Chapter 2 INDUSTRIAL AND INSTITUTIONAL STOVES IN ASIA (contd.)

THAILAND

Khaolam Industry

Industrial   Institutional   Food   Non-Food

Khaolam is sold to passing motorists along with other products such as coconut sugar lumps, pickled garlic and tropical fruits.	The sticky rice, blackbean and coconut milk mixture is placed inside the bamboo section. The top end of the bamboo is then sealed with bamboo leaves

Profile of Khaolam Industry
Khaolam is a popular dessert made out of glutinous, or sticky, rice that is baked in a bamboo stem. It is very popular amongst Thais, khaolam can be purchased almost anywhere. When prepared properly, the cooked sticky rice which has been extracted from the bamboo stem often is wrapped in the membrane which lines the inside of the bamboo stem.

The Khaolam in the northern provinces is similar to that produced in this case study, which was conducted in the Bangkhonti Nok district in the Samut Songkrom province (approx. 70 km south of Bangkok). The only difference is that in the north, producers tend to fill up more of the stem. The cooked khaolam is then cut into smaller sections and sold separately. It could be said that the northern khaolam makers are more efficient in their use of bamboo.

Recently, it has been announced by some business entrepreneurs that khaolam will soon be exported to other countries.

The charcoal stove is an important part of the khaolam industry because of the large amount of heat needed to cook the sticky rice inside the bamboo stem.

Scale of Industry
Household/cottage industry with 5 laborers

Fuel Type
Charcoal

Size of Stove
(660 × 117 × 70) cm

Stove Makers
Users

Stove Materials

• Galvanized iron pipe (7.5 cm diameter, 650 cm length)
• Galvanized iron sheet
• Wood
• Charcoal bed
• Wire

Cost/stove: approx. Bt. 4,000

Stove Utensils
Bamboo poles cut into one-foot sections using a motorized circular saw Kitchen utensils

Stove/Industry capacity
Cooked khaolam has a shelf life of two days. One stove can cook a maximum of 200 pieces of khaolam. Sales by the case totals approximately 100 or more pieces per day. lif there is a celebration, it is possible to produce 300 or more pieces.

Fuel Consumption
Approx. 1.5 sacks charcoal/day

Financial Calculation

Stove Operation
The glutinous rice is soaked in water and placed in a basin allowing it to absorb water for about 24 hours. If the quality of the glutinous rice is good, the soaking time may be less than 24 hours. After the soaking process, the glutinous rice is mixed with the black beans which have been boiled, as well as the coconut milk. This mixture is then placed into one open end of the pre-cut bamboo sections. Banana leaves are used to cover the opening of the bamboo stem and this is now ready for cooking. The bamboo sections are allowed to lean against the metal pipe, suspended above the stove. Since the metal pipe is located at the center of the stove, khaolam can be cooked on either side of the stove.

The poles are cut into 1-foot sections. The bamboo inter-node is kept at the middle of the 1-foot section. A motoized circular saw is used to cut the large number of bamboo sections. Sections are then sorted according to size

Charcoal is loaded into the stove. Sometimes, the charcoal is fired separately and when this has started to burn, the embers are transferred into the khaolam stove. Other times, an electric fan is used to speed up the lighting of the charcoal pieces.

If the stove is not very hot, cooking of the khaolam can take as much as two hours; if the stove is hot, cooking can be done in a little over half an hour. One indicator to determine whether the sticky rice is cooked is by observing the coconut milk which oozes out of the banana leaf stopped end. If the milky substance has dried and appears burnt, the khaolam is already cooked.

Ergonomics
No heavy lifting nor bending are required during the process

Stove Maintenance
Cleaning of the stove simply requires sweeping away ash and sprinkling sugar on the stove every day.

Stove Durability
4–5 years

Flow Chart of Stove Operation

Boiled Mackerel Industry

Industrial   Institutional   Food   Non-Food

Stove for making cooking Platu showing part of the chimney, fuel loading chute, and ash bin

Profile of Boiled Mackerel Industry
Samut Songkram province is on the coast about 60 kilometers south of Bangkok. The province is home to several fishing villages, fish sauce factories and processors of other seafood products. Steamed and salted short-bodied mackerel, locally known as “platu” is very popular among Thais and can be purchased at any market in Thailand. Steaming freshly caught fish is one way of prolonging its shelf-life without refrigeration.

Scale of Industry
Household/cottage industry with 5 laborers

Fuel Type
Waste wood. Fuel wood is delivered by a 10-wheel truck; a full load costs about Bt. 7,000.

Size of Stove
97 cm (high) × 82 cm (wide)

Stove Makers
Local mason

Stove Materials
Body:

• Bricks
• Cement
• Sand
• Iron bar

Grate:

• Cast iron

Chimney:

• Metal sheet

Cost/stove: Bt. 6,000 – Bt. 7,000

Stove Utensils

• Stainless steel vat for steaming (if is necessary for the pot to be of stainless steel, as it resists corrosion by salt)
• Wire frame for cooking
• Cover for pot
• Refrigerator

Stove/Industry capacity
Each box of fish weighing 20 kg can yield approximately 80 trays of fish. A total of 3 boxes can be steamed each day.

Fuel Consumption
Average fuel usage/day is approx. 3.5 sacks of fuel wood/stove

Financial Calculation
Average selling price per tray is Bt. 15. After deducting cost of production, the profit is about Bt. 300– Bt. 350/box. A total of three boxes can be steamed each day, providing an income of Bt. 900 – Bt. 1,050/day. However, when there is a lot of fish and the price of fish is low, they can steam four to five boxes of fish. The selling price, however, does not vary much. Other sources of income are from the sale of by-products, such as fish offal used by factories producing fish sauce.

Bamboo trays are used for making salted Platu. Two or three fish fit into these trays. The trays are then loading into a wire frame that goes into the cooking vats. Up to 50 trays can be loaded onto these wire frames

Stove Operation
Before loading fresh fish on to the bamboo trays, the fish ar dipped in hot water for cleaning. Bamboo steaming trays can be reused many times. After the fish have been washed with salted water, they are sorted according to size. Same sized fish are placed on the bamboo trays. If the fish are big, two fish are loaded on each tray; if they are small, three can fit on one tray. After the fish have been placed on the bamboo trays, the trays are arranged inside a wire frame container. Each cooking batch can accommodate about 50 bamboo trays.

The cooking vat which is sitting inside the stove is filled with water up to 75% sull (approx. 100 – 120 It of water). One bag of salt (30 kg) is added to the water. Fuel wood is fired and the chimney draws the fire into the stove. The fire is maintained until the solution is boiling. Once the solution is boiling, the wire frame with bamboo trays is lowered into the pot and a lid is placed over the pot. Water and salt (2 kg) are added to maintain the salinity level of the cooking solution when other batches are added. Cooking time varies from 6 – 7 minutes per batch for small fish to 15 – 20 minutes for large fish.

When the solution has been brought to a boil, the fire is reduced and the solution is allowed to simmer. No more fuel is added for the last batch of the day. The pot with the solution is not removed from the stove after the day's work is done. The same cooking solution can be used for about seven days. After the seventh day, the cooking solution is replaced.

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

Stove Maintenance
The stove is wiped with a damp cloth after each use. Care is taken not to spill water on to the hot stove. Ash is removed every day.

Stainless steel vats (inverted in this photo) are used for cooking Platu.

Stove Durability
The stove is assumed will be last for 8 years.

Flow Chart of Stove Operation

Coconut Sugar Industry

Industrial   Institutional   Food   Non-Food

This stove can accomodate three woks. This photo shows two opening one with and the other without a wok.
Coconut fronds (leaves and midribs), husks, and shells are used as fuel for this stove.

Profile of Cococut Sugar Cake Industry
Coconut sugar cakes have a distinct flavor which distinguishes them from other types of sugar cakes. A similar product comes from the toddy palm which is a separate species and distinct from the coconut palm.

In order collect coconut juice (not the liquid endosperm which comes from the inside of the coconut or coconut milk which is the milky-white liquid obtained from squeezing grated coconut meat), the blossom end of an unfurled coconut flower bunch (inflorescence) is cut with a sharp knife. Coconut water is collected in sections of bamboo stem which are tied onto the end of the coconut flower bunch. A juice collector will have to regularly trim the end of the coconut flower bunch to stimulate juice flow. In some cases, it may be done on a daily basis. One coconut tree may have more than one flower bunch in which juice is collected. The collected coconut juice is used as raw material for the coconut sugar cake industry which is common in coastal Thailand.

Scale of Industry
Backyard scale industry with 2 full time laborers

Fuel Type
Coconut fronds (leaves and midribs), husk and shell

Size of Stove
(290 × 90 × 55) cm

Stove Makers
Brick mason

Stove Materials
Body :

• Bricks
• Gravel
• Cement
• Sand
• Reinforcing iron bars

Grate :

• Strip metal

Chimney :

• Bricks

Cost/stove : Bt. 30,000

After the coconut juice has thickened, it is removed from the fire and allowed to sit on a used tire. The syrupy substance is stirred to evaporate more water using the residual heat in the syrup	Bamboo baskets are placed over the wok to prevent the froth from spilling over. Beside the stove are cans called “peep”. This can is a unit of measurement used by the Thais and can contain about 20 litres.

Stove Utensils
Cast iron woks (90 – 100 cm diameter): 4 pcs

Stove/Industry capacity
One day: 4 woks of coconut juice at the rate of 1.5 hours/wok produces: 1 large can, or “peep”, of fresh coconut juice

Fuel Consumption
One “peep” of coconut sugar juice requires approx. 180 coconut fronds

Financial Calculation

The income is divided by two persons, each receiving 140 baht. This is approximately equal to the minimum wage earn by laborers in this area.

Stove Operation
The wok is placed on the stove. The stove can accommodate three woks at one time. The woks are filled with freshly collected coconut juice at a rate of 1.5 tang (about 25 – 30 liters) in each wok and the fire is started. Coconut fronds (leaves and midribs), husk and shells are used as fuel for this process.

When the liquid starts to boil, a basket which is open at both ends is placed over the wok. This basket prevents the froth from boiling over and spilling into the fire. The fire is maintained and the liquid is stirred constantly until it thickens and becomes viscous. The wok is taken off the fire and placed over a used tire. The tire prevents the thickening and cooling viscous liquid from tipping over while the liquid which still has a lot of residual heat continues to lose moisture.

Before the liquid hardens, this is transferred into bowls which have been lined with plastic film or cellophane. The sugar cakes are then allowed to cool and harden in the bowls. When the cakes have hardened, these are removed from the bowls. Each cake weighs about one kilogram.

When the fuel is ingnited, the chimney draws smoke away from the fire and draws in air to fuel the fire. The chimney is very important for this industry, as it enables the fire to enter further into the stove. Without the chimney, the fire would be able to heat up only the wok nearest it. With the chimney, enough heat is able to reach the farthest wok. The other two woks are moved closer to the fire as the first (nearest to the fire) is done.

Ergonomic
Heavy lifting is required to take off the wok from the fire. Continuous stirring of the liquid until it thickens is also heavy work.

Stove Maintenance
As the stove uses large amounts of fuel, ash needs to be removed every day. Care must be given not to allow water to spill on the stove while it is hot. If this happens, a new stove may need to be built.

Before the syrup hardens, it is transferred into bowls, which have been lined with cellophane to prevent the sugar lumps from sticking to the sides. Each lump weights about 1 kilogram.

Flow Chart of Stove Operation

Stove Durability
The stove is at least 25 years old.

Pig Slaughter House

Industrial   Institutional   Food   Non-Food

This is the stove used for scalding slaughtered pigs. There are two woks opposite each other, which have been built-in to the stove

Profile of Pig Slaughter House
This pig slaughter house is in the Amphur Muang (central district) of Nakhon Pathom province.

Scale of Industry
Backyard industry with 5 laborers

Fuel Type
Rubber wood and eucalyptus. Other wood waste can also be used. Fuel wood is purchased by the truckload. One 10-wheel truck load of fuel costs Bt. 4,000.

Size of Stove
(423 × 156 × 61) cm

Stove Makers
Local mason

Stove Materials

• Bricks
• Cement
• Reinforcing steel bars

Cost/stove: Bt. 30,000

Stove Utensils
Wok: 2 pc, built-in

Stove/Industry capacity
Number of carcasses processed/day = 30 – 40 carcasses

Fuel Consumption
Each wok uses about three sacks of fuel wood.

Financial Calculation

Stove Operation
After slaughtering the pig and evisceration, the whole pig carcass is lowered into the wok which has been filled with water that has been brought to just below boiling. Dipping in the hot water takes only about 2 – 3 minutes. The carcass is then removed from the wok and the hair is removed by scraping. The dipping in hot water allows the process of hair removal much easier. Then, the carcass is washed with clean water before it is butchered to be sold.

Ergonomic
Lifting of the heavy carcasses is required.

Stove Maintenance
Daily sweeping of the stove to remove dirt and ash. Furthermore, a damp piece of cloth is used to wipe down the stove. Around the wok, the concrete may break off and must then be repaired.

Stove Durability
The stove is more than 10 years old.

A holding pen for pig to be slaughtered	Pigs being eviscerated

Flow Chart of Stove Operation

MYANMAR

Candle Industry

Industrial   IInstitutional   Food   Non-Food

Candle making machine

Profile of Candle Making Industry
Due to the country-wide power shortage, candles are in great demand throughout Myanmar. For that reason, small-scale candle making industries are becoming more and more popular in every part of the country. The process of making candles is not sophisticated and it doesn't need hi-tech machinery. The raw materials for the candles are wax and thread which are imported from China. The process of making candles starts with melting wax. The melted wax is then taken to the candle machine by a metal scoop and poured into the mold that has a thread inside. After pouring, the melted wax needs to cool down to become solid wax. The solid wax is then taken out from the hold by pressing the foot pedal under the machine which cuts and releases the thread.

The process of candle making cannot be done without use of the wood stove. The wax must be melted, so the stove is essential for the entire process.

Scale of Industry
Cottage industry with 6 laborers.

Fuel Type
Iron wood

Size of Stove
Shape of the stove is cylindrical.
Diameter: 50.08 cm; 45.72 cm high

Stove Makers
Users

Stove materials

• Mild steel sheet metal from old steel
  drums (170.6 cm × 45.72 cm)
• Grate: porous metal piece
• Pot rest: 3 iron grills

Stove Utensils
Cylindrical tub (55.8 cm diameter; 30.48 cm high)
The tub sits on the pot rest

Stove/Industry capacity
Single process: melts 64 kg of raw wax. The first tub will take one hour for the wax to melt completely. There are three types of candle molds:

• Large mold: one scoop produces 10 large candles (3 cm diameter × 15 cm high; weight: 0.09 kg)

• Medium mold: one scoop produces 32 medium candles (1 cm diameter × 13 cm high; weight: 0.0252 kg)

• Small mole: one scoop produces 50 small candles (0.5 cm diameter × 13 cm high; weight: 0.004 kg)

The tub is continuously filled and refilled throughout the day.
The production each day is: 370 packets of large candles (5 candles/packet), 830 packets of medium candles (8 candles/packet) and 1,250 packets of small candles (32 candles/packet).

Fuel Consumption
990 kg of iron wood/day

Typical stove used in candle industry

Financial Calculation

Stove Operation
To be able to pour the raw wax into the candle making mold, the wax must first be melted by heating it in the tub. Eucalyptus wood pieces are used to fire the stove. When the flame is ready, the tub is placed on the stove and 64 kg of wax is added into the tub. When all of the wax is completely melted, it is ready to be taken to the candle making machine. The tub is continually heated from 8:00 a.m. until 5:00 p.m. Fuel is added as needed.

Flow Chart of Stove Operation

Ergonomics
The person who is taking care of the stove and the wax scoop may be exposed to heat quite often and will have to lift 64 kg of wax at the beginning of the day. However, during the rest of the day, he just needs to refill smaller amounts of wax into the heated tub. When that person carries the metal scoop which contains hot melted wax to the mold, he must hold the scoop carefully so that the wax will not spill and cause serious injury.

Stove Maintenance
Daily maintenance of the stove is needed. The ashes from the stove must be removed daily.

Stove Durability
Approx. 5 years

Plum Jam Industry

Industrial   Institutional   Food   Non-Food

Wok and stove used in Plum jam industry

Profile of Plum jam Industry
Plum jam is a very popular traditional snack in Myanmar. Though it is not very nutritious, Myanmar people like it very much. In every snack shop, betel nut shop and canteen, you can find plum jam of at least four or five different brands. The raw ingredients for plum jam are plums, jaggery (palm sugar) and sugar cane molasses. They are available everywhere in Myanmar, so the plum jam industries are widely spread throughout the country.

The process of making plum jam is not very difficult. First, wash the plums through several rinsings. Add a specified amount of jaggery and sugar cane molasses into the wok and stir it continuously until the two substances are thoroughly mixed, then add the plums. After adding the plum, remove the wok from the stove and keep it as is overnight. The next morning, add the rest of the ingredients into the wok and then the plum jam is ready for packaging. The stove is essential in the making of plum jam.

Scale of Industry
Cottage industry with 12 laborers.

Fuel Type
Charcoal and rice husk briquette

Size of Stove
Shape of the stove is cylindrical. Two kinds of stove are used - a traditional one and an improved briquette stove.
Radius: 50.08 cm
Height: 45.72 cm

The size of the improved briquette stove is almost the same as the traditional one, but the designs of the combustion chamber and grate are different.

Stove Makers
Blacksmith (locally available)

Stove Materials

• Mild steel sheet metal from old steel drums (170.6 × 45.72)cm
• Grate: porous metal piece
• Pot rest: 3 iron grills welded to the stove body

There is no such pot rest in the improved briquette stove design.

Stove Utensils

• Iron wok (69 cm diameter opening × 23 cm high × 34 cm diameter bottom)
• Wooden ladle (92 cm long)

Stove/Industry capacity
Single use: 24 kg plums, 10.4 kg jaggery, 10.4 kg sugarcane molasses, 1.6 kg salt, 0.5 mixed spices, in each wok.

Each day: 15 woks, producing 727.2 kg. plum jam every day.

Fuel Consumption
3 gunny bags of charcoal
28 briquettes (size of briquette: height 6 cm × diameter 12 cm; weight: 0.75 kg)

Financial Calculation

Stove Operation
Before cooking, the plums must be washed with water two or three times and then placed on a big bamboo tray to be rinsed with water. For ignition, first place a certain amount of charcoal on the metal grate inside the stove, then ignite the bamboo stick and place it inside the combustion chamber. When the flame starts, place the work on the pot rest and then pour the jaggery and molasses into the wok. Soon all the jaggery and molasses will melt and must be stirred with a wooden ladle until the two substances are thoroughly mixed. This process will take one hour. When the substances are thoroughly mixed, take the wok off the stove and add the plum (24 kg). All the steps up to this point involve the stove, and the same process is repeated over again and again.

Stirring with wooden ladle

The following steps do not require the stove: After adding the plum, the stirring must be resumed until everything is mixed and the solution has cooled. Cover the wok and keep everything as is over night. Next morning, add the rest of the ingredients (e.g. salt 1.6 kg, chili powder 1.6 kg, mixed spices 0.48 kg).

Ergonomics
The process of making plum jam is technically easy, but it is not physically light. While the plum jam is cooking, the person who is stirring is exposed to heat and smoke emission from the wood burning stove the entire time. When the cooking is done, the responsible person must remove the heavy wok from the stove.

Stove Maintenance
Ashes must be removed from the stove daily

Stove Durability
Approx. 5–8 years

Flow Chart of Stove Operation

Tamarind Juice Industry

Industrial   Institutional   Food   Non-Food

Profile of Tamarind Juice Industry
As Myanmar is a tropical country, tamarind trees grow in every part of the country. The tamarind fruit is an essential ingredient for many traditional Myanmar dishes. In addition to this, the people also make juice from tamarind fruit and drink one glass of tamarind juice before going to bed because it is one of the best indigenous medicines that helps to smooth the digestive track and aid stomach functions. Most people do not want to bother making the juice themselves, so they just buy the ready-made bottled juice.

The industries which produce tamarind juice can be found in Yangon, as well as in the center of Myanmar (Mandalay, Sagaing, and Magway provinces) where the vast majority of tamarind trees grow.

The process of making tamarind juice is very simple. the first step is to put the raw tamarind and solid jaggery (palm sugar) into two separate pots, add 10 liters of water to each pot and store them overnight. Early the next morning, stir both pots with a long wooden ladle until the raw tamarind and jaggery are completely dissolved in the water. Then, the fluid jaggery must be strained through a fine cloth sieve and poured into a larger aluminum pot (82 cm × 32 cm), then it is ready for cooking. The jaggery fluid must be cooked until it boils, at which point the raw tamarind juice is added. The raw tamarind must be strained before it is added to the boiling jaggery fluid. The mixture of the two fluids must be stirred continuously until the mixture boils and becomes thick. When it is done, the pot must be removed from the stove and allowed to cool down for a few hours. When it is cooled, the tamarind juice is ready to be bottled.

Scale of Industry
Cottage Industry with 4 laborers.

Fuel Type
Iron wood

Size of Stove
Improved three stones stove made with 6 bricks

Stove Makers
Users

Stove Materials

• Bricks : 6 pieces (23 × 10 × 8)cm
• Clay : 3 – 3.5 kg

Stove Utensils

• Aluminum pot (82 cm × 32 cm)
• Wooden ladle

Stove/Industry capacity
Capacity per pot: 8 kg tamarind; 40 kg jaggery; 1,25 kg salt
Production per day is 2 pots (216 liters of juice) because the juice must be bottled manually, a process which is time consuming.

Fuel Consumption
32 kg iron wood/day

Financial Calculation

Stove Operation
Before placing the aluminum pot on the stove, the fire is ignited by using a bamboo stick which has been soaked in a petrol. when the flame has ignited, place the aluminum pot on the stove and pour jaggery fluid into the pot. when the jaggery fluid starts boiling, the raw tamarind is added. The stirring process must continue. when the fluids are thoroughly mixed and are boiling, stop stirring and remove the pot from the stove. The whole process concerning the stove will take two hours and produce 108 liters for tamarind juice each time.

Ergonomic
The person tending the stove will be exposed to heat during the cooking. Lifting the heavy pot is also necessary every day. The smoke emission in the factory is rather high and ventilation is poor.

Stove Maintenance
No special maintenance, however the ashes must be removed at the end of each day.

Stove Durability
Approx. 3–5 years

Flow Chart of Stove Operation

Tea Shop

Industrial   Institutional   Food   Non-Food

The two pothole stove at tea shop of Yangoon University

Profile
The teashop business is one of the most popular businesses in Myanmar. It is a favorite business to undertake with limited capital. At least one teashop can easily be found in almost every part of Myanmar, even in very tiny hamlets.

The business hours for all teashops are flexible, but most of them usually start at around 4 am, by preparing hot water, brewing tea and frying snacks. They use a two pot-hole iron stove to boil water and tea. First, they ignite both potholes and put on one kettle on each pothole. When the water starts to boil, they add dried tea leaves into one kettle and brew it for about 20 minutes. The other kettle is only for the hot water. As the brewed tea is consumed, hot water and more tea leaves are added to the tea kettle. The process of boiling hot water and brewing tea is continuous until 5 or 5:30 pm.

Snacks are made by mixing wheat flour with eggs, water and salt. When the mixture is ready, they start the fire in a mild steel sheet stove. 1.6 kg of oil is poured into a frying pan and heated for frying the snacks. The process of preparing and frying snacks also starts around 4 am and finishes around 10 am, at which time the amount of snacks made is sufficient to last until the shop closes.

Scale of Industry
Small industry with 4 laborers.

Fuel Type
Charcoal, iron wood

Size of Stove
For boiling: square with two pot-holes (boiling water, brewing tea):
Radius: 30.08 cm
Height: 42.75 cm

For frying: cylindrical (frying snacks):
Diameter: 50.08 cm
Height: 45.72 cm
Design and construction materials approximately the same as for the stove from the candle factory.

Stove Makers
Blacksmith (locally available)

Stove materials

• Mild steel sheet metal from old steel drums (170.6 cm × 45.72 cm)
• Grate: metal strip

Tea shop utensils

Stove Utensils

• Kettle, aluminum: 24.5 cm diameter × 19.75 cm height
• Frying pan, metal: 70 cm diameter × 0.5 cm thickness at edge and 0.25 cm in center
• Ladle, metal

Stove/Industry capacity
Stove for hot water and tea: 5 liter water
Stove for frying snacks: 3.2 kg oil, 12.8 kg wheat flour

Fuel Consumption
12.8 kg charcoal + 16 kg iron wood/day

Financial Calculation

Flow Chart of Stove Operation

Stove Operation

• Stove for hot water and tea :
Fill both kettles with 5 liters of water and add charcoal in the first and second fireboxes. Ignition is initiated with eucalyptus wood pieces. When the stove is ready, place the kettles on the stove. One kettle is only for hot water and the other is for brewing tea.

• Stove for frying snacks :
Soak the fire wood with gasoline and ignite it with the lighter. Pour 1.6 kg of oil into the frying pan and heat. When the oil is hot enough, add the wheat flour mixture into the oil and fry it until it is crispy. Each day, 3.2 kg of oil and 12.8 kg of wheat flour are consumed.

Ergonomics
The two people taking care of making the tea and frying snacks are exposed to heat. Heavy lifting is involved for the tea maker because that person has to lift the tea kettle quite often to pour the tea.

Stove Maintenance
Daily maintenance, e.g. cleaning ashes from the firebox, wiping the spill of hot water and tea on the stove, is required.

Stove Durability
Approx. 5–8 years

NEPAL

Beaten Rice Industry

Industrial Institutional Food Non-Food

	Stove used in beaten rice industry (in operation)

Profile of Beaten Rice Industry
The beaten rice industry is mostly found in the Terai region, as well as in and around the Kathmandu Valley in Nepal. As the name implies, it is prepared from rice. First of all, paddy is soaked in water for about 1–1.5 days, then roasted for about five minutes. It is then fed to a simple power driven machine which removes the husk and squeezes the roasted paddy to obtain the final product. This takes another five minutes.

Scale of Industry
Cottage industry with 2–5 laborers. Space required is about 2,000 sq.ft.

Fuel Type
Rice husk

Size of Stove
(170 × 170 × 85) cm

Stove Makers
Users

Stove Materials
Body:

• Brick 200 pcs.
• Mud 12 bags (1 bag = 50 kg)
• Steel bar 1 pc (dia = 10 cm; length = 85 cm)

Chimney:

• Sheet metal pipe (240 cm height × 20 cm diameter)

Accessories:

• Wooden frame :
  4 pcs (210 × 10 × 7.5) cm
  4 pcs (170 × 10 × 7.5) cm
• Iron rod 2 pcs (2.5 cm. dia ; 180 cm. long)
• Iron stirrers 4 pcs

Stove Utensils

• Shape : Wok (parabolic shape)
• Size : 73cm diameter, 25 cm high
• Material : Alloyed cast iron

Stove/Industry capacity
Paddy consumption/hour : 50 kg
Beaten rice production/hour : 35 kg
Working hours/day : 8 hours

Fuel Consumption
480 kg rice husk/day

Financial Calculation

Accessories used in beaten rice industry

Stove Operation
The vertical steel rod present inside the combustion chamber is heated by burning straw. When it is sufficiently heated, rice husk has to be sprinkled over it continuously. As soon as the rice husk comes in contact with the heated rod, it burns. Previously soaked paddy is roasted in all the works by means of hanging stirrers made of cast iron which are mounted over the iron bars supported by the wooden frame. The roasted paddy is ready to be squeezed to obtain the final product, i.e., beaten rice. When the fire is to be extinguished, the process of sprinkling rice husk over the heated rod is stopped and the rod slowly cools down.

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

Stove Maintenance
Dirts and ashes should be removed regularly.

Stove Durability
Approx. 5 years

Flow Chart of Stove Operation

Mustard Oil Industry

Industrial   Institutional   Food   Non-Food

Typical of stove used in mustard oil industry

Profile of Mustard Oil Industry
Mustard oil industries are found almost everywhere in Nepal. Mustard seeds are first crushed in a power driven crusher, the crushed seeds are then roasted and finally squeezed by means of an oil press to obtain mustard oil. The residual mass finds wide application in preparation of animal food. Stoves are used at the stage of roasting the crushed mustard seeds.

Scale of Industry
Cottage industry with 6 laborers. Space required is about 1,800 sq.ft.

Fuel Type
Fire wood

Size of Stove
(125 × 135 × 95) cm

Stove Makers
Users/trained personnel

Stove materials
Body:

• Brick 500 pcs.
• Mud 8 bags (1 bag = 50 kg)
• Cement 0.5 bag
• Sand 2 bags
• Metal strips 4 pcs.

Chimney:

• Sheet metal pipe (210 cm high × 13 cm diameter)

Stove Utensils

• Shape: Flat, circular sheet
• Size: 12 gauge sheet (dia. 100cm)
• Material: Alloy cast iron

Stove/Industry capacity
Number of processings/day: 32
Mustard seeds/processing: 25 kg
Fire wood consumption/processing: 2 kg
Mustard oil production/processing: 8 lt
Residual mass production/processing: 16 kg

Fuel Consumption
2 kg fire wood/processing

Financial Calculation

Stove Operation
The stove is fired using rice husk/straw along with fire wood. When the flat metal sheet, which is permanently fixed within the stove body, is sufficiently heated, crushed mustard seeds are roasted on the sheet by means of a wooden ladle. The flat metal sheet is used for roasting. Within a few minutes, the roasted mass is ready to be squeezed to obtain mustard oil. Squeezing can be done either by manual oil pressor by power driven automatic machine. At the end of the day, the fire is extinguished and the partly burnt fire wood is stored for further use.

Stove used in mustard-oil industry (in operation)

Ergonomics
The operator is exposed to the heat during cooking; heavy lifting or pressing are required.

Stove Maintenance
Repairs for cracks and external damages
Cleaning of ash
Cleaning of chimney

Stove Durability
10–12 years

Flow Chart of Stove Operation

Roadside Hotel/Restaurant

Industrial   Institutional   Food   Non-Food

A typical of stove used in roadside hotel/restaurants

Profile
Roadside hotel/restaurants are too common in major highways in Nepal. The items served include rice, curry, pickle, mutton, chicken, fried fish, ea, beer, etc Although traditional cook stove are rapidly being replaced by kerosene stoves, but still the former one is more popular in this sector.

Scale
Number of labour: 7 labourers. Space required is about 8,00 sq.ft.

Fuel Type
Fire wood

Size
(120 × 150 × 70) cm.

Stove Makers
Users.

Stove Materials
Foundation:

• Bricks

Body:

• Stone.
• Clay/Mud

Cost per stove = Rs. 700

Stove Utensils

• Shape: Varies: Parabolic, Cylindrical with flat bottom, etc
• Size: Variable
• Material: Alluminium, Alloyed cast iron, etc

Stove/Industry Capacity
Working hours is 15 hours per day. Number of people served for lunch and dinner average per day: 40 Number of people served for tea, snacks, etc. average per day : 100 Number of people served beer, hard drink, etc average per day : 15

Fuel Consumption
50 kg of fuel wood

Financial Calculation

Stove Operation
The stove is fired using fire wood with aid of kerosene. When the dish to be cooked is on the cook stove, the necessary preparation is made for the next item so that stove does not become idle. At the end of the day, fire is extinguished and remaining fire wood is stored for use on the following day.

Ergonomics
No heavy lifting required during the cooking process.

Stove in a restaurant (in operation)

Stove Maintenance
Repairs for cracks and external damages and removal of ashes should be done regularly.

Stove Durability
8–10 years.

Flow Chart of Stove Operation

Sweet Shop

Industrial   Institutional   Food   Non-Food

Stove in a sweet shop (in operation)

Profile of Sweet Shop Industry
Small scale sweet shops are scattered almost everywhere in Nepal. Many varieties of sweets are produced and sold. The basic ingredients required are flour, ghee, milk, and sugar. Wood-burning stoves are more common than kerosene stoves in this sector. Simultaneous operation of two or more stoves is also common.

Scale of Industry
Cottage industry with 4 laborers. Space required is about 400 sq. ft.

Fuel Type
Fuel wood

Size of Stove
(75 × 75 × 35) cm

Stove Makers
Users

Stove Materials
Body:

• Bricks : 80 pcs.
• Mud 2 bags (1 bag = 50 kg)
• Metal strips : 2 pcs.

Stove Utensils

• Shape: Parabolic, cylindrical, etc.
• Size : Variable (diameter ranging from 60–68 cm)
• Material : Alloyed cast iron

Stove/Industry capacity
Average production of sweets = 18 kg/day

Fuel Consumption
50 kg fuel wood/day

Financial Calculation

Stove Operation
The stove is fired with kerosene oil. The wok is heated and ghee is poured into it. When it is sufficiently heated, a previously prepared past of flour (by adding water, sugar, etc.) is poured and formed into the desired shapes (as per the shape of the final product). Gentle stirring is done using a thin wooden stick until the final product is ready. At the end of the day, the fire is extinguished.

Flow Chart of Stove Operation

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

Stove Maintenance
Repairs for external damages and removal of ash

Stove Durability
5–6 years

Wool Dyeing Industry

Industrial   Institutional   Food   Non-Food

Stove used in wool dyeing industry (in operation)

Profile of Wool Dyeing Industry
The wool dyeing industry is one of the significant cottage industries located in the Kathmandu valley. It imparts color to wool which is utilized in the carpet industry. First, the pigment powder is dissolved in boiling water. Then, the wool to be dyed is dipped in the hot solution and stirred until the wool acquires the color of the required concentration. The process can take one to five hours. Then, the soaked wool is dried in the sunlight. The dyed wool is then ready to be supplied to the carpet industries.

Scale of Industry
Cottage industry with 8 laborers.

Space required is about 8,000 sq.ft.

Fuel Type
Fire wood

Size of Stove
(175 × 175 × 160) cm

Stove Makers
Stove technicians/trained personnel

Stove Materials
Body:

• Brick 1,500 pcs.
• Cement 4 bags
• Sand 16 bags
• Metal strips 4 pcs.

Grate:

• Cast iron

Chimney:

• Sheet metal (810 cm high × 20 cm diameter)

Stove Utensils

• Shape: Cylindrical with flat bottom
• Size: 98 cm dia. × 75 cm high
• Material: Copper

Stove/Industry capacity
100 – 200 gm pigment powder is dissolved in 500 lt boiling water. About 26 kg wool to be colored is dipped into the solution and then stirred. The stirring process can take 1–1.5 hours, depending upon the quality and concentration of the color to be imparted. The soaked wool is dried in the sunlight. About five processing can be done each day. Thus, approximately 130 kg wool can be dyed in one day.

Fuel Consumption
400 kg fire wood/day

Financial Calculation

Stirring action in wool dyeing stove

Stove Operation
The vessel is filled with water before the fire is started. Logs of fire wood are placed inside the combustion chamber and the fire is started using a little kerosene. Then the water starts to heat. At the time, the workers arrange for pigment powder and wool to be colored. When the water starts boiling, the powder is mixed into it and stirred until it dissolves completely. The wool is then introduced into the solution and stirred. The process is continued until the desired quality of color is imparted to the wool. At the end of the day, the fire is extinguished and the partially burnt wood is stored for further use.

Ergonomics
No heavy lifting is required; but the operator is exposed by heat and chemical fog during the processing.

Stove Maintenance
Repairs for cracks and external damages and removal of ashes should be done regularly.

Stove Durability
20 – 30 years

Flow Chart of Stove Operation

PHILIPPINES

Bibingka Industry

Industrial   Institutional   Food   Non-Food

Typical of stove used in Bibingka industry

Profile
Bibingka is a good source of carbohydrates and is very popular in the Philippines. The main ingredients are coco milk, ground rice, sugar, salt, and yeast. All of these ingredients are thoroughly mixed, then poured into tin cans which have been lined with banana leaves, then baked for 10 – 15 minutes.

The stove used in this survey is the only stove designed for making bibingka.

Scale
Cottage/home industry with 1–2 laborers

Fuel Type
Firewood

Size of Stove
(30 × 20 × 14) inches

Stove Makers
Owner

Stove materials
Galvanized iron shaped into a box with two layers (first layer for sticks of wood, second layer for tin cans)

Stove Utensils
Round tin cans for shape of the bibingka, using banana leaves as lining/wrapper

Stove/Industry capacity
Monday – Saturday (1 am – 11 am) produces 1,000 – 2,000 pieces of bibingka
Sunday (1 am – 5 pm) produces 1,500 – 2,000 piece of bibingka

Fuel Consumption
5 bundles of 20 medium sized wood per day

Financial Calculation
Monday – Saturday profits = P 700.00 – P 800.00 Sunday profits = P 1,200.00 – P 1,500.00

Exchange rate: US $ 1= P 42.00

Stove Operation
Firewood is lit to heat the stove evenly, meanwhile the bibingka mixtures are prepared. When an even heat is attained the tray of bibingka mixture is placed in the second layer.

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

Stove Maintenance
Ash removed after every use and users avoid spilling water on the stove to prevent rust.

Stove Durability
Usually 2 – 3 years, depending on thickness of galvanized iron.

Flow Chart of Stove Operation

Corn Cubs Industry

Industrial Institutional Food Non-Food

	Typical stove used in corn cub industry

Profile
Boiled corn cobs (maize) is a good source of carbohydrates. It is eaten either as snacks or sometimes as replacement for rice.

Scale
Cottage industry with one labor.

Fuel Type
Wood and sawdust.

Size of Stove
Drum size (circular, usually a recycled container of lard oil)

Stove Makers
Those involved in the business.

Stove materials
Foundation:
A recycled drum filled with sawdust (compacted) with a bamboo at the center to make a hole. A hole is made outside of the drum where the wood or fuel will be inserted.

Body:
Another drum is placed on top which is used for cooking the corn cobs.

Stove Utensils
Drum of same size of the stove.

Stove/Industry capacity
100 pcs. of corn cobs in 3 hours × 2 sets per day

Fuel Consumption
3–4 medium sized wood used in 3 hours

Stove Maintenance
The stove is replaced every 3–4 months. Sawdust is added every after cooking (3 hours)

Stove Durability
The drum used as stove is usually changed every 3 months. The drum used to boil the corn cobs is changed every 4 months.

Hospital Stove

Industrial Institutional Food Non-Food

	Typical of stove used in the hospital

Profile
This cook stove is used by a hospital to cook meals for patients and staff. The hospital was built in 1980.

Scale
Institutional

Fuel Type
Firewood

Size of Stove
(60 × 25 × 28) inches

Stove Makers
Planned by hospital engineers

Stove materials
Foundation:

• Clay bricks - 250 pcs.
• Sand & Gravel
• Cement

Body:

• Clay bricks - 1,000 pcs.
• Sand & Gravel
• Cement
• Steel
• Tiles

Stove Utensils
Metal rings for 3 burners

Fuel Consumption
15 sticks chopped wood

Stove Maintenance
Ashes removed after every cooking

Stove Durability
In use almost 20 years, as yet no repair nedded.

Flow Chart of Stove Operation

Pancit Industry

Industrial   Institutional   Food   Non-Food

Typical of stove used in Pancit industry

Profile
Pancit is commonly eaten in and outside the country. It is widely produced as it is consumed in restaurants, as well as for special celebrations.

The main ingredients are flour, oil, water, salt, and food coloring. All ingredients are mixed together, then flattened by a machine called a “hammer”. It is then put through the slicer. After being sliced, the dough is soaked in boiling water with oil. After 5–10 minutes of boiling, it is strained and placed on the table under a fan to be cooled.

Scale
Cottage/home industry with 4 laborers.

Fuel Type
Rice Hull

Size of Stove
(75 × 50 × 40) inches

Stove Makers
Owner

Stove materials
Foundation:

• Sand & Gravel - 5 cu
• Cement - 5 bags
• Hollow blocks - 500 pcs.
• Salt & brown sugar - mixed in the cement for durability

Grate:

• Stripe metal

Chimney:

• Bricks

Stove Utensils
Wok, big (permanently placed on stove plates)

Stove/Industry capacity
Pancit is usually made at night from 4 pm or 6 pm to 10 pm. during this time, 5 sacks of flour are used in one processing (4–5 hours). The final product is 250 kg pancit, or 50 kg pancit per each sack of flour.

Fuel Consumption
15 sacks of rice hulls processing (5 hours)

Financial Calculation
Net from pancit P 4.00/kg × 250 = P 1,000.00/day

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

Stove Maintenance
After using the stove, all ashes must be removed in preparation for use the next day. Cracks are repaired by applying cement, brown sugar and salt to guarantee durability.

Stove Durability
Has been used for almost 10 years.

Flow Chart of Stove Operation

Pinatubo Eatery

Industrial Institutional Food Non-Food

Typical of stove and utensils used in Pinatubo eatery

Profile
The restaurant is frequently visited by travelers because of its strategic location. The cookstove has been used for 9 years. It is used for cooking rice, viands and boiling water.

Scale
Small scale industry.

Fuel Type
Rice hulls 9–10 sacks/day from 6 AM to 9 PM.

Size of Stove
(30 × 24 × 20) inches

Stove Makers
Owner

Stove materials
Foundation & Body:

• Cement 5 sacks
• Small clay bricks 800 pcs.
• Sand and gravel 2 cu.
• Small round bars 5 pcs.

Stove Utensils
Cooking utensils; metal rings of different sizes

Stove/Industry capacity
Can cook all viand and rice needed from 6 AM to 9 PM.

Fuel Consumption
20 large pieces of wood

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

Stove Maintenance
Ashes is removed daily. Water spillage is avoided to prevent cracks.

Stove Durability
This cookstove is used for 9 years with repair.

Flow Chart of Stove Operation

Rice Cake Industry

Industrial Institutional Food Non-Food

Typical of stove used in rice-cake industry

Profile of Rice Cake Industry
Rice-cake is popular and commonly consumed in the urban as well as rural areas in Phillipine. Just like bread rice cake is consumed for breakfast, merienda, a gift for special occation and a way of life for Philippinos. The materials used to make rice-cake are : rice, sugar, food color, Lye, baking powder and some water.

Scale
Small scale industry, household industry

Size
Size place is 120 sqms. The average labor is 5 person, but during peak season (Christmas) the labor are 20.

Fuel Type
Rice husk

Stove Makers
Locally available (masons)

Stove Materials
Foundation and body:

• Adobe stone size 16 × 8 inches
• Cement 10 sacks
• Sand 4 m3

Grate:

• 2 pieces of 14 × 18 inches stripe metal

Stove ring:

• ½ inch thick metal, 27 inches in diameter.
  Cost per stove = P 12,000.00

Stove Utensils

• Wok : 29 inches in diameter, used for boiling water for steaming
• Steamer: 26 inches in diameter, made of iron strip or plate with holes, placed on top of the wok.
• Steamer cover: 27 inches in diameter, serves as cover for the food inside the wok.
• Cheese cloth
• Metal basin : 2 feet tall and 17 inches in diameter, all ingredients are mixed here before put on top of the steamer.

Stove/Industry Capacity
108 kg of ground rice complete with ingredients can be processed for about 5–6 hours.

Financial Calculation

Stove Maintenance
Cleaning of the inside of stove and chimney must be done once a week

Stove Durability
Up to now it has been 45 years with minor repairs such as patching the cracks at the mouth or side of the stove, or just merely patching the cracks with cement.

Flow Chart of Stove Operation