyes.

Flow Chart of Stove Operation

Ergonomic
The stove and processing system is not good because it requires much bending and exposure to heat (steam vapors) which cause considerable ergonomic stress to the operator.

Stove Maintenance
The stove is regularly maintained. The ashes in the stove are cleared every two weeks. The entire stove will be cleaned with muddy water once a week.

Stove Durability
Approximately 5 years

Bringing the yarn out of the cauldon

Drying yarn in the sun

CAMBAODIA

Bread Industry

	A typical kiln used in bread industry

Profile of the Bread Industry
Bread is a popular food in Cambodia, usually eaten for breakfast with either tea or coffee. Bread is made from wheat flour with several other ingredients such as salt, yeast, sugar, et cetera, mixed and formed into a dough. The dough is then shaped into desired shapes and sizes and baked in the oven. There are many types of oven, modern ones fuelled by gas, electricity or kerosene and other types using wood or charcoal as fuels.

Scale of Industry
The average production is 1,700 – 2,000 loaves of bread per day. The space required is (8 × 12) m with 10 laborers.

Fuel Type
Wood

Size of Kiln
(300 × 200 × 260) cm

Kiln Makers
Skilled masons, the kiln design is from China

Kiln Materials
Body (double wall)

• Bricks
• Clay
• Racks : Metal
• Cover : Metal

Chimneys

• Metal

Cost per kiln including racks : 8,840,000 Riels

Kiln Utensils
Racks and pans made of sheet metal

Kiln/Industry capacity
Kiln capacity/cycle = 290 loaves of bread
Production capacity = 1,700–2,000 loaves/day (6 hours)
The product consist of 2 size; big and small
One cycle = 20 minutes

Fuel Consumption
2 stare of wood are consumed per day.
1 stare =(1×1×0,30) m

The dough is shaped and weighed, then arranged in metal trays

Kiln Operation
Bread production usually starts in the middle of the day. A dough is made from 120 kg of flour, salt, sugar, other ingredients and water. The dough is left to rise. Afterwards, it is shaped and weighed so that uniform loaf size is achieved. They are then arranged in metal trays. The oven is ignited in the late afternoon and preheated until a desired temperature is achieved. The trays are slid into the oven and the dough is baked for approximately 20 minutes. Between 250–290 loaves of bread of various sizes are baked in a batch. Daily, the oven is operated for a total of 6 hours. For the last batch operation, the fire is left to die out. The bread will be sold in the next early morning.

Flow Chart of Kiln Operation

Ergonomic
A great deal of strength is needed to mix the ingredients to form a dough. However the bread making process does not require much heavy lifting, even though the operator is exposed to heat during the baking process.

Loading dough into the kiln

Kiln Maintenance
Ash needs to be cleaned daily. There is also a need to maintain the temperature so that the oven wall is prevented from cracking.

Kiln Durability
According to the owner; the stove needs to be overhauled every 3 years.

Children Orphanage Center

Profile
The Kompong Chhnang Children's Orphanage presently accommodates 32 persons, including 11 children (age 0 – 14 years), 4 women over 14 years old and 17 men (age 15 – 59 years). The children residing here are fatherless children, orphans and children of poor families. The orphanage also welcomes children who study in the province but are not able to pay for housing in Kompong Chhnang.

The kitchen is a permanent building with a large hall serving as the dining room. The building has wooden walls and is covered with a zinc roof. It is not protected from the wind.

There are two big permanent stoves built by GRET, a French NGO in 1991. One is a rice husk stove which has been broken and unused for a long time. The other stove is a double pot (two hole) stove with a chimney. Although this stove is cracked (in the tunnel between the two pot holes, the stove body and the fire entrance), it is still being utilized. This stove model is designed similarly to the improved palm sugar stove from Thailand. In addition to the two large stoves, the cook also uses three stone stoves with small pots or woks.

Scale of Use
There are two cook and one helper serve this orphanage, the space required is (5×8) m

Fuel Type
Split fire wood

Size of Stove
(238×100×71)cm

Stove Makers
NGO workers (CFSP Cambodia)

Stove materials
Body:

• Bricks
• Clay
• Sand
• Insulation: mixed clay, sand, rice husk

Grate:

• Cast iron

Chimney

• Clay pipes: 3 m height

Stove Utensils
Wok, cast iron

Stove/Industry capacity
The stove is used to accommodate 35 people in average per day; maximum capacity is 60 people

Fuel Consumption
7,5 kg of dry wood are consumed per time cooking or in average 20 kg per day

Stove Operation
The average cooking time is 2–3 hours/day. For breakfast they serve small and light meals only

Flow Chart of Stove Operation

Ergonomic
No heavy lifting nor bending are required during the cooking process

Stove Maintenance
Cleaning and ashes removal should be done regularly

Typical stove used in Children Orphanage Center

Stove Durability
The stove has 2 years old and assumed will last for next 10 years

Khsam Pagoda

Typical of stove used in Khsam Pagoda

Profile
Most people in Cambodia are Buddhist. In addition to performing a religious service, Buddhist monks also undertake an important role in the social life of the community.

Scale of Use
The number of monks and monk servants in residence in the Khsam Pagoda change each month. The average is approximately 92 monks and 13 young monks in residence. The pagoda kitchen serves meals two times every day - breakfast and lunch. There is no dinner served to the monks. The amount of food cooked each day varies according to what the monks receive during their walks in the town during the day.

Fuel Type
Split fire wood

Size of Stove
(196×112×75) cm

Stove Makers
Masons/locally available (for traditional stove); NGO workers (CFSP Cambodia) for improved stove

Stove materials
Body:

• Bricks, Clay, Sand
• Insulated with mixed clay, sand, rice Husk
• Surface : Cement, Ceramic tile

Grate:

• Cast iron

Chimney:

• Clay pipe
• Sheet metal for chimney cap

Door:

• Metal

Stove Utensils
Wok and pan (50–60 cm diameter)

Fuel Consumption
Approximately 18–20 kg of dry wood are consumed per day

Stove Operation
Cooking for food and boiling drinking water are done in the early morning (for breakfast) and in the mid day (for lunch). There is no dinner for the monks.

Flow Chart of Stove Operation

Ergonomic
No heavy lifting nor bending are required during the cooking process

A double pothole stove used in Khsam Pagoda

Stove Maintenance
So far there is no damages or cracks occurred during 2 years of operating the stove. Ashes and dirt should be removed regularly

Stove Durability
Approximately 10 years

Palm Sugar Industry

Typical of stove used in palm sugar industry

Profile of Palm Sugar Industry
The well known palm sugar is sugar made of palm juice and it is processed through traditional ways. There is only one common process, boiling the juice, which containing 9% – 16% of saccharose to evaporate the water content. The process will facilitate the forming of sucrose molecule. This method is done in every places where palm sugar is produced, ranging from India, Bangladesh, Sri Lanka, Myanmar, Malaysia, Thailand, Cambodia, The Philippines up to Indonesian Archipelago.

There are three types of products : liquid, paste and crystal sugar. To enable the process going on, palm juice should be tapped from palm tree then boiled to evaporate the water content of the juice and to form sucrose so the juice will become sugar.

Scale of Industry
Household industry with 5 – 6 laborers. Usually one family which father, mother, son and relatives are involved in the production process. Space required is around (6 × 6) m.

Fuel Type
Wood

Size of Stove
mproved stove :(225×75×60) cm Traditional stove :70 cm diameter, 40 cm high

Stove Makers
Users/locally available (for traditional stove); NGO workers (CFSP Cambodia) for improved stove

Stove Materials
Traditional stove : Bricks and clay; no chimney neither grate

Body :

• Bricks: 280 pcs
• Clay: 1 m3
• Rice husk: 1 gunny sack
• Straw: 1 gunny sack

Chimney:

• Sheet metal; 2.5 meters high
• Metal cap

Grate:

• Metal

Stove Utensils
Iron wok with 60 liter of capacity

Stove/Industry capacity
One day they usually can process 50 liter of juice which has been collected from at least 25 tubes. The production is calculated by total production in one season which has average 147 days/season Total production in one season is about 1,074 kg of sugar.

Fuel Consumption
2.5 kg wood for each 1 kg sugar produced (improved cook stove; 15% more efficient than the traditional stove in wood consumption and duration)

Traditional stove for palm sugar production

Exchange rate : US $ 1 : 3,800 Riels

Stove Operation
All the fresh juice which has collected will be poured into the wok. Usually the amount of the juice is about 30 to 40 liter in a wok. The stove then start to ignited; therefore the juice will be boiled very soon. Boiling is the only process to evaporate water content of the juice and to form sucrose so the juice will become sugar. Soon as the sugar is formed, usually it is indicated by the brownish color of boiled juice and the juice becomes thicker (more viscous), the will be taken off from the stove. People do it by taking off the wok from the stove and put it down on the ground, then poured the sugar into the mould or storing jar.

Flow Chart of Stove Operation

Pouring sugar solution into the storing jar

Ergonomic
Heavy lifting is required especially at the end of the process when pouring the sugar into the mould or storing jar. Another heavy thing is stirring is required continuously during the process.

Stove Maintenance
Small cracks can be repaired easily using clay, ashes and little sugar juice.

Stove Durability
Approximately 6–8 years for ICS and 2 years for traditional stove

Teacher Training Center

Single pothole stove

Profile
The Teacher Training Center is in Suramarith School in the Kompong Chhnang province. The center is a government pedagogy institute for training teachers from all districts and sub-districts in Kompong Chhnang Province.

The improved stove was placed in the training center with hopes that when the trainees return to their homes, they will disseminate information about the improved stoves. There are 2 stoves in this center; one with single pothole and the other has 2 potholes.

Scale of Use
The center provides two meals every day - lunch and dinner - for 150 persons who are training at the center.

Space required : (8×10) m

Fuel Type
Split fire wood

Size of Stove
Single pothole : (120× 94× 75) cm
Double potholes : (210× 92× 84) cm

Stove Makers
NGO workers (CFSP Cambodia)

Stove materials
Body:

• Bricks
• Clay
• Sand
• Insulation: mixed clay, sand, rice husks

Grate:

• Cast iron

Stove Utensils
Wok, cast iron

Fuel Consumption
In average 32 kg of wood are consumed for single pothole and 75 kg of wood for double potholes

Stove Operation
The stove is using to provide 2 meals every day; lunch and dinner

Flow Chart of Stove Operation

Ergonomic
Cooking position is standing; no heavy lifting nor bending are required during the process

Stove Maintenance
Ashes and dirt should be removed every day

Stove Durability
The stove has 2 years old and so far no cracks or damages appears. It was estimated that will last for next 10 years

Two pothole stove

INDIA

Cardamom Curing Industry (Large)

Profile of Large Cardamom Curing Stores
Large cardamom (Amonmum subalutum roxburgh) is the native cash crop of Sikkim and is now being cultivated in eastern Nepal, Bhutan and other northeastern Indian states, such as Darjeeling. India is the largest producer country of large cardamom with an annual production of 3,500–4,000 tonnes, followed by Nepal (2,500 tonnes) and Bhutan (1,000 tonnes).

The export of large cardamom increased during the 1980s by more than ten-fold, with a three-fold increase in the unit price achieved over the past decade, making this a major economic cash crop of the state. Productivity among different plantations varies from as low as 100 kg/ ha to as high as 450 kg/ha, depending on several factors, such as altitude, age, composition, and density of shade trees, etc.

The fresh large cardamom capsules contain about 70–80% moisture, depending on the maturity of the capsule at the time of harvest. Unlike in southern India, where only matured capsules are plucked, the whole large cardamom capsule bunch is plucked in Sikkim. Later, each capsule is separated from the bunch and cleaned for drying. In order to acheive longer storage life and also to bring out its aroma, it must be dried down to a moisture content level below 10%.

Scale of Industry
Large cardamom curing is a small farmers' business. The majority of the plantation units are on small cultivated areas - more than 85 % of the plantations are very small with cultivation area of less than 2 ha. These plantations represent one-third of the total cultivated large cardamom area in the state. Less than 1% of the holdings have a cultivation area of more than 10 ha. Almost 90% of the large cardamom cultivation areas are privately owned.

Fuel Type
Firewood. Large cardamom grows under shade trees. Since large cardamom has to be dried immediately on its harvesting, generally it is dried in bhatti (curing house) in the field. Farmers use fallen trees or cut down nearby trees for use as fuel for the drying process.

Size of Stove
(335 × 310 × 138) cm

Stove Makers
Masons/brick layers (locally available); sometimes, owner

Stove Materials
The bhatti consists of 2 ft thick stone wall structure on all four sides with an opening of about 3' × 4' in the front to make the fire. In many cases, the bhatti is made by digging a depression into the steep slope of a hill. In such cases, the back of the bhatti consists of earth surface and some-times even two of the side walls are also earthen surfaces. Thus, in many cases, only the front wall with a large opening is made with a stone wall structure. In some bhatti, cement walls are used with a smaller fuel port opening.

Comparison of traditional Bhatti system & gasifier system for drying large Cardamom

A meshed platform, made of locally available bamboo mats, is placed on the top of this stone walled structure. It is supported on 4" to 6" diameter wood logs. In some bhatti, chicken wire mesh is used instead of the bamboo mats to minimize the fire hazard. 6" to 8" diameter wood logs are placed on all four sides on top of the mesh so that large cardamom capsules can be spread within these border logs. Unlike in southern India, where small/green cardamom is spread in single layers in order to prevent rubbing of the capsules which may result in faded green or yellow color, the large cardamom capsules in Sikkim are spread in a thick bed of 7" – 8" depth.

The top large cardamom bed area ranges between 4 –9 sq. meters, depending upon the size and capacity of the bhatti. The mesh is placed about 1.2 – 1.8 meters above the ground level where the fire is located. This height is probably necessitated in order to reduce the charring and burning of capsules due to flying sparks and to keep the flue gas temperature below a certain level to prevent over-drying.

Stove Utensils
Wiremesh trays or bamboo mats: 2.5 – 3 sq. meters

Stove/Industry capacity
Generally, farmers dry about 400 – 600 kg fresh large cardamom capsules in one batch and depending upon size of the estates, 4 – 20 batches are dried in one season.

Stove Operation
The drying of large cardamom is done immediately after harvesting. Capsules collected in the estate throughout the day are brought to the curing chamber (bhatti), in gunny sacks or bamboo baskets. Individual capsules are separated from the bunch. After the completion of the previous drying batch, the fire is extinguished and dried capsules are sorted in the gunny sacks. Then, the fresh capsules are spread in 8" – 10" thick beds on the wiremesh tray by uniformly spreading it with bamboo or a spoon-like wooden spreader. After completion of spreading, the fire is again ignited. The earlier carbonized wood pieces are used to help ignition. During the night, wherever there is no permanent shed, the large cardamom bed is covered with a plastic sheet to prevent moisture absorption by capsules during chilly night weather. After completing 20 – 24 hours of drying, the capsules are turned. For this purpose, dried capsules are stored in the sacks and partly dried capsules are spread on the meshed structure as the bottom layer. Then the dried capsules are spread on top of this layer. This accelerates the drying process of capsules on the bottom layer and helps to maintain uniformity in the drying operation. After the reshuffling of the capsule bed is completed, the fire is again increased to complete the drying within the next two hours. In traditional bhatti, the total drying time varies from 25 – 40 hours, depending upon several factores, such as the inital moisture content of the capsules, the bhatti structure (opening mesh, leakage holes, etc.), and the fire level maintained.

Flow Chart of Stove Operation

In some bhatti, a metallic checken wire mesh is used instead of bamboo mats. Where bamboo mats are used, the operator keeps the fire at a low level or he tries to reduce the flame height by placing fresh wood over the burning wood. In spite of this, the flying sparks often manage to reach the large cardamom bed causing fire. In order to overcome this problem, the operator must pay close attention to the stove and sprinkle water on the mats from below as soon as any smoke appears.

The capsules are spread on the meshed structure

Traditional Bhatti for drying large Cardamom

Stove Maintenance
Routine repair of stone walls is done every season before starting the first drying batch. The bamboo mats are generally replaced every one or two years, however, the wire mesh lasts for several years.

Stove Durability
Approximately 5 – 6 years.

Cardamom Curing Industry (Small)

Profile of Small Cardamom Curing Stores
Small cardamom (Elettaria cardanomum maton) known as the “Queen of Spices” is a native of the southwestern mountains of the Indian peninsula. Small cardamom is grown abundantly in the lush green forests of Western Ghats, touching the states of Kerala, Karnataka and Tamil Nadu. At present, Kerala occupies 60% of the estimated area and 74% of production of small cardamom in India. The current world production of small cardamom is estimated to be about 7,700 M.T., shared by India (57%), Guatemala (33%), Tanzania (6%), and Sri Lanka (4%).

Fresh small cardamom capsules have a moisture content of about 80% (w.b.) that must be reduced to about 10% (w.b.) The fresh green cardamom must be properly dried in order to bring out the aromatic flavor and for longer preservation. Sun drying is not allowed, as it bleaches the green color of small cardamom making it an appealing. The quality of the cured capsule is determined by its green color and size, which varies from 8.5 mm bold variety to 4 mm pan variety. The green color will be retained only with proper curing while drying. While drying, care should be taken to remove moist air which otherwise bleaches the color of the capsule resulting in faded green or yellow color cardamom. The rate of moisture removal during the initial stage of drying must also be carefully controlled to prevent bubbling of capsules which results in blackish-yellow capsule and splitting of the skin.

Scale of Industry
Small cardamom is mainly a small farmer's business, with 84% of planters with less than 4 ha. of land, but 5% of planters own 41% of the total area. Thus, these plantations are dominated by small farmers in number and by a few very large farmers. Productive plantations range in size from small areas well under 0.5 ha. to very large estates of over 200 ha.

Fuel Type
Firewood as a source of energy for drying small cardamom.

Stove Makers
Masons/brick layers (locally available)

Stove Materials
The majority of the small cardamom is still cured by a time-old, inefficient process in cardamom curing chambers, locally called “cardamom stores”. The general operating principle of this curing chamber is that of space heating with a heat exchanger. Hot flue gas, created by the combustion of the fuel wood with air in an oven, is passed through metal pipes laid inside the curing chamber. Air surrounding the flue pipe heats up and rises to the top of the curing chamber by natural convection. The fresh cardamom capsules are spread in single layers on wire mesh racks inside the curing chambers.

Thermal analysis of the heat exchanger (flue pipe type) indicates that this conventional small cardamom curing chambers operates with very low overall efficiency (about 3.8%). The design and dimensions of these curing chambers have wide variations. There are two categories of the cardamom stores in operation.

The first type (fuel efficiency is 2% and below) consists of a single chamber without any upper story. The oven is usually outside the chamber and the hot flue gas pipe from the oven passes through the chamber and then outside. At the end of the second or third hour of operation, the windows are opened to remove the excess moisture. The chamber contains no insulation.

The hot flue gas pipes in the curing chamber

The second type of curing chamber consists of a ground floor where the oven (in some cases outside) and hot flue gas pipes are situated and one or two upper stories in which small cardamom capsules are spread in single layers on the ground on wooden rafters and wire mesh, and on vertical wire mesh racks. The windows are opened after the second or third hour to allow all moisture to escape. Most of the existing curing chambers fall under this category (fuel efficiency is 3.8%). In some curing chambers, an exhaust fan is provided at the top to remove moist air during the initial period of drying.

Stove Utensils
Wiremesh trays: (0.5 × 1) m

Stove/Industry capacity
Varies from 100 kg fresh capsules to 1,000 kg fresh capsules, depending upon the size of the plantation and yield.

Fuel Consumption
Around 3–4 kg of firewood is required to dry 1 kg of green cardamom. On an average 0.23 – 0.25 kg of cured capsules are obtained from 1 kg of green cardamom.

Stove Operation
The small cardamom is loaded on wire mesh racks inside the curing chamber when the temperature is approximately 35°–38°C. The temperature is slowly increased to 42° –45°C during the first 7–8 hours. During this period, ventilators are kept open to drive out the moist air. In some large curing chambers, exhaust fans are fitted in the roof to drive out the moisture during the first 7 – 8 hours. Later, the ventilators are closed and the temperature is slowly raised to 50° -55°C and maintained at that level for the next 10–15 hours. During the last 5–6 hours, the temperature is raised to 58° – 60°C to ensure that the moisture content is brought down to within the desired level of 8 – 10%. Total time required for curing of small cardamom varies from 20 – 24 hours (curing chambers fitted with an exhaust fan) to 30 – 36 hours (old curing chambers without exhaust fan).

Flow Chart of Stove Operation

Stove Maintenance
The furnace (where the wood is burnt) and the inital portion of the flue gas duct are the major components that need frequent repair.

Stove Durability
Durability of furnace where wood is burnt is about 5–8 years, depending upon fabrication quality. The grate and initial flue gas pipe/duct needs replacement approximately every other year.

Charka Silk Reeling Industry

	Boiling the cocoons to release the gum before reeling the silk filaments

Profile of Charka Silk Reeling Industry
A charka is the simplest mechanism for silk reeling, in which both the cooking and reeling operations are carried out in the same basin. No electricity is required to run the charka. Though the quality of silk yarn produced in charka units is poor, the charka units account for nearly 50% of India's total raw silk yarn production, which is about 15,000 metric tons per annum. The silk yarn thread produced in the charka oven is generally a little rough and course, and is preferred for weaving traditional handloom silk sarees in India. There are more than 35,000 charka ovens in India, the majority of them are located in the traditional sericulture states in southern India - Andhra Pradesh, Karnataka and Tamil Nadu.

The charka reelers buy the cocoons from the government regulated cocoon markets and sometimes poor quality (partly reeled, double or pierced cocoons from nearby cottage basin silk reeling units) cocoons to produce raw silk yarn. Various steps involved in the production of raw silk yarn from cocoons are: stifling, cooking, and reeling. Stifling is the process of killing the pupa. Cooking is the process of locating the end of the silk baves by subjecting the cocoons to boiling water. The sericin and part of the gum is dissolved in this operation. This process allows release of gum from the cocoons and makes them amenable for continuous unwinding of silk filament. The cooked cocoons are then subjected to reeling, wherein the located ends are reeled onto the reels.

The stove is an important part of the charka reeling unit as it provide thermal energy needed for cooking cocoons. In the majority of charka units stifling is also done using the same stove by putting about 7 – 10 kg of cocoons into a bamboo basket in which the sides are closely woven, but the bottom is loosely woven in order to allow the steam to pass through easily. A thick gunny sack is tightly stretched over the top, leaving the sides and the bottom free. The basket is placed over the mouth of a vessel in which water is boiled.

Scale of Industry
Small-scale cottage industry with 2 laborers (often family members)

Fuel Type
Biomass fuel (e.g. groundnut shell, tamarind husk, paddy husk, coffee beans, sawmill waste, maize cob, eucalyptus leaves, etc.)

Size of Stove
(126 × 76 × 45) cm

Stove Makers
Masons/brick layers (locally available), sometimes owner

Stove Materials
Although charkas are not made according to any specifications of measurements, they are all similar in design and constructional details. Generally, each charka oven consists of three distinct parts, namely the mud platform, distributor and reel.

The mud platform is rectangular in shape, usually measuring about 60 – 75 cm high × 90 cm wide × 120 cm long. The forepart has a built-in fireplace with a basin fitted over it. The other part of the platform is solid, with a flat top intended for the reeler to sit and attend to the reeling operations. The basin is of thick copper sheet metal and is generally of circular shape, measuring about 50 cm in diameter and 20 cm in depth. Occasionally, instead of a copper basin which is comparatively costly, one half of a vertically bisected earthenware pot is used. Even the use of an aluminum basin is quite common. The basin is buried up to its brim in the mud platform with a spacious part of the basin's underside exposed to the fireplace below. The basin is used for both cooking and reeling operations.

The fireplace, which is not provided with a grate or ash pit is generally built for burning fire wood or dry twigs. At the opposite end of the opening, there is a chimney provided for the flue gases to escape.

A typical Charka stove

Construction material for one charka oven:

• Bricks 200 pcs
• Cement 10 kg
• Sand 30 bondlies
• Paddy husk 5 kg
• Chimney 1 pc (4" diameter)
• Grating 1 pc (6" × 6")
• Metal steel rod 0.5 kg (10 mm)
• Chicken wire mesh 1 meter
• Fire box door/air door 1 each

Stove Utensils
Cooking vessel: copper preferred (aluminum also used), for both cooking and reeling operations; in the form of a reverse frustrum cone with top opening about 18" diameter at the top and base diameter about 12 " wide, with depth about 6".

Stove/Industry capacity
One batch requires 45 minutes - one hour, processes approx. 1 kg of cocoons
One shift produces 4 – 5 batches.

Fuel Consumption
Specific fuel consuption (kg fuel/kg cocoon) is higher for fast burning fuels, such as groundnut shell and eucalyptus leaves, compared to slow burning fuels, such as paddy husk:

• Groundnut shell 2.44 kg/kg cocoon
• Eucalyptus leaves 3.26 kg/kg cocoon
• Sawmill waste 1.93 kg/kg cocoon
• Paddy husk 1.87 kg/kg cocoon

It is estimated that more than 120,000 metric tons of biomass fuel is consumed every year in charka reeling ovens.

Exchange rate: US $ 1 = Rp. 42

Stove Operation
The process is carried out by two persons sitting on opposite sides of the basin. One person attends to the cooking operation and the other to the manual reeling operation. First, the water in the basin is brought to boiling temperature. The cocoons are then cooked for a few minutes, with simultaneous stirring and mixing. After the cooking is over, the temperature in the basin is reduced by adding cold water and by simultaneously reducing the burning rate of the fuel by closing a damper to cut the air supply. The manual reeling operation starts now with the reeler rotating the charka by hand and the other person attending to the process of feeding the silk threads to the charka. In some units, where severa/charka ovens are installed under the same shed, the reel is power-driven by a common shaft. After all the cocoons are processed, the cooking operation will start again by increasing the burning rate and the process continues. After every batch of operation (processing 1 kg cocoons in about 1 hour), the water in the cooking basin is replaced.

Flow Chart of Stove Operation

Ergonomics
No heavy lifting nor bending are required during the process.

Stove Maintenance
Ash and char are removed from below the grate and cleaning of the vessel is done every day. The amount and frequency of ash removal depends on the type of fuel used.

Stove Durability
5 years if maintained properly

Silk Reeling Industry

	Cottage basin silk reeling oven

Profile of Silk Reeling Industry
India is a traditional seri-cultural country and ranks second only after China in silk production. Mulberry silk production accounts for the major share. It is concentrated mainly in the states of Andhra Pradesh, Karnataka and Tamil Nadu. The current annual production of silk yarn in India is about 15,000 tons. There are over 26,000 cottage basin ovens installed in different states.

The worm rearer feed the silkworms (pupae) with mulberry leaves and they grow rapidly. After the fifth instar (stage of worm growth), the worms are mounted on bamboo mounts to allow them to spin the cocoons. After the spinning is complete, the cocoons are sold to the reelers.

The reelers buy the cocoons from the government regulated cocoon markets and produce raw silk yarns. The reeling industry is predominantly a cottage-based one. There are various steps involved in production of raw silk yarn from cocoons: stifling, cooking, reeling, re-reeling, skeining, bookmaking and bundling.

Thermal energy is needed for the first four steps. The first two steps are more energy intensive and account for the major share of the total energy requirement. Stifling is a process for killing the pupae by heating the cocoons with steam for a short duration and drying the cocoons for storage. The stifle cocoons are stored until they are cooked.

The processing of stiflling cocoons - cooking, reeling, and re-reeling - is the main activity of the silk reeling units. The cocoons are cooked in boiling water contained in aluminium or copper cooking vessels for about 1–2 minutes, with continuous, vigorous stirring with wooden rods. This process allows release of gum from the cocoons and makes them amenable for continuous unwinding of silk filament in reeling basins.

The cooked cocoons are then subjected to reeling, wherein the ends of the filament are reeled onto the reels. In re-reeling, the already reeled raw silk is reeled again on to the standard sized reels. The raw silk is then skeined and bundled.

Scale of Industry
Predominantly cottage-based industry. For operating a typical 6-pan oven, about 20–25 laborers required.

Fuel Type
Primarily fuel wood

Size of Stove
(230 × 80 × 115) cm.

Stove Makers
Masons/brick layers (locally available), sometimes owner

Boiling the cocoons

Stove Materials
For 4-pan oven:
Body:

• Bricks 750 pcs
• Cement 3 bags
• Sand 2 cart load
• Paddy husk

Grate:

• Grating 1 pc, 10" × 10"
• MS rod 4 kg, 10 mm
• Chicken wire mesh 4 meters
• Fire box door/air door, 1 pc.
• Pipe fittings 3/4" gate valve, 2m GI pipe

Chimney:

• Metal sheet 1 pc, 6" diameter

The cooking operations and the reeling operations are carried out separately.

Cooking unit
The cooking unit consists of a masonry structure of a convenient height in which several, usually four, cooking basins are embedded in row. The basins are normally made of copper (20 cm–22 cm diameter, 20 cm depth). The oven is well constructed with ash, pit, grating, and chimney for the flue gases to escape. In the path of the exhaust gases, a fairly large metallic water drum is embedded to serve as a hot water source for the reeling basins. The cooking unit is located a little distance away from the reeling unit to prevent the heat and smoke from causing disturbance to the reelers. The average water temperature in the cooking vessels is 87°–96°C. A handful of cocoons are taken each time and put into the cooking basins. A stick is used to brush the cocoons to separate the floss and locate the ends of the filaments. The whole operatine takes about 1–2 minutes.

Reeling unit
The reeling unit consists of four to five reeling basins. Each basin is usually made of copper and is embedded into a table (45 × 25 × 7.5) cm. The average temperature of water in the reeling basin is maintained at around 40°C in order to facilitate reeling operation. Taps are provided to draw water the hot water drum of the cooking unit.

Stove Utensils

• Pans: 3 – 6 pc, preferably copper, 8.5" – 9" opening with 7.5"–8" bottom, permanently fixed on stove.
• Water drum: 1 pc, mostly copper, 40 cm–55 cm diameter, 150–250 lt.

Stove/Industry capacity
Generally, the 6-pan cottage basin oven has 10 reeling basins. The reeler generally processes about 100 kg cocoons/day with 10 reeling basins, to produce 10 kg raw silk yarn/day.

Fuel Consumption

Approximately 1.73 kg fuel wood/kg cocoon processed = 17 kg/1 kg silk yarn

Overall energy efficiency of the ovens is auite low (-10%). It is estimated that about 1,450.000 tons of fuel wood are consumed every year for silk yarn production. This varies seasonally and the the quality of cocoons which affects the amount of cocoons required to obtain one kilogram of silk yarn.

Exchange rate: US $ 1 = Rs. 42

Stove Operation
About one hour before actually reeling begins, the oven is ignited. All the cooking vessels and the water preheating drum are filled. It takes about an hour to heat all the water used for inital filling of the reeling basins. During operation, the reeling basin water remains warm due to hot water carry over from coking basins to reeling basin along with the cooked cocoons. Warm water is added to the reeling basin if required.

Flow Chart of Stove Operation

One person maintains the fire inside the oven to keep water in the entire cooking basin boiling. One person manages the water supply in all the cooking vessels. The cocoons are cooked with the water inside the cooking basin is in the range of 90°-96° C. If it is too hot, the operators add water. Some amount of charcoal is removed from the oven in order to use it in the re-reeling operation. It is placed on wire mesh placed below the re-reeling shaft to keep the air warm oround the re-reeling shaft. This helps to dry the thread more quickly.

Unwinding of the silk filaments

Ergonomics
No heavy lifting nor bending are required during the process.

Stove Maintenance
Routine daily maintenance, e.g. removal of ash and char from below the grate and cleaning the vessels, are necessary.

Stove Durability
5 years if maintained properly

INDONESIA

Bakpia Industry

Stove used in Bakpia industry

Profile
Bakpia is a snack which is quite well known in Indonesia. It originated from China. There are several types of bakpia with various fillings such as chocolate, beans, pork, fruits, etc. In Yogyakarta there is one very famous bakpia industry with mungbean filling. This snack which is made from mung beans is a popular souvenir item that domestic Indonesia tourists take home with them.

Although it is located in the urban center of Yogyakarta, wood stove is still used. According to the producer, the use of wood stove is maintained as it imports a certain flavour to the cake, which is made of mixture of mungbean and sugar. This is then wrapped within a flour-egg dough and placed on a stainless steel sheet and baked in an oven.

Scale of Industry
Household industry with 15 laborers.

Fuel Type
Wood for the stove to cook the dough Charcoal for the oven to bake the bakpia

Size of Stove
Stove: (150 × 170 × 70) cm
Oven: (105 × 135 × 200) cm

Stove Makers
Masons, locally available

Stove Materials
Stove
Foundation:

• Bricks
• Cement

Body:

• Brick: 1000 pcs
• Portland cement: 2 sacks
• Sand: 1 m3
• Sheet metal (for racks)

Chimney:

• Clay pipes

Cost/stove: Rp. 150,000

Oven Foundation:

• Bricks, Cement, Sand

Body:

• Brick: 2,500 pcs
• Portland cement: 4 sacks
• Sand: 3 m3
• U-rail: 2 pcs, 200 cm length

Chimney:

• Clay pipes

Cost/oven: Rp. 600,000

Exchange rate US $ 1 = Rp. 8,350,-

Stove Utensils

• Wok: diameter 90 cm, steel, fixed permanently to stove, sealed securely
• Pan: stainless steel, height 70 cm, diameter 65 cm
• Tray: metal (150 × 70 × 5) cm
• Table: glass covered to make patties and arrange on the tray

Stove/Industry capacity
Stove: 25 kg mung bean mixture to make approximately 5,000 bakpia Oven: 2,500 pieces of bakpia/batch

Fuel Consumption
Stove: 2 bundles of firewood (18–20 kg)

Oven: 1 sack of charcoal (25 kg)

Stove Operation
The pan is 75% filled with water which is then boiled in preparation for steaming the mung bean paste. When the water begins to boil, the mung beans which have been mixed with sugar, are placed in the wok. At the same time, the flour-egg dough is prepared. The mung bean paste is wrapped in the dough, shaped into cakes and placed on the tray, which is then placed in the oven.

Flow Chart of Stove Operation

The Bakpia are arranged in the tray then placed in the oven

The charcoal are used to bake the cakes. The oven is preheated while the bakpia are being prepared. After approximately 15 minutes, the bakpia are turned over then baked until done.

Ergonomic
No heavy lifting nor bending are required during the process.

Stove Maintenance
Stove: Ashes are cleared away every morning before use. If there are any cracks in the wok, they must be repaired immediately with a mixture of cement and sand. The chimney is cleaned when necessary, usually every six months.

Oven: The ashes are always cleared away before use. If the oven is damaged, it is repaired with cement and sand, by widening the crack and plastering it with cement and water.

Stove Durability
10 years in operation

Coconut Oil Industry

Boiling coconut milk

Profile of Coconut Oil Industry
Cooking oil made from coconut primarily serves the traditional market. The price of the oil is very much influenced by the price of factory-produced cooking oil.

The coconut are grated using simple grating machine. This flesh is then mix with water, and squeezed to obtain coconut milk. The coconut milk then boiled under continuous and strong fire before sieved to separate oil and waste (blondo) which can be eaten.

The stove is very important in this industry because it cooks the coconut milk for approximately 2 hours until all the oil is extracted.

Scale of Industry
Household industry with 4 laborers.

Fuel Type
Coconut shell and wood

Size of Stove
(150 × 50 × 30) cm

Stove Makers
Brick layer (locally available)

Stove Materials

Body:

• Bricks: 20 pcs
• Cement: 1 sack
• Sand: 0.5 m3
• Clay
• Metal strip

Cost/stove: Rp. 150,000

Stove Utensils
Wok: 3 pieces-diameter 60 cm, permanently fixed on the stove and tightly sealed with clay

Stove/Industry capacity
30–35 lt. coconut oil from 300 coconuts are produced daily

Fuel Consumption
300 coconut shells (from those used for processing),

Fire wood: 25 kg for 3 days of work.

Add some water to grated coconut

Coconut is grated using a simple grating machine

Exchange rate: US $ 1 = Rp. 8.350

Stove Operation
The three woks are filled with coconut milk and the fire is ignited. Within 15 minutes, the coconut milk in the first wok starts to boil. The milk must be stirred constantly to avoid any sticking to the wok. After two hours, the milk in the first wok has become oil and is sieved to separate oil and the waste(blondo). The milk in the second wok which is already hot is then transferred to the first wok.

Flow Chart of Stove Operation

Stove used in coconut oil industry

Ergonomic
Convenient for cooking because no bending is necessary as the stove is high enough.

Stove Maintenance
Routinely cleaned. Ashes are always removed prior to use. Any damage to the body is immediately repaired by local masons.

Stove Durability
Approximately 5 years

Geplak Industry

Profile of Geplak Industry
Geplak is made from coconut and sugar. This snack, characteristic of the Bantul regency of Yogyakarta province, is produced by a family industry which continues to thrive because the demand for geplak continues to increase, not only in Yogya and the surrounding area, but throughout the country.

The stove is used in the cooking of the young coconut and sugar mixture.

Scale of Industry
Household industry with 15 laborers.

Fuel Type
Coconut shell.

Firewood can be used in needed in addition to the coconut shell and if easily available.

Size of Stove
(90 × 70 × 25) cm

Stove Makers
Users, locally available

Stove Material
Body:

• Brick: 100 pcs
• Sand: 1 m3
• Clay: 0.5 m3
• Rice husk: 1 sack
• Iron bar: 1 piece (70 cm)

Chimney:

• Clay pipes

Cost of stove: Rp. 100.000

Stove Utensils

• Wok: diameter 60 cm
• Metal basin (for cooked geplak)
• Woven basket (for cooling)

Stove/Industry capacity
There are 5 stoves; each stove can cook approximately 20 batches/day which produce 8 kg of geplak/batch.

Fuel Consumption
Each stove cooking 15 – 20 batches/ day uses approximately 2 sacks of coconut shells (50 kg) and 3 bundles of firewood (15 kg)

Exchange rate: US $ 1 = Rp. 8,350,-

Stove Operation
Shredded coconut and sugar are mixed while heating on the stove. If the mixture no longer sticks to the pan, add flavoring and coloring. After 30 minutes on the stove, the geplak is cooked.

Flow Chart of Stove Operation

Ergonomic
No heavy lifting is required, but the cook need to bend or sit during the process because the stove is low.

Stove Maintenance
Ashes are removed every morning. If there is any damage to the stove opening, it must be repaired immediately with a mixture of sand and clay. The chimney is cleaned every 3 months.

Stove Durability
Approximately 5 years

A typical stove used in Geplak industry

Gudeg Restaurant

Single pothole stove	The three pothole stove is used in Gudeg making

Profile of Gudeg Restaurant
One of the food items which Yogya is famous for is gudeg, a dish made from young jackfruit stewed in coconut milk. Gudeg can be found in almost every restuarant in Yogya.

The stove which uses firewood is important for retaining the characteristics flavor of gudeg while it is boiling the young jackfruit, chicken, tofu, tempe, and sambal krecek, a side dish made with beef rind. In order to get best taste, the gudeg made one day should be consumed the next day. Fried chicken, often served as a side dish, must also be cooked using a wood burning stove for flavor.

Scale of Industry
Household industry with 20 laborers

Fuel Type
Fire wood

Size of Stove
(100 × 100 × 50) cm for 1-hole stove
(160 × 80 × 40) cm for 2-hole stove
(180 × 75 × 40) cm for 3-hole stove

Stove Makers
Brick layers (locally available)

Stove Materials
2-and 3-hole stoves:

• Cement
• Iron (8 m)
• Clay
• Sand

Single hole stove:

• Square stones
• Clay
• Sand
• Iron railing for top of hole

Stove Utensils

• Wok: diameter 60 cm, steel, 6 pcs
• Pan: stainless steel, 35 cm high, diameter 50 cm, 12 pcs
• Metal basin: diameter 40 cm, 10 pcs

Stove/Industry capacity
Each day (4 am – 8 pm):

• 100 whole chickens
• 3,000 eggs
• 2 kwintal young jackfruit
• 120 pc tempe
• 100 pc tofu
• 5 kg beef rind

Fuel Consumption

Approximately 2 m³ firewood/day

Exchange rate: US $ 1 = Rp. 8,350,-

The three pothole stove	The two pothole stove

Stove Operation
The stove is ignited at 4 a.m. and kept in operation until 8 p.m. The heat should be kept low in order to obtain the specific taste of gudeg.

Flow Chart of Stove Operation

Ergonomic
No heavy lifting nor bending are required during the process.

Stove Maintenance
Ash and charcoal are removed daily. If any stove is damaged, it is repaired immediately and left to dry for one day.

Stove Durability
Approximately 10 years

Beef Rind Industry

Stove for frying in beef rind industry	A typical stove for boiling

Profile of Beef Rind Chips Industry
Kerupuk rambak (beef rind chips) are made from buffalo or beef rind. This family industry has been in existence for more than 20 years, and continues to thrive in response to a high demand for the product. This high protein food is used in sambal krecek, a side dish that is served with gudeg, as well as with Padang-style food (from West Sumatra), and also by itself as a snack food.

The stove is used to boil the raw rind so that it can be easily cleaned, and also to fry the dry rind.

Scale of Industry
Household industry with 20 laborers.

Fuel Type
Hard wood (for frying), wood shavings or firewood (for boiling)

Size of Stove

• Stove for boiling:
  (140 × 140 × 55) cm
• Stove for frying:
  (380 × 75 × 40) cm

Stove Makers
Brick layers (locally available)

Stove Materials
Stove for boiling:

• Brick: 200 pcs
• Clay: 0,5 m3
• Clay pipe for chimney: 5 pcs Cost/stove: Rp. 100.000

3-hole stove for frying:

• Brick: 750 pcs
• Clay: 2 m3
• Clay pipe for chimney: 5 pcs Cost/stove: Rp. 350.000

Stove Utensils
Wok: diameter 100 cm, iron, 4 pcs

Stove/Industry capacity
Each day (7 am – 4 pm): 100 kg of raw rind are boiled. The 2-holes of the 3-hole stove is used for the first frying process; each time fries 50 kg for about 3 hours frying time. One of the holes of the 3-hole stove is used for the last stage, which needs a higher flame because the oil must be maintained at boiling temperature. The average production is 600 kg dry beef rind/day.

Fuel Consumption
1,500 kg dry wood + 20 kg sacks wood shavings/day

Exchange rate: US $ 1 = Rp. 8,350,-

Stove Operation

The wok on the single hole stove which is used to boil the raw rind is half-filled with water which is then heated until boiling. The raw rind which has been cut into squares (20 × 20) cm is added to the boiling water. When it is soft, it is removed from the fire and cooled. Then, the hair and underskin are removed. The rind then sliced into smaller pieces (1,5 × 5 cm) before frying.

Flow Chart of Stove Operation

Two of the woks on the 3-hole stove are prepared for the first stage of frying. They are half-filled with cooking oil and then heated until boiling. After the oil boils, the firewood is reduced, then the raw rind is added. The third hole (in the middle of the stove) is used for the final frying proceess. For this stage, the oil must boil constantly and the firewood must be centered under the pot.

The rinds are sliced into smaller pieces before frying

Ergonomic
No heavy lifting nor bending are required during the process.

Stove Maintenance
Ash is removed every day before use. If the stove is full of ash at mid-day, the ash must be cleared away so that the fire can burn well. If there is any damage to the stove, it must be repaired immediately.

Stove Durability
More than 5 years.

Tapioca Chip Industry

Typical stove used for steaming in tapioca chip industry

Profile of Tapioca Chip Industry
Tapioca chips, or as they are often called, krupuk terung Bandung (because most of these industries were originally in Bandung, West Java), is a popular snack. It is very inexpensive and can be eaten with any meal. One can easily find one of these industries in every town in Indonesia, so it can be said that it serves as the livelihood of thousands of families. For instance, in samll towns like Cepu and Padangan, Central Java, there are 35 tapioca chip industries, each employing an average of 5 – 12 people.

The stove functions to cook the dough and spices and also to fry the dried chips.

Scale of Industry
Household industry with 6 laborers.

Fuel Type
Dry rice husk (for cooking dough) Wood & rice husk (for frying chips)

Size of Stove

• Single hole stove; for boiling:
  (150 × 70 × 200) cm
• Double hole stove; for frying :
  (100 × 70 × 250) cm

Stove Makers
Masons, locally available

Stove Materials
Foundation :

• Bricks

Single-hole stove:
Body :

• Brick: 500 pcs
• Cement: 3 sacks
• Sand: 1 m3
• Iron ring (8 mm) to hold wok
• Used iron sheet metal (80 cm): 10 pc

Chimney :

• Bricks
• Iron sheet metal (0.3 mm): diameter 8 cm, 3 m high

Double-hole stove:
Body :

• Brick: 7,500 pcs
• Cement: 5 sacks
• Sand: 2 m3
• Iron ring (6 mm) to hold wok
• Used iron sheet metal (75 cm): 10 pc

Chimney :

• Bricks
• Iron sheet metal (3 mm): diameter 8 cm, 3 m high

Stove Utensils

• Chip cutting machine
• Wok: iron, 3 pcs (diameters 60 cm, 90 cm, 115 cm)
• Covers: aluminum
• Bamboo trays
• Drainers
• Frying equipment: made from wire

Stove/Industry capacity

• Single stove: steam 1.5 kwintal dough (7 am – 12 noon)
• Double stove: fry 1.5 kwintal chips (3 pm – 6 pm)

Fuel Consumption
Average: 100 sticks firewood + 15 sacks rice husk (8 kg each)

Exchange rate: US $ 1 = Rp. 8,350,-

Packaging the tapioca chips

Stove Operation
The single-hole stove is ignited at 5:30 am. The wok is filled 75% with water and heated. The initial firing uses teak wood until the flame is considered sufficient, then it is fed with rice husk to maintain boiling temperature. The chip ingredients are mixed, then placed above the boiling water. The pan is covered with an aluminum cover until the contents are cooked, then the cooked batter is quickly cut to size and dried in the sun.

Flow Chart of Stove Operation

The dried chips are then ready to be fried on the double-hole stove. This is done at 3 p.m., so that the chips will be fresh for distribution early the next morning. The stove is initially ignited with dry firewood and later with a combination of wood and rice husk to control the heat of the cooking oil. The back pot (medium hot) is used for the first frying and the front pot (over the central fire) is used for the final frying.

Ergonomics
No heavy lefting nor bending are required during the process.

Stove Maintenance

Ash is removed every morning. If there is any damage to the stove, it must be repaired with clay and water before being used again.

Stove Durability
The two stoves in use are 10 years old

Tofu Industry

Grinding the soybean	Boiling the soy porridge

Profile of Tofu Industry
Tofu is a famous and widely consumed food in almost any part of Indonesia and in many other countries in Asia. It is considered as a good source of protein. Tofu is made from soya beans which is finely grounded and extracted into a kind of milk. The milk is then boiled for a few hours until it becomes thick. The thick fluid is sieved with fine cloth to get fine grade of solution. The solution is then mixed with some acetic acid that functions as coagulant for the protein in the solution. Once it settled, the water is removed and the white soft part is collected and pressed until it becomes hard, and cut into small pieces called tofu.

Stove is an important part of tofu industry because it needs long time boiling of large quantity solution.

There are two methods of heating the soy porridge in the process of making tofu: by cooking over heat and by steaming.

Scale of Industry
Household industry with 10 laborers.

Fuel Type
Primarily residue from eucalyptus leaves obtained from the eucalyptus oil industry in the region. If continuous rain dampens the residue, then rice husks are used.

Size of Stove
Stove: (120×45×45) cm
Steamer: (120×60×55) cm

Stove Makers
Owner with the Department of Industry, Gunung Kidul regency, Yogyakarta Special Province

Stove Materials
For Direct Boiling Stove

Foundation:

• Square blocks: 4 m3
• Cement/sand mixture (1:5)

Body:

• White stone
• Cement/sand mixture (1:6)

Fire box:

• Bricks
• Cement/sand mixture (1:5)

Grate:

• Strip metal

Chimney:

• Sheet metal

Cost/stove: Rp. 250,000

For Steamer Stove

Foundation:

• Bricks, Cement, Sand

Body:

• Sheet metal

Grate:

• Strip metal

Chimney:

• Sheet metal

Cost of stove: Rp.8.500.000,-

Heating the soy porridge with steam	A typical of steamer stove

Stove Utensils

• Pan: stainless steel, height 60 cm, diameter 80 cm; 4 pcs
• Pan: stainless steel, height 60 cm, diameter 90 cm; 2 pcs
• Mold for square tofu
• Wok: iron diameter 90 cm

Stove/Industry capacity
Each day (7 am – 3 pm) 3.5quintal of soybeans are processed.

Fuel Consumption
4 m3 eucalyptus leaf residue to cook 10 quintal soybeans (3 days)

Exchange rate: US $ 1 = Rp. 8,350,-

Stove Operation
Fire is ignited with eucalyptus leaf residue which burns easily. The water in the pans begins to boil approximately 30 mintues later. At the same time, the soy beans which have been soaking in water are ground with a machine, then taken to the pans. The steam cooks the soy porridge.

Flow Chart of Stove Operation

It takes approximately 7 minutes after boiling for the tofu to agglomerate. The agglomeration is strained through a thin cloth screen to get the primary ingredient of tofu. It is then pressed into square molds.

Ergonomics
It need strong man to stir porridge continuously.

Stove Maintenance
Ash from the previous day is always cleaned away in the morning. When the water begins to boil, the steam pipes are checked for obstruction. The steam pipe connections are examined every 6 months. The ash in the chimney is cleaned once every year.

Stove Durability
Approximately 10 years

Wingko Snack Industry

Loading the Wingko into the oven	The racks are placed near the flame

Profile of Wingko Industry
This wingko industry is a family business which has been passed down through several generations. Because this snack food industry originated in Babat village in Lamongan, East Java, it has come to be known as Wingko Babat. The shelf life of this snack is one week, so the demand for it is high, especially with the growth of the tourist industry, as tourists will choose wingko to take home with them.

The stove serves to bake the dough of glutinous rice flour, grated coconut and granulated sugar.

Scale of Industry
Household industry with 4 laborers.

Fuel Type
Coconut shell (initial stage), teak wood (final stages)

Size of Stove
(250×200×150) cm

Stove Makers
Owner, Skilled people

Stove Materials
Foundation:

• Hollow tile bricks laid evenly 4 m3

Body:

• Bricks: 2,000 pcs
• Cement: 10 sacks
• Sand: 4 m3
• Palm sugar/sugar cane liquid: 125 kg
• Iron ring: 4/4 on corner to prevent damage to wall

Chimney:

• Sheet metal: 0,3 mm, diameter 8 cm, 3 m high

Stove Utensils

• Bucket (small bucket: 15 lt; large bucket: 50 lt)
• Tray: 15 cm diameter, 2 cm thick
• Rack: (40×27.5×2) cm (carries 6 trays)

Stove/Industry capacity
Every day: usually 200 trays backed in 2 ovens. If baked too long, the wingko tastes sour.

Fuel Consumption
180 sticks of teak wood (40 cm long, 6 cm diameter)

Exchange rate: US $ 1 = Rp. 8,350,-

Coconuts should be cleaned before grating	The Wingko; fresh from the oven

Stove Operation
35 coconuts are cleaned and grated, mixed with one bucket (15 kg) of granulated sugar, and let to sit for 12 hours. The next day, the coconut-sugar is mixed with hot water and 20 kg glutinous rice flour. This dough is placed on the trays.

Flow Chart of Stove Operation

While the coconut and rice flour mixture is being prepared, the ovens are ignited with coconut shells in the left corner of the stove. When the shells have begun to burn, the teak wood is added.

Six trays are arranged on 1 rack and are placed near the flame. After 10 minutes, the rack is moved every few minutes until the dough is baked evenly.

Ergonomic
No heavy lifting nor bending are required, but the cook is exposed to heat during the process.

Stove Maintenance
Ash is removed and the stove is swept clean every morning. The chimney is also swept with a long handled broom. If there are any cracks on the walls of the stove/oven, they are repaired with a mixture of cement, sand and palm sugar/sugar cane liquid. Maintenance is done by the baker who has been trained by the oven makers.

Stove Durability
One stove has been in operation for 15 years. This is a plan to rehabilitate next year

The other stove has been in operation for 5 years, and should last another 20 years