Shampoo case study.pdf

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SCHOOL OF ENVIRONMENT, RESOURCES AND DEVELOPMENT SCHOOL OF ENVIRONMENT, RESOURCES AND DEVELOPMENT ENVIRONMENTAL ENGINEERING AND MANAGEMENT PROGRAM ENVIRONMENTAL ENGINEERING AND MANAGEMENT PROGRAM

Term Paper II Term Paper II

Shampoo Production

Course:

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Table

Table of

of Contents

The word “cosmetics” comes from the Greek word kosmetikos meaning “skilled in The word “cosmetics” comes from the Greek word kosmetikos meaning “skilled in adornment/decoration”. The way people wear makeup and the reasons why they wear it adornment/decoration”. The way people wear makeup and the reasons why they wear it have changed dramatically over time and through different cultures. It is believed that have changed dramatically over time and through different cultures. It is believed that cosmetics have been used as early as Egypt circa 4000 BC to fulfill beautifying needs. cosmetics have been used as early as Egypt circa 4000 BC to fulfill beautifying needs. According to some sources numerous forms of cosmetics were extracted from the fertile According to some sources numerous forms of cosmetics were extracted from the fertile land of the Nile River. The shepherds and hunters of the Mesolithic Period would often land of the Nile River. The shepherds and hunters of the Mesolithic Period would often smear their bodies with locally made cosmetic products.

smear their bodies with locally made cosmetic products.

1.2

1.2 Cosmetic Cosmetic Market Market in in ThailandThailand

The cosmetics industry is one of the fastest growing sectors in Thailand. The year 1997 saw The cosmetics industry is one of the fastest growing sectors in Thailand. The year 1997 saw the fastest growth period in the cosmetic industry, with a growth rate of 20 percent. the fastest growth period in the cosmetic industry, with a growth rate of 20 percent. Although the economic crisis has had a negative impact on consumption levels, results Although the economic crisis has had a negative impact on consumption levels, results during 1999-2000 show that the cosmetics industry’s growth rate was at 15 percent.

during 1999-2000 show that the cosmetics industry’s growth rate was at 15 percent.

Thailand’s exports of cosmetic products increased by 72 percent in 2003 compared to a Thailand’s exports of cosmetic products increased by 72 percent in 2003 compared to a year before. The cosmetics market was expected to grow at an average of 18 percent in year before. The cosmetics market was expected to grow at an average of 18 percent in 2004, due mainly to Thailand's positive economic situation and expected positive GDP 2004, due mainly to Thailand's positive economic situation and expected positive GDP growth.

growth.

In 2005 cosmetics and toiletries in Thailand continued to record strong growth increasing In 2005 cosmetics and toiletries in Thailand continued to record strong growth increasing by

by 7% 7% of of the the previous previous year. year. The The main main factor factor behind behind growth growth of of the the market market was was increasingincreasing retail prices caused by an increase in energy prices and a change in consumer behavior in retail prices caused by an increase in energy prices and a change in consumer behavior in favor of expensive products. The most dynamic performances in 2005 were seen in skin favor of expensive products. The most dynamic performances in 2005 were seen in skin

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agents, i.e., wetting agent). Shampooing is frequently followed by

agents, i.e., wetting agent). Shampooing is frequently followed by conditionersconditioners which which increase the ease of combing and styling.

increase the ease of combing and styling.

1.3.2

1.3.2 The The Worldwide Worldwide Market Market Potential Potential of of ShampooShampoo

The latent demand (or potential industry The latent demand (or potential industry earnings) for hair care shampoo was earnings) for hair care shampoo was estimated to be $7.4 billion in 2005. The estimated to be $7.4 billion in 2005. The distribution of the world potential industry distribution of the world potential industry earnings, however, is not evenly distributed earnings, however, is not evenly distributed across regions. 2005 data shows that Asia is across regions. 2005 data shows that Asia is the largest market with $2.4 billion or 33 the largest market with $2.4 billion or 33 percent,

percent, followed followed by by Europe Europe & & the the MiddleMiddle East with $2.2 billion or 29 percent, and East with $2.2 billion or 29 percent, and then North America & the Caribbean then North America & the Caribbean with$1.9 billion or 25 percent of the world with$1.9 billion or 25 percent of the world market. market. 2,360 2,360 33% 33% 601 601 8% 8% 93 93 1% 1% 2,163 2,163 29% 29% 289 289 4% 4% 1,862 1,862 25% 25% Asia

Asia AfricaAfrica

E

Euurrooppe e & & MMiiddddlle e EEaasstt OOcceeaannaa N

Noorrtth h AAmmeerriicca a & & CCaarriibbbbeeaann LLaattiin n AAmmeerriiccaa

It shows the top 3 regions cover come 87 It shows the top 3 regions cover come 87 percent of

percent of the global the global latent demand latent demand for hairfor hair care shampoo

care shampoo

Table 1: Worldwide Market Potential for Table 1: Worldwide Market Potential for

Hair Care Shampoo (US $ mln): 2005 Hair Care Shampoo (US $ mln): 2005

Region Region Latent Latent Demand Demand US $ mln US $ mln % of % of Globe Globe Asia Asia 2,3602,360 3333

Europe & the Middle Europe & the Middle East

East 2,1632,163 2929

North America North America & the& the

Caribbean Caribbean 1,8621,862 2525 Latin America Latin America 601601 0808 Africa Africa 289 289 0404 Oceana Oceana 93 93 0101 Total Total 7,3687,368 100.0100.0

Source: Philip M. Parker, INSEAD, 2005 Source: Philip M. Parker, INSEAD, 2005

www.icongrouponline.com www.icongrouponline.com

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Nurture ShampooShampoo ManufacturingManufacturing Co.,Co., LtdLtd PPaa gg ee|| 33

1.3.3

1.3.3 Asia Asia MarketMarket

In case of Asia, three most populated countries China, India and Japan have a bigger In case of Asia, three most populated countries China, India and Japan have a bigger share of the product. 2005 data shows that China is the largest market with $796.18 share of the product. 2005 data shows that China is the largest market with $796.18 million or almost 34 percent, followed by Japan with $539.3 million or 22.85 percent, million or almost 34 percent, followed by Japan with $539.3 million or 22.85 percent, and then India with $385.47 million or 16.33 percent of the Asian market. It shows that and then India with $385.47 million or 16.33 percent of the Asian market. It shows that the top 3 regions cover 73 percent of the Asian potential demand for hair care shampoo. the top 3 regions cover 73 percent of the Asian potential demand for hair care shampoo. The other top three nations with one digit percentage share of Asian market of the The other top three nations with one digit percentage share of Asian market of the product

product include include South South Korea, Korea, Indonesia Indonesia and and Thailand Thailand with with approximately approximately six six percent,percent, five percent and three percent respectively

five percent and three percent respectively (Detail data in Appendix A(Detail data in Appendix A).). It has also been It has also been observed that the market of hair care shampoo shows a similar fashion as that of world observed that the market of hair care shampoo shows a similar fashion as that of world market with a slight decline till 2004 from 2000 and then increase steadily after that. market with a slight decline till 2004 from 2000 and then increase steadily after that.

Mark

Mark et Pet Potential for otential for HHair Care Shampoo air Care Shampoo in Asia:2005in Asia:2005

0 0 5 5 10 10 15 15 20 20 25 25 30 30 35 35 40 40 C C h h i i n n a

a J J a a p p a a n

n I I n n d d i i a a

S S o o u u t t h

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I I n n d d o o n

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l l a a n n d d

T T a a i i w w a

a n n

P P h h i i l l i i p

p p p i i n n e e s s

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a m m S S i i n n g g a a p

p o o r r e e_B_B u u r r m m a a S S r r i i L L a a n

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a Countries Countries P P e e r r c c e e n n t t ( ( U U S S $ $ m m l l n n ) )

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the main components of shampoos along with their characteristics. However, the the main components of shampoos along with their characteristics. However, the description of shampoo ingredients is given in details in

description of shampoo ingredients is given in details in Appendix C Appendix C ..

•

• Surfactants, including five categories (primary anionic - basic, secondarySurfactants, including five categories (primary anionic - basic, secondary

anionic - mild, amphoteric, cationic and nonionic), serve as foamers and anionic - mild, amphoteric, cationic and nonionic), serve as foamers and detergents which are easy to soluble in water.

detergents which are easy to soluble in water.

•

• Thickeners and foam stabilizers remain viscous to avoid precipitation andThickeners and foam stabilizers remain viscous to avoid precipitation and

stability against hydrolysis at higher temperature or extreme pH. They can be stability against hydrolysis at higher temperature or extreme pH. They can be polymers, natural gums or cellulose derivatives.

polymers, natural gums or cellulose derivatives.

•

• Conditioning agents make hair easy to comb after drying. Since conditioners areConditioning agents make hair easy to comb after drying. Since conditioners are

effective than shampoo, very low concentrations (0.5% by weight) a

effective than shampoo, very low concentrations (0.5% by weight) are sufficient.re sufficient. Conditioners are normally fatty components such as fatty alcohol, Conditioners are normally fatty components such as fatty alcohol, monoglyceride, vegetable oils, lanolin, herbal extracts and silicon.

monoglyceride, vegetable oils, lanolin, herbal extracts and silicon.

Shampoos can be made in various physical forms such as liquids, creams, paste, aerosol Shampoos can be made in various physical forms such as liquids, creams, paste, aerosol and dry. Liquid shampoos are common, either clear or opaque (pearlised), containing and dry. Liquid shampoos are common, either clear or opaque (pearlised), containing 20–40% solids, adjusted to approximately pH 5.5 and viscosities in the ratio of 500– 20–40% solids, adjusted to approximately pH 5.5 and viscosities in the ratio of 500– 1500 centipoise.

1500 centipoise.

Composition of shampoos can be modified for special application. Medicated shampoos Composition of shampoos can be modified for special application. Medicated shampoos generally use similar ingredients and added specific medicant. For instance, dandruff generally use similar ingredients and added specific medicant. For instance, dandruff shampoos contain fungicides such as zinc pyrithione and selenium sulfide which reduce shampoos contain fungicides such as zinc pyrithione and selenium sulfide which reduce loose dander by killing Malassezia furfur. Shampoos for infants are formulated with loose dander by killing Malassezia furfur. Shampoos for infants are formulated with particular

particular emphasis emphasis on on minimal minimal eye eye irritancy irritancy and and skin skin mildness. mildness. A A limited limited range range ofof proprietary

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Nurture ShampooShampoo ManufacturingManufacturing Co.,Co., LtdLtd P a g eP a g e | | 55

No

No further further processing processing is is required required after after blending, blending, and and the the product product may may be be packed packed offoff directly from the mixing vessel by filling system which composes of auto-bottle settling directly from the mixing vessel by filling system which composes of auto-bottle settling machine, bottle-washing machine, filling machine, lid-revolving, label-attaching and machine, bottle-washing machine, filling machine, lid-revolving, label-attaching and aluminum foil clapper.

aluminum foil clapper.

In some segments of the industry, one manufacturer may produce a shampoo base In some segments of the industry, one manufacturer may produce a shampoo base which is sold to, and further processed by, the formulator. Typically, this second level which is sold to, and further processed by, the formulator. Typically, this second level processing

processing will will involve involve only only the the addition addition of of water, water, color color and and fragrance. fragrance. ProprietaryProprietary and/or therapeutic ingredients may also be added at this stage (

and/or therapeutic ingredients may also be added at this stage ( Appendix D Appendix D).).

Washing

Washing water water 60 60 mm33/day/day

Product 43.5 m Product 43.5 m33/day/day

Losses 0.73 tons/day Losses 0.73 tons/day

Wastewater 59.8 m Wastewater 59.8 m33/day/day Deionized

Deionized water water 23.3 23.3 mm33/day/day Chemicals 21.6 tons/day Chemicals 21.6 tons/day

Process

Note: Note: S

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3.

3. Waste Waste Treatment Treatment PracticesPractices

Nurture Shampoo Manufacturing

Nurture Shampoo Manufacturing produces only haiproduces only hair care r care shampoo with the shampoo with the capacity ofcapacity of 44m

44m33/day. As this factory is small, it produces fewer amounts of pollution, wastewater,/day. As this factory is small, it produces fewer amounts of pollution, wastewater, solid waste, air pollution, and noise pollution.

solid waste, air pollution, and noise pollution.

In order to meet the Thai standard of wastewater effluent discharge, wastewater In order to meet the Thai standard of wastewater effluent discharge, wastewater treatment plant was implemented. Wastewater is collected and mixed together from treatment plant was implemented. Wastewater is collected and mixed together from washing operation, cleaning, laboratory experiment, and domestic wastewater washing operation, cleaning, laboratory experiment, and domestic wastewater (Appendix D).

(Appendix D).

Air pollution is one of the problems found in this factory but it is not a big problem Air pollution is one of the problems found in this factory but it is not a big problem because

because fewer fewer amounts amounts of of gas gas emission, emission, NONOxx, , SOSOxx, dust and soot, and aerosol, is, dust and soot, and aerosol, is emitted to the atmosphere. All gases coming from the factory are treated by using wet emitted to the atmosphere. All gases coming from the factory are treated by using wet scrubbers and bag house filters.

scrubbers and bag house filters.

Solid waste is another pollution factor in the factory. Most of the solid wastes are Solid waste is another pollution factor in the factory. Most of the solid wastes are plastics,

plastics, cardboards, cardboards, bottles, bottles, and and food food waste waste and and yard yard waste. waste. The The recycled recycled materialsmaterials such as plastic, bottle and cardboard are sold to recycling shop, and food waste and yard such as plastic, bottle and cardboard are sold to recycling shop, and food waste and yard waste are collected by municipal solid waste collectors.

waste are collected by municipal solid waste collectors.

Beside these three main pollutions, noise pollution is also found within the factory. Beside these three main pollutions, noise pollution is also found within the factory. Noise almost comes from blending machine and filling machine. This

Noise almost comes from blending machine and filling machine. This problem is solvedproblem is solved by putting these

by putting these processes in processes in a closed room and a closed room and all workers have all workers have to use eato use ear plugs or er plugs or earar mufflers.

mufflers.

Table 2- Wastewater Characteristic Table 2- Wastewater Characteristic

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3.1.1

3.1.1 PretreatmentPretreatment

Coarse solid such as plastic, cardboard, paper must be removed from the waste effluents Coarse solid such as plastic, cardboard, paper must be removed from the waste effluents to reduce abrasion and prevent damage to pumps, piping and sludge dewatering to reduce abrasion and prevent damage to pumps, piping and sludge dewatering equipment. For the wastewater of this shampoo factory, mechanical bar screens and equipment. For the wastewater of this shampoo factory, mechanical bar screens and Equalization & Neutralization are used for the operation. Equalization & Neutralization Equalization & Neutralization are used for the operation. Equalization & Neutralization play

play an an important important role role of of storing storing wastewater wastewater coming coming from from the the processes processes in in batchbatch operation and adjusting the pH between 6.5 and 8.0 to prevent disturbance in secondary operation and adjusting the pH between 6.5 and 8.0 to prevent disturbance in secondary biological treatment systems.

biological treatment systems.

3.1.2

3.1.2 Primary TreatmePrimary Treatmentnt

The main objective of primary treatment in the factory is to remove the settleable The main objective of primary treatment in the factory is to remove the settleable portion

portion of of SS SS and and oil oil & & grease. grease. Floatation Floatation process process is is used used to to separate separate solid solid or or liquidliquid particle

particle and and to to concentrate concentrate biosolids. biosolids. Among Among the the three three unit unit operations operations - - dissolved dissolved airair floatation, dispersed air floatation, cavitations floatation - dissolved air floatation is used floatation, dispersed air floatation, cavitations floatation - dissolved air floatation is used which consists of dissolved air under a pressure of several atmospheres introduced at which consists of dissolved air under a pressure of several atmospheres introduced at the bottom of the tank, scrapper at the bottom and skimmer at the top of the tank to the bottom of the tank, scrapper at the bottom and skimmer at the top of the tank to collect all settleable solid and to remove all the floating matter (oil and grease).

collect all settleable solid and to remove all the floating matter (oil and grease).

3.1.3

3.1.3 Secondary TrSecondary Treatmenteatment

Secondary treatment is designed to remove BOD associated with dissolved organic Secondary treatment is designed to remove BOD associated with dissolved organic material in the effluent and normally uses biological processes. The biological treatment material in the effluent and normally uses biological processes. The biological treatment process can

process can convert much of convert much of the dissolved the dissolved organic material organic material in effluent in effluent to water, to water, COCO22 or or organic suspended solids and expected BOD removal is 70-95%.

organic suspended solids and expected BOD removal is 70-95%.

Suspended growth biological treatment process is used here to treat the wastewater. The Suspended growth biological treatment process is used here to treat the wastewater. The

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Table 3- EOP Technologies for the Air Pollution Abatement Table 3- EOP Technologies for the Air Pollution Abatement

Processes

Processes Air Air Pollution Pollution Control Control DeviceDevice

Raw

Raw material material preparation preparation (Dust) (Dust) Dust Dust collection collection system system (bag (bag house house filter)filter)

Utilities

Utilities (Boiler) (Boiler) Wet Wet ScrubbersScrubbers

3.3

3.3 Solid Solid WasteWaste

In the process of making shampoo, it will not have large quantity of solid waste. Mainly In the process of making shampoo, it will not have large quantity of solid waste. Mainly we have paper, cardboard and plastic from production process and the office and food we have paper, cardboard and plastic from production process and the office and food waste from the canteen and yard waste from cleaning the garden. Paper, plastic and waste from the canteen and yard waste from cleaning the garden. Paper, plastic and cardboard will

cardboard will separate from separate from the waste the waste and and sell for sell for recycling. Threcycling. The other e other solid wastessolid wastes will be collected by the municipal solid waste collection system (Table 4).

will be collected by the municipal solid waste collection system (Table 4). Table 4- Solid waste generation

Table 4- Solid waste generation

S

Soouurrcce e WWaasstte e UUnniit t QQuuaannttiittyy MMaannaaggeemmeenntt

Office

Office Paper Paper and and Plastic Plastic Kg/day Kg/day 10 10 Recycle Recycle shopshop

Operation

Operation Cardboard Cardboard andand plastic

plastic

Kg/day

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‘Treated water’ using newest inventions like titanium micro-dispersion water ‘Treated water’ using newest inventions like titanium micro-dispersion water technology can be used for various cosmetic materials instead of normal demineralized technology can be used for various cosmetic materials instead of normal demineralized water. This method produces high-function cosmetic materials offering the efficacies of water. This method produces high-function cosmetic materials offering the efficacies of active ingredients contained in the cosmetic material as well as the effects of titanium active ingredients contained in the cosmetic material as well as the effects of titanium micro-dispersion water. But in our process we are using deionized water as the solvent micro-dispersion water. But in our process we are using deionized water as the solvent media.Following are some of the Environmental Issues we found out in Shampoo media.Following are some of the Environmental Issues we found out in Shampoo manufacturing industry.

manufacturing industry.

Air pollution:

Air pollution:MainlyMainly in shampoo production process we have air pollution due in shampoo production process we have air pollution due to NOx,to NOx, SOx, and particulate matter and vapor. NOx is produced from the furnace and SOx and SOx, and particulate matter and vapor. NOx is produced from the furnace and SOx and vapor from the fuel which is used to heat the boiler. Dust and soot is produced in the vapor from the fuel which is used to heat the boiler. Dust and soot is produced in the mixing units and the packaging area.

mixing units and the packaging area. NOx and other

NOx and other emissions from emissions from the furnace the furnace will be will be absorbed by the absorbed by the packed tower packed tower whichwhich is connected to the furnace whereas we have implemented SOx reduction technologies is connected to the furnace whereas we have implemented SOx reduction technologies like Dry Flue Gas Desulfurization Processes (FDG).

like Dry Flue Gas Desulfurization Processes (FDG).

In the manufacturing process of shampoo we experience odor problems due to the In the manufacturing process of shampoo we experience odor problems due to the chemicals which we use in the production process. We can not eliminate the odor chemicals which we use in the production process. We can not eliminate the odor problem and

problem and we use we use a dia dilution method lution method as tas these odors hese odors are non are non toxic. In toxic. In our industry our industry wewe provided

provided more more ventilation ventilation for for the the areas areas where where we we have have these these production production units units and and forfor workers we provide personal protective equipments like dust masks and respirators. workers we provide personal protective equipments like dust masks and respirators.

Noise

Noise pollution:pollution: As mentioned earlier, noise is produced from dissolve tanks, boilers,As mentioned earlier, noise is produced from dissolve tanks, boilers, mixers and filling machines. Noise pollution may be significant if we consider cosmetic mixers and filling machines. Noise pollution may be significant if we consider cosmetic industry as a whole.

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5

5 Cleaner Cleaner ProductionProduction

Cleaner production is the main tool to reduce the pollution from industries which Cleaner production is the main tool to reduce the pollution from industries which applies integrated preventive strategies to processes, products and services to increase applies integrated preventive strategies to processes, products and services to increase economic efficiency and to reduce risks to humans and environment.

economic efficiency and to reduce risks to humans and environment.

Cleaner production means economic savings from reduced consumption of raw Cleaner production means economic savings from reduced consumption of raw materials and energy, and lower treatment costs, as well as other benefits such as a materials and energy, and lower treatment costs, as well as other benefits such as a better

better company company image image and and better better working working conditions. conditions. Implement Implement cleaner cleaner productionproduction may not solve all environmental problems at a facility, but it will decrease the need for may not solve all environmental problems at a facility, but it will decrease the need for installing and operating end of pipe treatment equipment and reduce the quantity of installing and operating end of pipe treatment equipment and reduce the quantity of hazardous waste that must be treated and disposed of.

hazardous waste that must be treated and disposed of.

Following are some of the aspects addressed as cleaner production approaches. Following are some of the aspects addressed as cleaner production approaches.

Process

Process modification:modification: When environmental issues becomes more important, shampooWhen environmental issues becomes more important, shampoo manufacturers care about non-polluting materials such as organic ingredients (saponin manufacturers care about non-polluting materials such as organic ingredients (saponin extracted from pods of Acacia aulucumiformis), biodegradable bottles. Shampoo bottles extracted from pods of Acacia aulucumiformis), biodegradable bottles. Shampoo bottles made from beet extracts that biodegrade in compost pile, or fabrics that break down in made from beet extracts that biodegrade in compost pile, or fabrics that break down in soil safely, without any toxic by-products.

soil safely, without any toxic by-products.

As a new industry we have the best available technology in the present days. Most of As a new industry we have the best available technology in the present days. Most of the machines are run by computer softwares which will give accurate measurements on the machines are run by computer softwares which will give accurate measurements on batching and mixing of ingred

batching and mixing of ingredients. This will lead to optimum raw material usage.ients. This will lead to optimum raw material usage.

Recycling:

Recycling:In the boiler water will be In the boiler water will be recycled and use it back. recycled and use it back. We need to suppWe need to supply whatly what ever the amount we loose due to evaporation losses. For the Cooling tower we plan to ever the amount we loose due to evaporation losses. For the Cooling tower we plan to

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the WHO guideline. Therefore, we compare the pollution load of our production with the WHO guideline. Therefore, we compare the pollution load of our production with some of the soap production processes given in WHO guideline as shown in table 5. some of the soap production processes given in WHO guideline as shown in table 5.

Table 5- Typical Pollution Norms

Table 5- Typical Pollution Norms for Soap Productionfor Soap Production Unit Unit [U] [U] Waste Waste Volume Volume [m [m33/U]/U] BOD5 BOD5 [kg/U] [kg/U] TSS TSS [kg/U] [kg/U] Oil Oil [kg/U] [kg/U] Soap from kettle

Soap from kettle boiling

boiling tn tn product product 4.5 4.5 6 6 6 6 0.90.9 Liquid

Liquid Soap Soap tn tn anhydr anhydr - - 0.1 0.1 0.1 0.1 0.10.1 Liquid Detergent

Liquid Detergent tn tn anhydr anhydr - - 2 2 - -

--Table 6- Wastewater Pollution Load Table 6- Wastewater Pollution Load Parameter Flow Parameter Flow [m [m33/day]/day] Unit Unit [U] [U] Flow Flow [m [m33/tn]/tn] BOD BOD [Kg/tn] [Kg/tn] COD COD [Kg/tn] [Kg/tn] TSS TSS [Kg/tn] [Kg/tn] 0il 0il [Kg/tn] [Kg/tn] Pollution Pollution load load 110 tn 110 tn product product 2.5 0.875 2.5 0.875 1.75 1.75 1.625 1.625 0.30.3 7.

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After premixing, ingredients are mixed properly in main mixer at about 32

After premixing, ingredients are mixed properly in main mixer at about 32ooC. After that,C. After that, the liquid is transferred to storage tanks before being filled into bottles or refill bags. the liquid is transferred to storage tanks before being filled into bottles or refill bags. When production batch completes, machines are cleaned by hot water at 80

When production batch completes, machines are cleaned by hot water at 80ooC.C.

4 4 5

5 Raw

Raw Materials Materials Perfume Perfume (25(25ooC)C)

1 1 2 2 33 6 6 7 7 8 8

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Fat Trap Fat Trap Equalization Tank Equalization Tank pH Tank pH Tank Coagulation Tank Coagulation Tank Flocculation Tank Flocculation Tank Sedimentation Tank Sedimentation Tank pH Tank pH Tank 150 ton Tank 150 ton Tank Sludge pond Sludge pond Filter Press Filter Press Incoming Liquid Incoming Liquid waste waste Chemical Chemical Treatment Treatment CO CO22 Alum and Alum and CaCO CaCO33 Polymer Polymer CO CO22

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7.4

7.4 Solid Solid waste waste managementmanagement 7.4.1

7.4.1 Type Type of of solid solid wastewaste

a.

a. Paper i.e. box, casket, office paper, etc.Paper i.e. box, casket, office paper, etc. b.

b. Plastic i.e. plastic bags, sheath, bags to put raw materials, etc.Plastic i.e. plastic bags, sheath, bags to put raw materials, etc. c.

c. Hazardous waste i.e. batteries, fluorescent bulbs, spray bottles, etc.Hazardous waste i.e. batteries, fluorescent bulbs, spray bottles, etc. d.

d. Common waste i.e. yard, food waste, etc.Common waste i.e. yard, food waste, etc.

7.4.2

7.4.2 Waste Waste managementmanagement

a.

a. Waste for sell consists of paper, plastics, metal container, metallic scrap and oilWaste for sell consists of paper, plastics, metal container, metallic scrap and oil waste. Annual revenue from waste selling is of 1.7 million Bath.

waste. Annual revenue from waste selling is of 1.7 million Bath. b.

b. Waste for disposal by incinerator consists of scrap common waste and hazardousWaste for disposal by incinerator consists of scrap common waste and hazardous waste. Disposed waste annual expenditure is 1.8 million Bath.

waste. Disposed waste annual expenditure is 1.8 million Bath.

7.4.3

7.4.3 Waste Waste collectioncollection

Waste collected to landfill site includes scrap hazardous waste which consists of Waste collected to landfill site includes scrap hazardous waste which consists of chemical contaminated container i.e. canned, fluorescent bulbs, used oil etc. Layout of chemical contaminated container i.e. canned, fluorescent bulbs, used oil etc. Layout of waste collection zone is shown in appendix F.

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c.

c. TransportationTransportation

Rubbish is both compressed and loose waste by using container as shown in figure 9. Rubbish is both compressed and loose waste by using container as shown in figure 9.

Figure 9. Waste collecting truck and transportation Figure 9. Waste collecting truck and transportation

d.

d. Contaminated containerContaminated container

•

• Plastics tank size 200 L, metal tank size 200 L, fiberite and carton, used oil etc.Plastics tank size 200 L, metal tank size 200 L, fiberite and carton, used oil etc. •

• Revenue from contaminated container Revenue from contaminated container is around 1,700,000 Bath/annual.is around 1,700,000 Bath/annual.

e.

e. Waste disposalWaste disposal

Waste disposal process selected in Unilever company have two ways are compound of Waste disposal process selected in Unilever company have two ways are compound of incineration which is situated in factory and other wastes not be able to burn going to incineration which is situated in factory and other wastes not be able to burn going to landfill to be buried.

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Reference Reference

APO’s Demonstr

APO’s Demonstration Projects, 2ation Projects, 2000-2004, Asian Pr000-2004, Asian Productivity Orgoductivity Organization #HC 415 anization #HC 415 I 52I 52 G74 2000-04

G74 2000-04 Assoc.

Assoc. Prof. Prof. Dr.PleumchitDr.Pleumchitt t Rojanapanthu, Rojanapanthu, Hair Hair Care Care Products. Products. Pharmacy Pharmacy Department,Department, Faculty of Pharmacy Mahidol

Faculty of Pharmacy Mahidol University, Bangkok, ThailandUniversity, Bangkok, Thailand Chemical &

Chemical & Laboratory Laboratory Equipment. Equipment. 2005. 2005. Material SafetMaterial Safety Data Shy Data Sheet: Citric eet: Citric acid. (onlineacid. (online).). Available:

Available: www.sciencelab.com www.sciencelab.com [ 2007, January 28] [ 2007, January 28] Eckenfelder Jr., W. Wesley, 1989,

Eckenfelder Jr., W. Wesley, 1989, Industrial Water Pollution Control #TD745 E23 1989Industrial Water Pollution Control #TD745 E23 1989 Industrial Estate Authority of Thailand, Annual Repor

Industrial Estate Authority of Thailand, Annual Report 2005 # HD 890.55 A1 I t 2005 # HD 890.55 A1 I 53 2005;53 2005; Mary Ann H. Franson, Srandard methods for the examination of water and wastewater, Mary Ann H. Franson, Srandard methods for the examination of water and wastewater, Fifteenth Edition, Washington DC 20005, 1981.

Fifteenth Edition, Washington DC 20005, 1981.

Metcalf& Eddy, Wastewater Engineering, Treatment and Reuse, Fourth Edition, 2003. Metcalf& Eddy, Wastewater Engineering, Treatment and Reuse, Fourth Edition, 2003. Michican

Michican State. State. 2005. 2005. Reverse Reverse Osmosis Osmosis (RO). (RO). (online). (online). Available:Available: http://web1.

http://web1.msue.msu.edu/msue/msue.msu.edu/msue/iac/disasterresp/Hoiac/disasterresp/HomeImprovemenmeImprovement/wq24.pdf t/wq24.pdf OPTEK.

OPTEK. 2005. 2005. Clean-In-Place Clean-In-Place (CIP) (CIP) Applications Applications (online).(online). Available:

Available:http://www.optek.com/Application_Note/General/English/3/Clean- http://www.optek.com/Application_Note/General/English/3/Clean- In- In-Place_(CIP)_Applications.asp

Place_(CIP)_Applications.asp.. Stepan.

Stepan. 2007. 2007. Product Product shampoo. shampoo. (online). (online). Available:Available: http://www.stepan.com/

http://www.stepan.com/en/products/foen/products/formulations.asp?id=rmulations.asp?id=384 384 [2007, January [2007, January 28]28] Laws and Standards on Pollution control in Thailand, 4

Laws and Standards on Pollution control in Thailand, 4thth Edition 1997. Edition 1997. Lecture of Air pollution (ED78.06) Dr.Kim AIT

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Appendix A

Market Potential for Hair Care Shampoo in

Market Potential for Hair Care Shampoo in Asia (US $

Asia (US $ mln): 2005

mln): 2005

Country

Country Latent Demand US $ mlnLatent Demand US $ mln % of Asia% of Asia

China 796.18 33.74 China 796.18 33.74 Japan 539.30 22.85 Japan 539.30 22.85 India 385.47 16.33 India 385.47 16.33 South

South Korea Korea 135.94 135.94 5.765.76 Indonesia Indonesia 113.92 113.92 4.834.83 Thailand Thailand 71.73 71.73 3.043.04 Taiwan Taiwan 67.73 67.73 2.872.87 Philippines Philippines 53.6853.68 2.272.27 Malaysia Malaysia 39.6939.69 1.681.68 Bangladesh Bangladesh 35.4535.45 1.501.50 Hong Kong Hong Kong 32.3432.34 1.371.37 Vietnam Vietnam 26.9926.99 1.141.14 Singapore Singapore 19.6219.62 0.830.83 Burma Burma 11.1011.10 0.470.47 Sri

Sri Lanka Lanka 10.96 10.96 0.460.46

Nepal Nepal 5.84 5.84 0.250.25 North Korea North Korea 3.69 3.69 0.160.16 Cambodia Cambodia 2.79 2.79 0.120.12 Papua

Papua New New Guinea Guinea 2.11 2.11 0.090.09

Laos 1.56 0.07 Laos 1.56 0.07 Macau Macau 1.34 1.34 0.060.06 Brunei Brunei 1.02 1.02 0.040.04 Mongolia Mongolia 0.80 0.80 0.030.03 Bhutan Bhutan 0.40 0.40 0.020.02 Maldives Maldives 0.10 0.10 0.000.00 Other Other 0.10 0.10 0.000.00

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Thailand: Hair Care Shampoo in 2005, US

Thailand: Hair Care Shampoo in 2005, US $ mln

$ mln

City

City WorldWorld Rank Rank

US $ US $ mln

mln %C%Couountntryry %R%Regegioion %Wn %Wororldld

Bangkok

Bangkok 14 14 66.78 66.78 93.11 93.11 2.83 2.83 0.910.91

Chon

Chon Buri Buri 435 435 2.48 2.48 3.46 3.46 0.11 0.11 0.030.03 Songkhla Songkhla 933 933 0.76 0.76 1.06 1.06 0.03 0.03 0.010.01 Nakhon Nakhon Ratchasima Ratchasima 1,150 1,150 0.45 0.45 0.63 0.63 0.02 0.02 0.010.01 Chiang

Chiang Mai Mai 1,167 1,167 0.44 0.44 0.61 0.61 0.02 0.02 0.010.01 Khon

Khon Kaen Kaen 1,217 1,217 0.39 0.39 0.55 0.55 0.02 0.02 0.010.01 Nakhon Si Nakhon Si Thammarat Thammarat 1,361 1,361 0.28 0.28 0.4 0.4 0.01 0.01 00 Phitsanulok Phitsanulok 1,629 1,629 0.12 0.12 0.17 0.17 0.01 0.01 00 Hat

Hat Yai Yai 1,966 1,966 0.02 0.02 0.02 0.02 0 0 00

Total

Total 71.73 71.73 100 100 3.04 3.04 0.970.97 Source:

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Appendix C

Raw Materials

Chemical

Chemical Name Name Trade Trade NameName

Quantity Day Quantity Day

(Kg) (Kg)

Purpose for which it is Purpose for which it is

used used

PEG-150

PEG-150 Distearate Distearate STEPAN STEPAN PEG PEG 6000 6000 DS DS 244.4244.4 To increase theTo increase the viscosity

viscosity

Sodium Laureth Sulfate

Sodium Laureth Sulfate STEOL CS-230STEOL CS-230 8,9768,976

Surfactants are surface Surfactants are surface active ingredients, active ingredients, meaning they can meaning they can interact with a surface interact with a surface Disodium

Disodium

Cocoamphodiacetate

Cocoamphodiacetate AMPHOSOL 2C AMPHOSOL 2C 8,9768,976

To improve the To improve the foaming characteristic. foaming characteristic. Cocamidopropyl Cocamidopropyl Hydroxysultaince

Hydroxysultaince AMPHOSOL CS-50 AMPHOSOL CS-50 2,692.82,692.8

To improve the To improve the foaming characteristic. foaming characteristic. DL-2,4-Dihydroxy-N-(3- hydroxypropyl)-3,3-dimethylbutyramide, dimethylbutyramide, Butyramide Butyramide Panthenol 22.4 Panthenol 22.4 To modify these To modify these characteristic, characteristic, manufacturers add manufacturers add fragrance and fragrance and governmentally governmentally approved. approved.

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Processes Diagram

Reverse Reverse Osmosis Osmosis Steam Steam heat up to heat up to 70 70ooCC Air Air Pollution Pollution Hot water Hot water Ground Ground water water DI DI wawater ter Boiler Boiler Ingredient Ingredient Weighting Weighting Dissolve tank Dissolve tank Mixing tank Mixing tank Cooling tower Cooling tower Condense water Condense water QC QC _b_b Waste water Waste water S S t t e e a a m m

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Appendix E

Wastewater Treatment Flow Chart

d d a a r r y y_m_m e e n n

t t P P r r i i m a m a

r r y y T T r r e e a a t t m m e e n n t t P P r r e e t t r r e e a a t t m m e e n n t t Floatation (DAF) Floatation (DAF)

Biological Treatment (Aerobic) Biological Treatment (Aerobic)

Oil and Grease & Oil and Grease &

Settled Suspended Solid Settled Suspended Solid removal removal Equalization & Equalization & Neutralization Neutralization Screening Screening Industrial wastewater Industrial wastewater Industrial Process Industrial Process

Flow and pH adjustment Flow and pH adjustment Coarse solid Disposal Coarse solid Disposal

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Sludge Sludge Pressure Pressure control control valve valve Chemical Chemical Activated Carbon Activated Carbon Discharge Discharge (Reuse) (Reuse)

Flowchart of Wastewater Treatment Plant

C C o o a a r r s s e e s s o o l l i i d d Screening Screening E E f f f f l l u u e e n n t t W W a a t t e e r r Control device Control device Water Water Waste Waste E E f f f f l

l u u e e n n

t t W W a a t t e e r r Primary Primary Landfill Landfill Return Sludge Return Sludge Air blower Air blower Secondary Secondary Clarification Clarification E E f f f f l l u u e e n n t t Dewatering Dewatering Thickener Thickener Sludge Cake Sludge Cake

Waste Water Analysis

Effluent Water

Analysis

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Appendix F Appendix F

Figure G: Layout of Waste

Figure G: Layout of Waste management Unitmanagement Unit

Route Route

Disposal Waste

Disposal Waste _{Empty bin 2}_{Empty bin 2} _{Recycle Waste}_{Recycle Waste} EmptyEmpty container to container to be sold be sold Garden Garden Rest Room Rest Room Equipment Equipment Room Room Toilet Toilet Room Room Storage Tank Storage Tank Empty Empty Bin Bin Truck Truck Parking 1 Parking 1 Truck Truck Parking 2 Parking 2 Empty Empty Bin 1 Bin 1 Shrink Shrink Wood Wood Incinerator Incinerator Building Building