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

INDONESIA

Bakpia Industry

Industrial   Institutional   Food   Non-Food

Stove used in Bakpia industry

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

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

Scale of Industry
Household industry with 15 laborers.

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

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

Stove Makers
Masons, locally available

Stove Materials
Stove
Foundation :

• Bricks
• Cement

Body:

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

Chimney:

• Clay pipes

Cost/stove : Rp. 150,000

Oven
Foundation:

• Bricks, Cement, Sand

Body:

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

Chimney:

• Clay pipes

Cost/oven : Rp. 600,000

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

Stove Utensils

• Wok: diameter 90 cm, steel, fixed permanently to stove, sealed securely

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

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

Fuel Consumption
Stove: 2 bundles of firewood (18–20 kg)
Oven: 1 sack of charcoal (25 kg)

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

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

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

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

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

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

Stove Durability
10 years in operation

Flow Chart of Stove Operation

Coconut Oil Industry

Industrial   Institutional   Food   Non-Food

Boiling coconut milk

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

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

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

Scale of Industry
Household industry with 4 laborers.

Fuel Type
Coconut shell and wood

Size of Stove
(150 × 50 × 30) cm

Stove Makers
Brick layer (locally available)

Stove Materials

Body :

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

Cost/stove: Rp. 150,000

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

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

Fuel Consumption
300 coconut shells (from those used for processing), Fire wood: 25 kg for 3 days of work.

Financial Calculation

Add some water to grated coconut

Coconut is grated using a simple grating machine

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

Stove used in coconut oil industry

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

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

Stove Durability
Approximately 5 years

Flow Chart of Stove Operation

Geplak Industry

Industrial   Institutional   Food     Non-Food

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

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

Scale of Industry
Household industry with 15 laborers.

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

Size of Stove
(90 × 70 × 25) cm

Stove Makers
Users, locally available

Stove Material
Body:

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

Chimney:

• Clay pipes

Cost of stove: Rp. 100.000

Stove Utensils

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

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

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

Financial Calculation

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

Flow Chart of Stove Operation

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

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

Stove Durability
Approximately 5 years

A typical stove used in Geplak industry

Gudeg Restaurant

Industrial   Institutional   Food   Non-Food

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

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

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

Scale of Industry
Household industry with 20 laborers

Fuel Type
Fire wood

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

Stove Makers
Brick layers (locally available)

Stove Materials
2- and 3-hole stoves:

• Cement
• Iron (8 m)
• Clay
• Sand

Single hole stove:

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

Stove Utensils

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

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

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

Fuel Consumption
Approximately 2 m³ firewood/day

Financial Calculation

The three pothole stove	The two pothole stove

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

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

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

Stove Durability
Approximately 10 years

Flow Chart of Stove Operation

Beef Rind Industry

Industrial   Institutional   Food   Non-Food

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

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

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

Scale of Industry
Household industry with 20 laborers.

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

Size of Stove

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

Stove Makers
Brick layers (locally available)

Stove Materials
Stove for boiling:

• Brick: 200 pcs
• Clay: 0,5 m3
• Clay pipe for chimney: 5 pcs

Cost/stove: Rp. 100.000

3-hole stove for frying:

• Brick: 750 pcs
• Clay: 2 m3
• Clay pipe for chimney: 5 pcs

Cost/stove: Rp. 350.000

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

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

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

Financial Calculation

Stove Operation
The wok on the single hole stove which is used to boil the raw rind is half-filled with water which is then heated until boiling. The raw rind which has been cut into squares (20 × 20) cm is added to the boiling water. When it is soft, it is removed from the fire and cooled. Then, the hair and underskin are removed. The rind then sliced into smaller pieces (1,5 × 5 cm) before frying.
Two of the woks on the 3-hole stove are prepared for the first stage of frying. They are half-filled with cooking oil and then heated until boiling. After the oil boils, the firewood is reduced, then the raw rind is added. The third hole (in the middle of the stove) is used for the final frying proceess. For this stage, the oil must boil constantly and the firewood must be centered under the pot.

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

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

Stove Durability
More than 5 years.

The rinds are sliced into smaller pieces before frying

Flow Chart of Stove Operation

Tapioca Chip Industry

Industrial Institutional Food Non-Food

Typical stove used for steaming in tapioca chip industry

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

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

Scale of Industry
Household industry with 6 laborers.

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

Size of Stove

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

Stove Makers
Masons, locally available

Stove Materials
Foundation:

• Bricks

Single-hole stove:
Body:

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

Chimney:

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

Double-hole stove:
Body:

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

Chimney:

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

Stove Utensils

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

Stove/Industry capacity

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

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

Financial Calculation

Packaging the tapioca chips

Stove Operation
The single-hole stove is ignited at 5:30 am. The wok is filled 75% with water and heated. The initial firing uses teak wood until the flame is considered sufficient, then it is fed with rice husk to maintain boiling temperature. The chip ingredients are mixed, then placed above the boiling water. The pan is covered with an aluminum cover until the contents are cooked, then the cooked batter is quickly cut to size and dried in the sun.
The dried chips are then ready to be fried on the double-hole stove. This is done at 3 p.m., so that the chips will be fresh for distribution early the next morning. The stove is initially ignited with dry firewood and later with a combination of wood and rice husk to control the heat of the cooking oil. The back pot (medium hot) is used for the first frying and the front pot (over the central fire) is used for the final frying.

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

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

Stove Durability
The two stoves in use are 10 years old

Flow Chart of Stove Operation

Tofu Industry

Industrial   Institutional   Food   Non-Food

Grinding the soybean	Boiling the soy porridge

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

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

Scale of Industry
Household industry with 10 laborers.

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

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

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

Stove Materials
For Direct Boling Stove
Foundation:

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

Body:

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

Fire box:

• Bricks
• Cement/sand mixture (1:5)

Grate:

• Strip metal

Chimney:

• Sheet metal

Cost/stove: Rp. 250,000

For Steamer Stove
Foundation:

• Bricks, Cement, Sand

Body:

• Sheet metal

Grate:

• Strip metal

Chimney:

• Sheet metal

Cost of stove: Rp.8.500.000,-

Heating the soy porridge with steam	A typical of steamer stove

Stove Utensils

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

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

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

Financial Calculation
(For Steamer Stove)

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

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

Ergonomics
It need strong man to stir porridge continuously.

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

Stove Durability
Approximately 10 years

Flow Chart of Stove Operation

Wingko Snack Industry

Industrial   Institutional   Food   Non-Food

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

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

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

Scale of Industry
Household industry with 4 laborers.

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

Size of Stove
(250 × 200 × 150) cm

Stove Makers
Owner, Skilled people

Stove Materials
Foundation:

• Hollow tile bricks laid evenly 4 m3

Body:

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

Chimney:

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

Stove Utensils

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

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

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

Financial Calculation

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

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

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

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

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

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

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

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

Flow Chart of Stove Operation

LAOS

Cane Sugar Industry

Industrial   Institutional   Food   Non-Food

A typical of stove used in the cane sugar industry

Profile
In rural areas in northern Laos around Luang Prabhang province - there are still plenty of villagers producing cane sugar using traditional methods. Fresh cane juice is first obtained using a simple pressing tool. The juice is then boiled for 2 to 3 hours until a thick dark brown liquid is obtained. This liquid is then transferred to moulds. When the liquid has hardened, it forms blocks of cane sugar. The cane sugar blocks are lifted from the moulds and are ready for consumption or to be marketed.

The cane sugar is usually produced by farmers, who have done it for generations. It supplements their main occupation as rice farmers. While rice needs irrigation, sugar cane can be grown on dry land.

The stove is a crucial element in cane sugar production, used during the process of boiling cane juice into thick brown liquid which then cools to form cane sugar.

Scale of Industry
Cottage industry with 3 laborers. Space required is about (5×8) m for boiling and moulding; and (6×6) m for pressing raw sugar cane to get the juice.

Fuel Type
Fuel wood and bagasse

Stove Size
(290 × 100 × 30)cm. A long stove with four fireholes.

Stove Makers
Users, locally available

Stove Materials
Body:

• Clay, Sand, Ash Total cost stove per stove: almost no cost exept labor.

Stove Utensils

• Shape: 3 parabolic woks, 3 Cylindrical bamboo baskets
• Size: 66 cm diameter for work, 40 cm for bamboo basket
• Material: Alloyed cast iron and bamboo

Stove/Industry Capacity
On average 30 kg. of cane sugar are produced daily. Although there are 4 fire holes in a stove, only two or three holes are used regularly. The amount of raw materials and the operator capacity are sufficient to work only on two to three holes. Cane sugar is only produced during the dry season (March, April, June). At other times the cane sugar produced is of low quality. The harvest from 0.6 hectare of sugar cane plantation will be completely processed into cane sugar within 30 days.

Fuel Consumption
For every batch, a stove will consume 3 logs of wood measuring 1.5 m and a diamater of 12 cm. Therefore if two batches are done per day, and two stoves are operated, the fuel consumption will be 2×2×3 logs = 12 logs

Financial Calculation

When the liquid reaches the appropriate consistancy, the wok is lifted and the lmixture is transferred to moulds.

Stove Operation
Fresh canes are harvested early in the morning and is immediately processed using a simple pressing machine. The machine is operated using a buffalo which can be rented for 5000 kip per day. For the first batch fresh canes are pressed until approximately 75 litres of cane juice are obtained. This amount of liquid is then divided into two woks. The two woks are then heated simultaneously on a strong fire for two hours. As the liquid boils, foam and dirt rises to the top and are then periodically removed with a wooden spoon. To prevent an overflow of the foam during boiling, a bamboo cylinder, 40 cm in diameter, is immersed in the wok. After 2 hours, the liquid starts to thicken and is dark brown in colour. At this stage, the cane juice needs to be stirred continuously to prevent burning. When the desired thickness of the liquid is obtained, the wok is lifted and the liquid is transferred to moulds. The liquid is then left to cool and harden, forming cane sugar blocks. The blocks of cane sugar are then taken out of the mould. The cane sugar is now ready to be marketed.

The fire is extinguished by pulling out the remaining burning wood. The whole process is repeated for the next batch. The second batch is usually completed at 5.00 in the afternoon. At the end of the day, the burning wood in the stove, is left undisturbed until it dies out. The total working time in a day is between 6–7 hours.

Ergonomics
Generally the process does not require the lifting of any heavy load. The activity which appears most taxing, is, the continuous stirring of cane juice when it starts to thicken.

Stove Maintenance
The stoves surveyed do not require special maintenance. If cracks occur, they can be mended with a clay and ash mixture

Left the liquid to cool and harden, forming sugar cane blocks

Stove Durability
The stoves are 4 years old and are still functioning well. The stoves are estimated to last for another 5 years.

Flow Chart of Stove Operation

Noodle Industry

Industrial   Institutional   Food   Non-Food

The rice flour paste is steamed layer by layer in a steaming pot

Profile of Noodle Industry
Noodle is a popular food throughout Laos. It is eaten at all times, for breakfast, lunch or dinner. There are two types of noodle, one is made from wheat and is usually yellow in colour and the other made of rice flour and is white in colour. In Laos, noodle is usually produced by home based industry. The producers usually sell the noodle directly or supply restaurants. The main ingridient is rice which is made into flour and soaked overnight. A small amount of cassava flour is added to improve the noodle elasticity. On the following day, the rice flour paste is steamed layer by layer in a steaming pot. Noodle thickness depends on preference but is usually 2mm. Some of the noodles are sold fresh/wet while othrs are sold in dry form. In noodle production, wood fueled stoves are used during the steaming process.

Scale of Industry
Cottage industry with 3 laborers. Space required is about (8 × 6) m for grinding and slicing; another (6 × 10) m for steaming and drying.

Fuel Type
Fuel wood

Stove Size
(140 × 85 × 30) cm with 2 fire holes
(360 × 100 × 35) cm with 4 fire holes

Stove Makers
Users/locally available

Stove Materials
Body:

• Brick : 300 pcs.
• Cement
• Sand
• Clay

Labor: 125.000 Kip
Total cost per stove: 280.000 Kip (for 2 fire hole stove)

Total cost for 4 fire hole stove is 70.000 Kip because of the additional chimney.

Stove Utensils

• Shape: Cylindrical pan
• Size : Diameter 50 cm (2 pans)
• Diameter: 60 cm (4 pans)
• Material : Alluminium

Stove/Industry Capacity
The production of noodle is mainly depends on the orders, but on average 100 kg of rice per day produces 50 kg dried noodle, 60 kg wet noodle and 15 kg of crackers.

Fuel Consumption
The 2 fire hole stove requires 4–5 pieces of wood , 1,5 m long and about 20 cm diameter, for 2–3 hours working time.
For 4 fire hole stove requires 11–12 pieces of wood for 3 hours working time.

Financial Calculation

A two pothole stove used in the noodle industry	The noodle sheets are sliced using a simple slicer machine

Stove Operation
The stove is usually lit at 5.30 in the morning. Pots are half-filled with water. A round frame with cloth attached on its upper part is immersed in the pan. Once the water boils, rice flour which has been soaked overnight, is put in the pot, on the cloth. It is put in a spoon at a time until it forms a circle and is about 1–2 mm thick. The lid of the pot is put on for 2–3 minutes. After the rice paste is cooked, a new batch is put in and the process is repeated. Meanwhile the fire needs to be kept strong, to keep the water boiling so that steaming takes place.

To produce dry noodles, the rice paste is dried until it is dehydrated. While for the production of fresh/wet noodle, the rice paste is sliced and is immidiately ready for consumption. Flavouring such as sugar, salt etc are added to the left over pasta which is fried and made into crackers

Ergonomics
In general, there is no lifting or energy expanding activities required in the noodle production industry surveyed.

Stove Maintenance
The stove is now 4 year old. During the time, there has been no major breakdowns.

Stove Durability
It is assumed that stove will be last for another 10 years.

Flow Chart of Stove Operation

Paper Making Industry

Industrial   Institutional   Food   Non-Food

Spreading the fibres evenly on the mould

Profile of Paper Industry
Banxang Khon, a village 10 km from Luang Prabang, is famous for its paper making industry. The majority of Banxang Khon residents are involved in hand-made paper production. The hide of jute plant is used as the raw material in the paper production. The jute is first soaked in water containing a bleaching agent, followed by boiling. Next, the fibres are separated by beating the softened jute with a wooden mallet. The paper porridge is then molded on a plastic screen and allowed to dry. Flowers or leaves can be added to decorate the paper. When dry, it is lifted from the screen.

Stove is an important component in paper making. The jute hide needs to be boiled and then maintained at constant temperatures between 60–70°C for twelve hours.

The paper produced could either be bound into a book, painted or sold as it is, as a souvenier.

Scale of Industry
Home industry with 5 labors. Space required is 6×8 m for stove and moulding, and another 5×4 m for drying.

Fuel Type
Fuel wood

Stove Size
(15 × 95 × 50)cm

Stove Makers
Users, locally available

Stove Materials
Body:

• Brick
• Cement
• Sand

Chimney:

• Bricks
• Cost of stove : 200.000 Kip,-

Stove Utensils

• Shape: Square with parabolic in the bottom
• Size : (90 × 60 × 70)cm
• Material: Sheet metal

This container sits on the hole of the stove permanently, the narrow gap between stove and container is then sealed with clay and ash.

Industry Capacity
On average 100 sheets of paper (each measuring 55×80 cm) are produced daily. Some of these are plain sheets while others have flower/leaf decorations on them. For the production of 100 sheets of papers, 20 kgs of dry jute are required.

Fuel Consumption
6–8 pieces of woods each 1,5 m long and about 15 cm diameter are needed for a single batch.

Financial Calculation

Stove and boiling container used in the Jute paper industry

Stove Operation
20 kg. of jute are soaked overnight and then washed with detergent. The jute is then put in water containing bleaching agent and is stirred. Afterwards, the jute is transferred to another container for boiling. 20 kg. of ash is added to the water used for boiling the jute. It takes between 45–60 minutes to reach the boiling stage, after which the jute is simmered on a steady fire, with the temperature maintained at between 60–70°C for 12 hours. The softened jute is then beaten with a wooden mallet until the fibres are separated. The beating continues till the jute breaks into fine strands of fibres. Before being put into mold the jute needs to be weighed. On average 5 sheets of paper can be produced from a kilogram of jute fibres. If thicker sheets of paper are to be produced, more jute is added. The jute fibres are put in a tray filled with water. The mould is then immersed in the tray and the fibres are spread evenly on the mould. The mould is lifted from the tray and is dried in the sun.

The mould is a wooden rectangular frame, (55 × 80 × 3)cm. A plastic mosquito net is nailed to the frame. When the jute has been put on the moulds, the boiling container is cleaned. The next batch of jute which has been soaked, is ready for processing.

Ergonomics
There is no lifting of any heavy load during the process as small amount of jute fibres are taken each time.

Stove Maintenance
Avoiding boiling water from overflowing onto the stove will ensure that no major damage occurs. Small cracks can easily be repaired with sand and cement or clay and ash mixture.

Stove Durability
The stove surveyed was made in 1990, and it has been rebuilt twice. However by preventive maintenance, i.e. avoiding boiling water overflow, the stove is estimated to last for another 5 years.

Scrubbing the paper surface	Expose to the sun

Flow Chart of Stove Operation

Salt Industry

Industrial   Institutional   Food   Non-Food

The salt crystals are taken out using a wooden spoon

Profile
Usually salt is obtained by evaporating by seawater. However, since there is no sea in Laos, salt is obtained from inland salt mines. Firstly, groundwater has to be mined from depths between 200–400 meteres. The groundwater from the depths contains somewhere between 25–35% salt (NaCl). This salt water is then evaporated by boiling on a pair of stoves to produce crystal salts. Eventhough solar energy could be used to evaporate the salt water, the boiling process produces better quality salt.

Scale of Industry
Small scale industry with 50 – 200 laborers. Space required is about 20.000 sq.m.

Fuel Type
Saw dust

Size
(265 × 150 × 50) cm

Stove Makers
Users, locally available

Stove Materials
Body:

• Brick
• Mud
• Ash

Cost per stove : 60.000 Kips

Stove Utensils

• Shape : rectangular containers
• Size : (210 × 60 × 18) cm
• Material : Galvanized Sheet metal.

Stove/Industry Capacity
The average production of raw salt per pair of stove is 60 kg per batch. Boiling time is about 10 hours. Thus per day they only prepare 2 batches. The factory has 130 pairs of stoves. If it works at full capacity the total production is 15.6 tons of raw salt per day.

To obtain the final product iodine (45 ppm.) is added using simple mixer machine.

Fuel Consumption
0,15 m³ of saw dust are required to produce 60 kg of raw salt in a day.

Financial Calculation

Stove Operation
At first a round wooden log, 10 cm in diameter and 175 long, is placed horizontally at the base of the stove. Saw dust is then poured until it covers the log, (about 15–20 cm thick). Then, 3 wooden sticks are placed vertically on the log at a distance of about 50 cm from one another. The stove chamber is then filled with saw dust which is made firm by repeatedly stepping on it. The wooden sticks and the log are then slowly taken out. Hence air channel are created, one horizontal at the stove base and the other three vertical.

Saw dust is used as fuel in the salt industry	Pouring the saw dust into the stove chamber

The stove is lit from the vertical holes made earlier. An iron container is used to hold salt water. The salt water is filled almost to the brim, leaving only about 2 cm. to the container's lip. When the salt water becomes concentrated, it crytallises at the bottom of the container. When enough salt crystals are formed, the salt is taken out using a wooden spoon. More salt water is added when the water level in the container is low. The process is repeated until the salt water is completely evaporated and at about the same time, the saw dust is completely burnt. A batch of salt processing will take between 8–10 hours. Between 50–60 kgs of raw salt could be obtained from 200 litres of salt water. When a batch is completed, the iron container is lifted out, and the combustion chamber is cleaned. The same process is repeated for the next batch.

A wooden log is placed horizontally at the base of the stove; three wooden sticks are also placed vertically; then saw dust is poured into the stove chamber.

Ergonomics
Salt crystals collected in a bamboo basket needs to be transported to a storage area. Transporting it needs considerable strength as a basket full of salt can weigh up to 60 kgs. Another physically demanding job is the lifting up of the iron container, which needs to be cleaned at the base and then replaced on the stove. While other activities are not as physically demanding as these two.

Stove maintenance
The stove is made of layered bricks and plastered with mud, ash and clay. Sometimes some cracks appear which needs to be repaired with a mixture of mud and small amount of ash.

Stove durability
A stove last one year, while the iron container last about 6 months.

Flow Chart of Stove Operation

Sauna Stove

Industrial   Institutional   Food   Non-Food

The boiler requires a large amount of fuel wood to produce steam continuously

Profile of Sauna Stove
The sauna industry is sponsored by the Laos Red Cross Society. All materials for the sauna (drum, stove, sauna room, etc.) are the provided by the Red Cross; and all income goes to the Red Cross. There is one employee who is responsible for cleaning the rooms, firing the stove, putting the herbs in, etc.

The sauna only open in the evening from 6–9 PM.

The equipment used to produce steam consists of:
A boiler made of a used tank with a volume of about 200 L. The upper part has two outlets which channel steam by means of metal pipes to two steam rooms (one for woman, the other for men) which have wooden walls with a capacity of 5 persons per room. The water in the drum is first mixed with various types of herbs and leaves; more than 20 types of herbs and leaves are put in the mixture and are replaced every two days.

The stove used has two fireholes and is wood fueled. One hole is used to heat the water in the drum which sits tightly on the stove's lip. The gaps between the drum and the stove's lip are filled with clay mixed with ash. Another hole is 40 cm in diameter is used to boil water for making herb drinks for the visitors. A chimney is also present and is made of a metal pipe, 6 inches in diameter.

Scale of Industry
Household activity with one worker. A space of (4 × 3) m is needed for ground level where the stove is situated and (10 × 8) m is needed for the upper level where there are two sauna rooms and a rest and waiting area. Massage rooms (5 rooms) are beside the sauna room.

Fuel Type
Fuel wood

Size
(150 × 97 × 40) cm.

Stove Makers
Users, locally available

Stove Materials
Foundation:

• Stone, cement and sand

Body:

• Bricks
• Sand
• Cement
• Clay and ash for sealing

Grate:

• Iron bar 1 inch

Chimney:

• Iron pipe 6 inches

Cost of stove: 400.000 Kip

Stove Utensils

• Shape: Cylindrical iron drum, pan
• Size: 60 cm diameter for drum, 40 cm for pan
• Material: sheet metal and alluminum

Stove/Industry Capacity
The service hours for the sauna is 3 hours/day, starting at 18.00 up to 21.00 in the evening. The stove is ignited at around 5.30. The drum fill up with the water up to ⅓ part of the height (60–70 liter only). The herbs and some kind of leaves are then put into the drum. The fire should be kept big to boil the water and produce the stream. At 21.00 the fire is dimed by pulling out the wood from the stove, and then some water is splashed on the fire to extinguish it.

Fuel Consumption
10 pieces of fire wood with 1,5–2 m. long and 10 – 12 cm. diameter are consumed every evening.

Financial Calculation

Ergonomics
Generally there is no heavy load that needs to be carried. The drum needs only to be cleaned once in a while or when it appears very dirty.

Stove maintenance
There is no special maintenance requirements for the stove. Cracks can be repaired with a clay and ash mixture.

Stove durability
The stove is now 2 years and is still functioning well. It is estimated that the stove will last for five years.

Flow Chart of Stove Operation

MALAYSIA

Sidewalk Restaurants

Industrial   Institutional   Food   Non-Food

Profile
In Kepong, Kuala Lumpur, there are plenty of sidewalk food vendors. These eating places are jammed with custumers during lunch hour. Most of those frequenting the places are office workers from the surrounding Kepong. Many vendors still use wood charcoal. It is believed that the food cooked with charcoal taste better. Food is often served, on small portable stoves, known as anglo. Fish soup, seafood and vegetables will become more delicious if served hot, maintained hot with the anglo. Some types of food are first cooked with gas stove, and then served on charcoal anglo which keeps the food hot.

For some food types, clay wok is used instead of metal or alumunium one. The anglo used is usually tiny, with a diameter of about 25 cm. The anglo could easily be purchased in markets costing between 10–16 RM. For big restaurants, they serve food on more than 50 anglos at once.

Scale
Restaurant with 10–12 labors. Space required is about (8 × 10) m.

Fuel Type
Gass and/or charcoal

Size
25 cm height and 27 cm diameter (top); 17 cm diameter (bottom)

Stove Makers
Stove producer

Stove Materials
Body:

• Clay
• Cement and Sand
• Sheet metal for bucket

Grate:

• Clay or iron bar

Total cost per stove: 14.50 RM

Stove Utensils

• Shape: Parabolic, cylindrical, etc.
• Size: Varies from 22 to 35 cm diameter
• Material: Clay, Cast iron, Alluminium, etc.

Capacity
The restaurant surveyed has 12 round tables with each table accomodating 6 chairs. There are 50 anglos and 6 bigger cooking stoves in the restaurant. According to the owner, they serve on average between 200–250 customers per day. Working hour is between 11.30–20.00. And they cater for more than 15 food items in the restaurant.

Fuel Consumption
Depend on how frequent the stove being used, but in average 1 kg of charcoal are required per portable stove per day.

Stove Operation
For cooking, the restaurant uses either gas stoves or charcoal fueled cooking stoves. The portable stoves are placed, ready on the tables; when there is an order for food items which require the use of anglos, the anglos are loaded with glowing charcoal. Food is then ready for serving on the anglos.

Ergonomic
In the process, in terms of ergonomic, there is no need to lift heavy materials.

Stove Maintenance
There are no maintenance needed exept cleaning dirt and ash regularly. If cracks occur the stove just throw away and replace with new one.

Stove Durability
About 0,5 – 1 years

Flow Chart of Stove Operation

Tofu Sheet Industry

Industrial   Institutional   Food   Non-Food

Tofu sheet is taken out piece by piece, arrange in the pan then sold as fresh tofu sheet

Profile of Tofu Sheet Industry
Tofu sheet is a widely consumed food in Malaysia, especially in Chinese as well as vegetarian restaurants. There are also many Malays who enjoy the food. Tofu sheet is versatile and can be prepared with vegetable, beef, chicken or other dishes.

Tofu sheet comes in two forms, in fresh or dry forms, in the market. The raw material in tofu sheet production is soy beans. The beans are soaked overnight and ground into porridge. Water and acetic acid are added to the mixture. The mixture is heated at a temperature between 60–70°C. The sheet will form steadily on the surface of the mixture. At a thickness of 2 mm, the sheet is taken out and drained. More tofu sheets will be formed at the surface. However the interval of the sheet formation gets longer as the mixture gets less concentrated.
Stove is an important part of this industry required to heat up the tofu solution. Firewood is used as the fuel. Saw dust, rice husk or agricultural wastes are not used because they produce too much smoke and dust which will affect the quality of the tofu sheet.

Scale of Industry
Cottage industry with 3 laborers. The space required is about (6×18)m for the boiling room with 10 stoves; and a (6×6)m space is required for washing and grinding.

Fuel Type
Fuel wood

Size of Stove
(370 × 120 × 60) cm; a long single fire hole

Stove Makers
Masons; locally available

Stove Materials
Body:

• Bricks
• Clay
• Cement and Sand

Chimney:

• Bricks

Total cost per stove: 300 RM

Stove Utensils

• Shape: Rectangular, divided lengthwise, into two halves with a metal sheet
• Size: (370 × 120 × 22) cm
• Material     : Metal sheet

Stove/Industry Capacity
On average 25 kg of soy bean can be processed per stove in a day. Cooking is carried out continuously for 12 hours per day. 25 kg of soy bean could yield about 17 kg of dried tofu sheet. The producer has 10 operating stoves and on average 250 kg of soy bean can be processed per day.

Tofu sheets are hanged for air dried; sold as dried tofu sheet

Fuel Consumption
Each stove require 0.5 m3 of wood to process 25 kg of soy bean in a day.

Financial Calculation

Stove Operation
Soy which has been soaked overnight is ground into porridge. 250 liter of water is added to 25 kg of soy porridge. Acetic acid is added next and the mixture is stirred till all parts obtain uniform viscosity. The stoves are lit at about 6 o'clock in the morning.

The soy mixture is then heated to a constant temperature of 60–70°C. Tofu sheet will be formed at the surface of the mixture and will get thicker with time. When the sheet reaches certain thickness (± 2 mm), it is then sliced and drained. More tofu sheets will be formed, each formation stage will take longer as the mixture gets less concentrated. The stove is doused in the late afternoon at about 17.00 hours. The leftover mixture is thrown away.

Ergonomic
The process of tofu making does not require the lifting of heavy loads.

Stove Maintenance
There is no significant damage during the stove lifetime of more than 4 years. Small cracks could be repaired using clay or mud mix with ash.

Stove Durability
About 10 years

Loading fuel wood

Flow Chart of Stove Operation