Nile factory for feed in Damietta

Nile Feed Factory is a factory located in Kafr Saad city in Damietta governorate, which manufactures poultry feed by mixing a number of important nutrients for chicken growth. These ingredients differ in some proportions or some minor additives according to their purpose, whether for flesh or egg production.

Main Source of Pollution:

It was found through the field visits of ECO experts that the production capacity of the Nile Feed Factory in Damietta was about 65 tons / day (24000 tons / year) of poultry feed. There have also been many negative indicators of production processes:

1. Dust and suspended materials in the atmosphere of the factory.
2. High noise and temperature within the production departments.
3. All processing were manually.
4. High consumption of electricity & fuel than the normal rate by at least 25% due to the obsolete production lines and steam boiler.
5. Increasing the losses of final products by 5% compared with the optimum in such industries which does not exceed 2.5%.

Environmental compliance Implemented Options

To overcome these problems, it was found that all production processes must be adapted technologically and environmentally from the process of receiving and purifying raw materials, crushing and grinding of corn, mixing, compressing, cooling, granulating processes and finally  automatic filling.

It is also necessary to replace the current steam boiler, which contributes significantly to the loss of about 25% of energy, with another modern and environmentally friendly boiler to save losses and reduce emissions.

Environmental and Economic Benefits

Environmental benefits:

• Increase the production rate by 25% compared with the current rate
• Achieve savings in raw material losses of at least 124 tons per year.
• Rationalize energy consumption (electricity – solar) by at least 10%
• Maintain the safety and occupational health of factory workers from noise and exposure to high temperatures, dust and suspended particulate matter that damage the respiratory system
• Reduce harmful emissions (carbon dioxide, nitrous oxide and sulfur) at rates of 83, 0.1 and 0.3 tons, respectively.

Investment Cost: EGP 3,000,000.

Economic Returns: 1.1 million LE annually.

Return Period: 33 month.

    

 

 

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Obour Land for Food Industries

Obour Land is the fourth largest white cheese producer in Egypt. The company is producing for the local and export market. Obour Land employs 250 permanent employees working in two shifts, seven days/week.

Environmental compliance Implemented Options

• Replacement of manual packaging by automatic packing machine. Before the CP intervention, the company used manual filling methods leading to the waste of final product. By shifting to automatic packing technology, the company will produce less organic waste and diminishes the use of energy and water. Product quality will also be improved with less rejects.
• Switching from “mazot” (heavy oil) to natural gas as fuel for boiler

Environmental and Economic Benefits

Options	Environmental benefits	Economic saving / year(EGP)	Investment t/(EGP)	Pay-back period (months)
Replacement of the manual cutting and packaging with automatic system	BOD reduction: 17 t/year	500,000	2,000,000	48
Boiler fuel switch to natural gas	CO2 reduction: 633,000 t/year SO2 reduction: 20 t/year	131,000	90,000	8
Total		631,000	2,090,000	40