PROMOTIVE ACTION OF WORKER’S HEALTH,HYGIENE, AND ENVIRONMENT

IN PT. GUNUNG MADU PLANTATIONSINDONESIA

Extension Seminarof JICOSH Ergonomic Course

Presented by :dr. Evi Maiselma

PRESENTATION OUTLINE

Company Overview

Hazard Identification

Hazard Handling

Waste Management

Waste Water Treatment

Control & Monitoring

Constraint & Commitment

Summary

PT. GUNUNG MADU PLANTATIONSPT. GUNUNG MADU PLANTATIONSCane Plantations & Sugar FactoryCane Plantations & Sugar Factory

Lampung, IndonesiaLampung, Indonesiawww.gunungmadu.com

1975 : Established in Lampung Province

Status : Foreign Investment Company•Kuok Investment (Foreign Partner) :

45.00 %•PT Pipit Indah (Local Partner) : 27.50 %•PT Rejosari Bumi (Local Partner) : 27.50 %

1978 : Initial Production

Main Product : Plantation White Sugar (Domestic Market)

Co-Product : Molasses (Domestic & Foreign Market)

COMPANY OUTLINES

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

1978 1979 1982 1984 1985 1987 1988 1989 1991 1992 1993 1994 1996 1997 1999 2000 2001 2002 2003

Sugar (metric Ton)

PRODUCTION CHART

THE PLANT SITE

Jakarta

Tokyo

• 7,000 km from Tokyo• 400 km from Jakarta• 100 km from Provincial city

PLANTATIONS AREA

• 7 Area Divisions• 35,000 Hectares

Total Land• 25,000 Hectares

planted with cane

Year Staff &Manager Employee Total Daily

Workers

1985 120 1,640 1,760 10,000

1987 125 1,598 1,723 10,500

1989 124 1,519 1,643 8,000

1991 131 1,627 1,758 8,5001993 133 1,723 1,856 8,5001995 142 1,745 1,887 8,5001997 147 1,654 1,801 7,5001999 153 1,553 1,706 8,5002000 153 1,526 1,679 8,5002001 152 1,549 1,701 8,5002002 151 1,542 1,693 8,5002003 147 1,553 1700 8,000

EMPLOYEES & WORKERS

1%17%

82%

Manager Employee Daily Worker

EMPLOYEES & WORKERS COMPOSITION, 2003

FACILITIESRESIDENCE LOCATION

TOTALSite A I II III IV VI

Kindergarten 1 1 1 1 1 5

Elementary School

1 1 1 1 1 5

Junior School 1 1

Mosque 1 1 1 1 1 1 6

Church 1 1 1 1 4

Hospital 1 1

Policlinic 1 1 1 1 1 5

Canteen 1 1 1 1 4

Mini market 1 1 1 1 1 1 6

Club House 1 1 1 1 1 5Foot Ball Field 1 2 1 1 1 1 7Tennis Court 1 1 2 1 1 1 7Volley Ball Court 2 2 4 2 2 2 14Badminton Court 1 6 1 1 1 10Basket Ball Court 1 1 2Swimming Pool 1 1

SITE FACILITIES

MAIN ACTIVITIES

Cultivation

Crop Maintenance

Harvesting

Milling

Processing

Steam Generating

Laboratory

Workshop

Research

Health Service

Waste Management

Waste Water Treatment

PHYSICAL HAZARDS• Dust• Vibration• Noise• Sunburn

CHEMICAL HAZARDS• Herbicide & insecticide

application• Fertilizer application

BIOLOGICAL HAZARDS• Poisonous animal attack• Parasite infection

PSYCHO-SOCIAL HAZARDS• Overwork

Cultivation

Crop Maintenance

Harvesting

Hazard Identification

at Workplace

PlantationsFactory

WorkshopResearch

LaboratoryHospital

Plantation

SUGAR PROCESSING FLOW CHART

BAGASSE

FILTER MUD

MOLASSES

SUGAR

CURING

MASSECUITE

BOILING

SYRUP

EVAPORATION

CLEAR JUICE

CLARIFICATION

MIXED JUICE

MILLING

CANE

WATER

SO2 GAS

MILK LIME

IMBIBITION WATER

SO2 GAS

PHYSICAL HAZARDS• Dust• Ash• Noise• Vibration• Heat

CHEMICAL HAZARDS• Chemical for equipment

cleaning• Chemical for processing• Chemical for Boiler

PSYCHO-SOCIAL HAZARDS

• Overwork

Milling

Clarification

Evaporation

Hazard Identification

at Workplace

PlantationFactory

WorkshopResearch

LaboratoryHospital

Factory

Hazard Identification

at Workplace

PlantationFactory

WorkshopResearch

LaboratoryHospital

Workshop

PHYSICAL HAZARDS• Dust• Vibration• Noise

CHEMICAL HAZARDS• Used Oil

RADIATION HAZARDS• Welding radiation

PSYCHO-SOCIAL HAZARDS

• Overwork

Repairing

Fabricating

Assembling

Tissue Culture

Biological Control

Breeding

Hazard Identification

at Workplace

PlantationFactory

WorkshopResearch

LaboratoryHospital

Research

CHEMICAL HAZARDS• Chemical for analysis

BIOLOGICAL HAZARDS• Infectious diseases

Lab Analysis

Lab Analysis

Lab Analysis

Hazard Identification

at Workplace

PlantationFactory

WorkshopResearch

LaboratoryHospital

Laboratory

CHEMICAL HAZARDS• Chemical for analysis

Medical Treatment

Curing Room

X-ray Unit

Hazard Identification

at Workplace

PlantationFactory

WorkshopResearch

LaboratoryHospitalHospital

BIOLOGICAL HAZARDS• Communicable disease

RADIATION HAZARDS• Photo (X-ray)

radiation

JICOSH Extension Seminar

!

HAZARD HANDLING

Modification and Improvement in the

Process

Protection

Eliminating or Minimizing Hazard Source

JICOSH Extension Seminar

WASTE MANAGEMENT

Source Reduction

Recycling & Reusing

Utilization

JICOSH Extension Seminar

Cane

Bagasse

• Derivative Industry(Alcohol, MSG, Cattle Feed)

• Power Generator(Burnt ash is used for farm)

• Derivative Industry(Mushroom, Paper, Cattle Farm)

• Transported to farm as organic fertilizer

Liquid Waste

Juice Sugar

Molasses

Filter Mud

WASTE MANAGEMENT

Solid Waste

WWT

AnaerobePond

(60,900 m3)Buffering Pond(29,700 m

3)

Facultative 3 Pond(6,129 m

3)

Stabilizing Pond(8,100 m3)

Aerobe 1Pond

(18,654 m3)

Facultative 2 Pond(8,400 m3)

Facultative 1 Pond(8,400 m3)

Aerobe 2 Pond

(34,428 m3)

Monitor Pond(4,590 m3)

WASTE WATER TREATMENT

Splitter (Oil and Water)(660 m3)

For irrigation

to the river

Fishing Test

Total Volume = 244,150

m3

Facultative 4 Pond(6,129 m

3)

Facultative 5 Pond(6,129 m

3)

JICOSH Extension Seminar

WASTE WATER TREATMENT

JICOSH Extension Seminar

CONTROL & MONITORING

ENVIRONMENT

• Air Quality Measurement• Water Quality at Resource• Water Waste Quality after

Treatment

WORKER• Pre-employment Medical

Check-up• Periodical Medical Check-up• Pre-replacement Medical

Check-up

JICOSH Extension Seminar

HAZARD SUMMARY

HAZARDS

• Ash• Dust• Noise• Vibration• Heat• Herbicide and

Insecticide• Chemical• Radiation• Poisonous animals

attack• Waste

EFFECT

• Worker’s Health Respiratory System Hearing System Nervous System Heat Stroke & Water

Body losses Acute & Chronic

Intoxication Skin & eyes Irritation GIT disturbance Poison effect of

animal Radiation effects

• Environment Air Pollution Water Pollution Natural Balance Social Aspect

HYGIENE• In-house keeping

ENVIRONMENT• Waste

Management• Waste Water

Treatment• Reforesting,

Green Belt• Routine

Monitoring

HEALTH• Emergency Help• Curative Action• Preventive Action• Promotive Action

JICOSH Extension Seminar

Month Debit (M3/day) pH

BOD COD TSS

(ppm)

April 3,371 8.83 30 70 41

May 4,549 8.63 32 76 35

June 3,606 8.53 33 75 20

July 3,514 8.16 41 85 40

August 2,816 8.46 42 90 50

September 4,306 8.31 43 70 42

Tolerable Value

6 - 9 60 100 50

EFFLUENT ANALYSIS BY GOVERNMENT, 2003

JICOSH Extension Seminar

EFFLUENT ANALYSIS BY GOVERNMENT, 2003

0

20

40

60

80

100

BOD COD TSS

April May June July Aug Sept Max

JICOSH Extension Seminar

ParameterAmbient Emission

Measured Tolerable Value

Measured Tolerable Value

SO2 50.11 ug/m3 365 6.32 mg/m3 1000

NOX 26.82 ug/m3 150 69.53 mg/m3 1000

CO 875 ug/m3 10.000 254.23 mg/m3 -

CO2 - - 5.13 % -

O2 - - 11.48 % -

H2S < 0.001 ppm 0.02 - -

NH3 0.003 ppm 2 - -

Total Particle - - 214.26 mg/m3 350

Ash 42.1 ug/m3 230 - -

Noise Level 48.6 dB 70 - -

AIR QUALITY MEASUREMENT BY GOVERNMENT, 2003

JICOSH Extension Seminar

ENVIRONMENT AWARD

JICOSH Extension Seminar

OUR CONSTRAINTS

Human Factor (negative attitude & bad habit)• Indiscipline• Carelessness• Low awareness of the importance of OSH

Need training and OSH campaign

It is the nature of sugar industry to create

hazards• Noise, Heat, Vibration, Ash, etc

Need more budget to provide safety

infrastructures & protection equipment

Daily workers turn-over is high, and they work only in harvesting season.

Need OSH continual campaign

JICOSH Extension Seminar

OUR COMMITMENT

Healthy Worker, Healthy Company

No Serious Hazard

No Environmental Damage

No Occupational Disease

GMP Sugar is the cleanest sugar produced in the region

Thank You