PROMOTIVE ACTION OF WORKER’S HEALTH,

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PROMOTIVE ACTION OF WORKERS HEALTH, HYGIENE, AND
ENVIRONMENT IN PT. GUNUNG MADU PLANTATIONS INDONES
IA Extension Seminar of JICOSH Ergonomic
Course Presented by dr. Evi Maiselma
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PRESENTATION OUTLINE
Company Overview
Hazard Identification
Hazard Handling
Waste Management
Waste Water Treatment
Control Monitoring
Constraint Commitment
Summary
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PT. GUNUNG MADU PLANTATIONS Cane Plantations
Sugar Factory Lampung, Indonesia www.gunungmadu.co
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COMPANY OUTLINES

• 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)

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PRODUCTION CHART
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THE PLANT SITE
Tokyo

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

Jakarta
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PLANTATIONS AREA

• 7 Area Divisions
• 35,000 Hectares Total Land
• 25,000 Hectares planted with cane

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EMPLOYEES WORKERS
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EMPLOYEES WORKERS COMPOSITION, 2003
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SITE FACILITIES
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MAIN ACTIVITIES
Cultivation
Laboratory
Health Service
Milling
Crop Maintenance
Waste Management
Processing
Workshop
Harvesting
Steam Generating
Research
Waste Water Treatment
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Hazard Identification at Workplace Plantations
Factory Workshop Research Laboratory Hospital

• PHYSICAL HAZARDS
• Dust
• Vibration
• Noise
• Sunburn

Cultivation
Plantation
Crop Maintenance

• CHEMICAL HAZARDS
• Herbicide insecticide application
• Fertilizer application

• BIOLOGICAL HAZARDS
• Poisonous animal attack
• Parasite infection

Harvesting

• PSYCHO-SOCIAL HAZARDS
• Overwork

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SUGAR PROCESSING FLOW CHART
CANE
BAGASSE
MILLING
IMBIBITION WATER
MIXED JUICE
MILK LIME
FILTER MUD
CLARIFICATION
SO2 GAS
CLEAR JUICE
SO2 GAS
EVAPORATION
SYRUP
BOILING
MASSECUITE
MOLASSES
CURING
WATER
SUGAR
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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

Milling

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

Factory
Clarification

• CHEMICAL HAZARDS
• Chemical for equipment cleaning
• Chemical for processing
• Chemical for Boiler

Evaporation

• PSYCHO-SOCIAL HAZARDS
• Overwork

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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

• PHYSICAL HAZARDS
• Dust
• Vibration
• Noise

Repairing
Fabricating

• CHEMICAL HAZARDS
• Used Oil

Workshop

• RADIATION HAZARDS
• Welding radiation

Assembling

• PSYCHO-SOCIAL HAZARDS
• Overwork

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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

• CHEMICAL HAZARDS
• Chemical for analysis

Research

• BIOLOGICAL HAZARDS
• Infectious diseases

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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

• CHEMICAL HAZARDS
• Chemical for analysis

Laboratory
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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

Medical Treatment

• BIOLOGICAL HAZARDS
• Communicable disease

Curing Room

• RADIATION HAZARDS
• Photo (X-ray) radiation

Hospital
X-ray Unit
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HAZARD HANDLING
Protection
Modification and Improvement in the Process
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WASTE MANAGEMENT
Source Reduction
Recycling Reusing
Utilization
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WASTE MANAGEMENT
Liquid Waste
WWT
Cane
Juice
Sugar
Molasses
Solid Waste
Bagasse
Filter Mud

• Derivative Industry
• (Alcohol, MSG, Cattle Feed)

• Transported to farm as organic fertilizer

• Power Generator
• (Burnt ash is used for farm)
• Derivative Industry
• (Mushroom, Paper, Cattle Farm)

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WASTE WATER TREATMENT
Anaerobe Pond (60,900 m3)
Facultative 3 Pond (6,129 m3)
Facultative 2 Pond (8,400 m3)
Facultative 4 Pond (6,129 m3)
Facultative 5 Pond (6,129 m3)
Total Volume 244,150 m3
Splitter (Oil and Water) (660 m3)
Buffering Pond (29,700 m3)
Facultative 1 Pond (8,400 m3)
Aerobe 1 Pond (18,654 m3)
Aerobe 2 Pond (34,428 m3)
Fishing Test
Stabilizing Pond (8,100 m3)
For irrigation
Monitor Pond (4,590 m3)
to the river
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WASTE WATER TREATMENT
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CONTROL MONITORING

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

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

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HAZARD SUMMARY

• HAZARDS
• Ash
• Dust
• Noise
• Vibration
• Heat
• Herbicide and Insecticide
• Chemical
• Radiation
• Poisonous animals attack
• Waste

• EFFECT
• Workers 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

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

• HYGIENE
• In-house keeping

• ENVIRONMENT
• Waste Management
• Waste Water Treatment
• Reforesting, Green Belt
• Routine Monitoring

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EFFLUENT ANALYSIS BY GOVERNMENT, 2003
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EFFLUENT ANALYSIS BY GOVERNMENT, 2003
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AIR QUALITY MEASUREMENT BY GOVERNMENT, 2003
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ENVIRONMENT AWARD
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OUR CONSTRAINTS
Need training and OSH campaign

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

Need more budget to provide safety
infrastructures protection equipment

• It is the nature of sugar industry to create
• hazards
• Noise, Heat, Vibration, Ash, etc

Need OSH continual campaign
Daily workers turn-over is high, and they work
only in harvesting season.
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OUR COMMITMENT
No Serious Hazard
No Occupational Disease
No Environmental Damage
Healthy Worker, Healthy Company
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Thank You