Sai Gon – Dong Xuan Brewery Joint Stock Company

Case study

19/02/2012

Sai Gon – Dong Xuan Brewery Joint Stock Company was established since 1965 under the Sai Gon Beer – Alcohol – Soft drinks Corperation (Sabeco). The company specialises in production and trading of beverage products. Annually, the company production reaches 30 million litter beer/year; 1.5 million litter alcohol/year; 3 million wine bottles/year. Total employees are 362 persons.

Located in Thanh Ba district, before applying Cleaner Production (CP), the main pollution sources of the Company were air emissions, dust, wastewater and solid wastes. The wastewater has high COD and BOD5 levels which are 7.8 to 10.6 times higher than Vietnamese standard. Besides, air emissions released from the production adversely affected the workers' healths and the surrounding environmentIn order to solve that issue, the Company has approached to the Cleaner Production in Industry Component (CPI) under the Ministry of Industry and Trade.

With the support of Phu Tho Department of Industry and Trade, in 2007, the Company participated in CP demonstration project under the CPI. From May to October 2007, the Company set up a Cleaner Production Team, led by Mr. Khuất Văn Triệu - Company Director and the other 5 members to carry out Cleaner Production Assessment. The focus of the assessment was the alcohol production line. After conducting a walk-through assessment and identification of waste streams, the Team conducted mass and energy balances for the production line. All collected data have been used to analyse and identify Cleaner Production options for each production step.

After conducting CPA and identifying improvement options, the Company has carried out some no-cost and low-cost Good housekeeping options with total budget of VND 78.5 millions. Such application has brought about VND 533 millions for the company each year. In the second phase, the Company has actively implemented high-investment options to improve the product quality and solve completely the environmental issues at place, specifically investing VND 1.9 billions for recycle and reuse of cooling water; introduction of automatic bottle cleaning system; introduction of steam bag for hot air supplier system in the workshop. By 2009, the benefits derived from those solutions were VND 2,325 millions by reduction of 800 ton coal/year, 120.000 kg tapioca starch/year, 13.600 m3 water and other costs.

Particular benefits derived from Cleaner Production are as follows:

Technical benefit	Economic benefit	Environmental benefit
Phase 1: (2/2007 - 10/2007)
Reduction of 2% of tapioca starch/product unit	Annual saving of VND 189 millions	Reduction of 2% of dust to the environment (estimated) Reduction of pollutant load to the environment; Annual reduction of 5 million m3 waste water; Annual reduction of 250 ton CO2 Annual reduction of 30.000 kwh electricity
Reduction of 40% of ferment/product unit	Annual saving of VND 37 millions
Reduction of 7.1% of water supply/product unit	Annual saving of VND 2 millions
Reduction of 35% of coal consumption/product unit	Annual saving of VND 1,8 billions
Reduction of 10% of electricity consumption/product unit	Annual saving of VND 57 millions
Phase 2: (10/2007 - 2010)
Reduction from 3.9 - 5.9% of tapioca starch/product unit	Annual saving of VND 360 – 516 millions	Annual reduction of 12.7 ton dust to the environment Improved working conditions Annual reduction of 5000 m3 wastewater discharged to the environment; Improved wastewater quality before discharged Reduced air pollutant load Fire prevention
Reduction of 40% of ferment/product unit	Annual saving of VND 24.5 – 39 millions
Reduction of 21 – 28.6% of water supply/product unit	Annual saving of VND 3.2 – 5.9 millions
Reduction of 35 – 37.5% of coal consumption/product unit	Annual saving of 1 – 1.8 billions
Reduction of 20% of electricity consumption/product unit	Annual saving of 45 – 108 millions
Reduction of 0.4 – 1% of broken bottle rate	Annual saving of 1,8 – 2 millions	Annual reduction of 1000 broken bottles (solid wastes)

Typical Cleaner Production options of the Company are as follows:

No.	CP Option	Investment	Performance	CP technique
1	Control suitable water flow speed	VND 12 millions	Stable product quality; annual saving of VND 3 - 5 millions; Annual reduction of 5 million m3 waste water	PC
2	Put a stainless steel sheet at the break point of the tower surface (as presented in the figure) to avoid spilled water when the water stream changes			EM
3	Workers should pay attention to avoid blocking water stream overflowing out to the fermenting tower surface			GH
4	Increase air supplying for boiler, supervise boiler operation to minimise incomplete burning coal in slag	VND 80 millions	Annual saving of 800 ton coal(VND 1.8 billions)	PC
5	Introduce steam bag for hot air supplier system in the workshop			EM
6	Insulate all equipment in boiling system: pipes, tanks etc.			GH
7	Introduce vacumn cleaner in milling area	VND 60 millions	Annual saving of VND 210 millions	EM
8	Recycling of cooling water via cooling tower	VND 1.7 billions	Annual saving of VND 150 millions	OR
9	Regularly maintaining centrifugal machine	-	Annual saving of VND 35 millions Reduction of wasted alcohol (0.015 %)	GH
10	Recover condensed water for boiler	VND 5 millions	Annual saving of 400m3 water serving for the boiler (VND 60 millions)	OR

Remarks: GH: Good Housekeeping; EM: Equipment Modification; PC: Process Control, OR: Onsite Recovery

Some images on CP equipment:


Auto bottle cleaning equipment with higher efficiency, no environmental pollution	Increase air supply for the boiler, monitor the boiler operation to reduce non-completely burnt coal in slags

Perceiving the benefits from CP application, the company insisted to maintain the CP team activities and integrate CP in the general management system at place. In order to facilitate CP application, a simple environmental management system has been developed. The Company has also set up environmental policy, whereby it is requested that the environmental protection law and other regulations should be followed strictly, ensuring the sustainable development of the company and reducing waste emission sources. The Company has integrated process management system with the environmental management system, therefore, energy and material consumption is monitored at the same time with the monitoring of pollutant parameters in the waste streams.

The environmental monitoring plan has been initiated. The aim of the plan is to monitor significant improvements from applying CP or to adjust if there is any reduction in environmental benefits. The environmental monitoring system covers both air and water environment monitoring.

CP not only brings about benefits from energy saving, emission minimization, reduced water consumption, but also helps the Company increase production, improve product quality, prove prestige. The implemented CP options at the Company are typical case studies for enterprises in the sector of beverage production in Vietnam./.

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