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:
Body:
Grate
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
| Financial Calculation | |
| Expenditures | |
| • Flour 80 kg | = Tk. 2,000 |
| • Sugar 30 kg | = Tk. 750 |
| • Hydrogenated vegetable oil 12 kg | = Tk. 1,000 |
| • Other ingredients | = Tk. 500 |
| • Fuel wood | = Tk. 250 |
| • Labor | = Tk. 500 |
| • Depreciation | = Tk. 800 |
| TOTAL COSTS | = Tk. 5,800 |
| Income | |
| • Bread: 50 kg | = Tk. 1,000 |
| • Cake: 25 kg | = Tk. 1,500 |
| • Biscuits: 70 kg | = Tk. 4,200 |
| TOTAL INCOME | = Tk. 6,700 |
| 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.
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
Flow Chart of Stove Operation
Industrial Intitutional Food Non-Food
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:
Body:
Grate & Ring:
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.
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
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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:
Body:
Grate:
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.
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.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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:
Body:
Grate & Ring:
Total cost of stove Tk 700
Exchange rate :US $ 1 = Tk 48
Stove Utensils
Aluminum wok 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.
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.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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
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
Financial Calculation
Expenditures
| • Milk: 250 kg | = Tk. 4,100 |
| • Sugar: 60 kg | = Tk. 1,800 |
| • Flour & ingredients | = Tk. 600 |
| • Oil/ghee | = Tk. 700 |
| • Fuel wood | = Tk. 500 |
| • Labor | = Tk. 700 |
| • Depreciation | = Tk. 1,000 |
| TOTAL COSTS | = Tk. 9,400 |
| Income | |
| • Sweetmeat: 160 kg | = Tk. 11,200 |
| Profit/day | = Tk. 1,800 |
| 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.
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.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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:
Body:
Grate:
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
Financial Calculation
| Expenditures | |
| Total expenditure average per day | Tk. 3,500 |
| Income | |
| Total income average per day | Tk. 5,000 |
| Profit/day | Tk. 1,500 |
| Exchange rate US $ 1 = Tk 48 | |
Flow Chart of Stove Operation
 |  |
| 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. |  |
| 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 |
Industrial Institutional Food Non-Food
Dipping the yarn into the cauldron
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:
Grate :
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
Financial Calculation
| Expenditures | |
| Chemicals | =Tk. 50 |
| Fuel wood: 200 kg. | = Tk. 300 |
| Labor | = Tk. 250 |
| Depreciation | = Tk. 50 |
| TOTAL COSTS | = Tk. 650 |
| Income | |
| Yarn: 200 kg @ Tk. 4 | = Tk. 800 |
| Profit/day | = Tk. 150 |
| 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.
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
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
 |  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)
Chimneys
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
Financial Calculation
| Expenditures | |
| Flour 120 kg | 360,000 Riels |
| Ingredients (sugar, salt, etc) | 20,000 Riels |
| Fuel wood | 20,000 Riels |
| Labor 10 person | 40,000 Riels |
| Depreciation | 10,000 Riels |
| Total Expenditures | 450,000 Riels |
| Income | |
| Average 1,700 loaves | 490,000 Riels |
| Profit/day | 40,000 Riels |
| Exchange rate : US $ 1 = 3,800 Riels | |
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.
Industrial Institutional Food Non-Food
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 :
Grate :
Chimney
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
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
Flow Chart of Stove Operation
Stove Durability
The stove has 2 years old and assumed
will last for next 10 years
Industrial Institutional Food Non-Food
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:
Grate:
Chimney:
Door:
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.
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
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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 :
Chimney :
Grate :
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
Financial Calculation
| Average total production per season: 1,074 kg | |
| Selling price @ 800 Riels/kg : | 859,200 Riels |
| Production cost | 219,500 Riels |
| Margin/season | 639,700 Riels |
| Thus income/months in average: 130,500 Riels | |
| 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.
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.
Flow Chart of Stove Operation
Stove Durability
Approximately 6 – 8 years for ICS and
2 years for traditional stove
Industrial Institutional Food Non-Food
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:
Grate:
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
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
Flow Chart of Stove Operation
 | Two pothole stove |
Industrial Institutional Food Non-Food
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 sometimes
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 spoonlike
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.
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.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
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 hot flue gas pipes in the curing chamber
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 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).
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.
Flow Chart of Stove Operation
Industrial Institutional Food Non-Food
 |  |
| 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.
| A typical Charka stove |  |
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.
Construction material for one charka oven:
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:
It is estimated that more than 120,000 metric tons of biomass fuel is consumed every year in charka reeling ovens.
Financial Calculation
| Expenditures | |
| Cocoons: 10kg @ Rs. 10 | = Rs. 1,000 |
| Labor: 2 persons (Rs. 50/day) | = Rs. 100 |
| Fuel: 25–30 kg @ Rs. 1,000/ton | = Rs. 30 |
| Depreciation | = Rs. 5 |
| TOTAL COSTS | = Rs. 1,135 |
| Income | |
| Silk yarn: 1 kg @ Rs. 1,200 | = Rs. 1,200 |
| Jute waste | = Rs. 80 |
| TOTAL INCOME | = Rs. 1,280 |
| Profit/day | = Rs. 145 |
| 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
several charka ovens are installed under
the same shed, the reel is powerdriven
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
Industrial Institutional Food Non-Food
 |  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:
Grate:
Chimney:
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
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.
Financial Calculation
| Expenditures | |
| Cocoons: 100 kg @ Rs. 125/kg | = Rs. 12,500 |
| Labor: 25 people (Rs. 40/day) | = Rs. 1,000 |
| Fuel: 250–300 kg | = Rs. 300 |
| Power (electricity + kerosene) | = Rs. 15 |
| Depreciation | = Rs. 40 |
| TOTAL COSTS | = Rs. 13,855 |
| Income | |
| Silk yarn: 10 kg @ Rs. 1,400/kg | = Rs. 14,000 |
| Profit/day | = Rs. 945 |
| 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.
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
Flow Chart of Stove Operation
