Diploma Thesis in Cooperation with LCM 2007 Title: Material Flow - - PowerPoint PPT Presentation

Diploma Thesis in Cooperation with

LCM 2007 – Title: Material Flow Nets and Green Coffee Processing in Costa Rica

Author: Kirsten-Verena Bull

Diploma Thesis in Cooperation with

• Dr. Jeffrey R. Jones

Laboratory GIS, CATIE Turrialba, Costa Rica Tel: (00 506) 558-2333 eMail : jjones@catie.ac.cr Kirsten-Verena Bull Diploma Thesis in Business Administration & Informatics University of Hamburg, Germany eMail: verena.bull@web.de

Contact:

• Prof. Dr.-Ing. Bernd Page

University of Hamburg, Germany Department of Informatics eMail: page@informatik.uni- hamburg.de Martina Prox ifu Hamburg GmbH, Hamburg, Germany

• www. ifu.com

eMail: m.prox@ifu.com

Diploma Thesis in Cooperation with

Thesis: The EMIS-Software Umberto for Environmental Performance Evaluation (EPE)

• f Green Coffee Processing Plants

with Focus on Beneficios in Costa Rica

Author: Kirsten-Verena Bull

General Context

Coffee Market

• Second largest commodity trade in the world after petroleum
• Some 70 to 80 producer countries and 20 key consumer countries
• An estimated total of 100 million people are directly related to the sector
• Structural changes caused decrease of prices for green coffee
• Dependent on the country: economic, social and environmental problems
• Various efforts for compensation inherent documentation requirements

Environmental Informatics

• New research field in informatics since approximately 1993
• Provision of information basis for solution of environmental problems
• EMIS aid to systematically obtain, process and present environmentally

relevant information in the business domain for routine environmental management and strategic decision making Introduction Foundations Data Collection First Evaluation Conclusions & Outlook General Context Objective

Objective

Analysis and presentation of possibilities and requirements of the application of the EMIS-System Umberto and the underlying concept of Material Flow Nets for environmental performance evaluation of green coffee processing plants Focus on two beneficios in Costa Rica Concentration on implementation of Material Flow Nets with Umberto. Consideration also of assessment methods and reference modelling. No evaluation of interfaces and environmental cost accounting with Umberto Use of the ISO 14031 standard for environmental performance evaluation (EPE) as orientation and framework

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook General Context Objective

Foundations

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Umberto MFN I/O B. & MF Anal.

• Ref. Models

Based on the Plan-Do-Check- Act Cycle of ISO 14031:1999, data source: [DIN1999]

The EMIS-System Umberto

An EMIS is a “software-application for the acquisition, documentation and assessment of environmental impacts caused by corporate performance as well as for the generation, planning and management of environmental protection methods, thus supporting the tasks of corporate environmental management” ([Wohl2005], p. 144, own translation into English) The EMIS-Software Umberto has originated in a cooperation of the ifu Hamburg GmbH and ifeu Heidelberg GmbH The core concept of Umberto is called “Material Flow Nets” Here: Focus on three aspects: material flow nets, Input/Output balances & material flow analysis, and reference modelling.

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Umberto MFN I/O B. & MF Anal.

• Ref. Models

Material Flow Nets

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Umberto MFN I/O B. & MF Anal.

• Ref. Models

I/O Balances & MF Analyses (1)

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Umberto MFN I/O B. & MF Anal.

• Ref. Models

I/O Balances & MF Analyses (2)

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Umberto MFN I/O B. & MF Anal.

• Ref. Models

Reference Models

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Umberto MFN I/O B. & MF Anal.

• Ref. Models

(Data source: see information on last slide)

Data Collection

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

Based on the Plan-Do-Check- Act Cycle of ISO 14031:1999, data source: [DIN1999]

Excursus GCP – Overview Process Steps Modelling

Excursus: eEPCs by ARIS

Business Process: “target oriented cooperation of business responsibilities in direct relation to strategic business goals. A business process consists of a sequence of temporally, spatially and logically interrelated procedures, tasks and functions, the executing organizational units and the necessary control information. A business process is crossfunctional or inter-organizational oriented and is initiated and terminated by an event.” ([Krus1995], p. 24, own tr.

into English)

The ARIS-Methodology supports development of business processes. The eEPCs can also be reduced to Petri-Nets Application of lean modelling approach for eEPC, for definition of system limits

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

Basis Symbols

Excursus GCP – Overview Process Steps Modelling

Green Coffee Processing – Overview (1)

The green coffee beans are obtained from coffee cherries The two mainly cultivated species worldwide are “Coffea arabica” and “C. canephora var. robusta” The purpose of green coffee processing is to reduce the water content of the fresh coffee cherries to some 11-12% Three different kinds of green coffee processing exist: Dry Processing, Wet Processing, Semi-Dry Processing Different influence factors on processing performance Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Green Coffee Processing – Overview (2)

System limits:

• Place: Production sites, wet

method, beneficios in Costa Rica, two beneficios

• Time: Harvesting season, not

the maintenance time. Together with logical limit also reason for disregard of the composting area and the residual water treatment in lagoons Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

• Logic: Wet and dry process of the wet method of green coffee processing.

Waste management and material/energy supply only considered to some

• extent. Administration processes are not used in the models
• Flows: Focus on the main material and energy flows typical in beneficios:

coffee cherries as raw material and their succeeding intermediate products; burning materials and electric energy as operating materials. Costs are not regarded Excursus GCP – Overview Process Steps Modelling

Process Steps (1)

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

1

Area Purpose

• Collection, storage and separation of harvested coffee cherries
• Decision about processing method
• Cleaning of coffee cherries and separation of impurities
• Separation of coffee cherries according to maturity
• Separating the pulp (outer skin and mesocarp) of the coffee

cherries from the coffee beans by squeezing the beans out of the pulp

• Separation of pulped beans from other material
• Final separation of wet parchment beans
• Direction of separated materials to different process steps

2 3 3

Coffee Reception Separation

• f Impurities

Pulp Removal (Pulping and Repassing) Pulping Output Pregrading

Excursus GCP – Overview Process Steps Modelling

Process Steps (2)

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Area Purpose

• Removal of residual parts of the mesocarp (insoluble in water

and still tightly attached to the endocarp of the coffee bean)

• Washing of wet parchment coffee beans to remove the soluble

fermented mucilage

• Increasing temperature of wet beans and unripe coffee cherries

for decrease of moisture content to about 12% to prevent fermentation and allow storage

• Generally performed via several drying steps
• Preservation of bean characteristics and thus commercial value

as long as possible. The recognized average ideal moisture content of beans at beginning of storage is about 12%

4 4 5 6 8

Excursus GCP – Overview Process Steps Modelling

Mucilage Removal Parchment Bean Washing Bean Drying Intermediate Storage

Process Steps (3)

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Area Purpose

• Removal of parchment or complete pulp from dry parchment

beans or dried coffee cherries

• Further grading of green coffee beans according to size,

density/gravity and colour

• Grading allows more uniform roasting later but especially it

helps to meet demands of clients. Thus grading activities determine the final qualities of green coffee beans leaving the green coffee processing plant Process Water and Pulp Management

• Treatment of process water to minimize water consumption by

recycling water and repassing

• Environmentally safe disposal of wastewater
• Treatment of solid byproducts, especially pulp

Provision of Hot Air

• Supply of a stream of heated air or water to mechanical dryers

9 9

Bean Hulling and Polishing Grading Waste Mana- gement & Op. M/E Supply

Excursus GCP – Overview Process Steps Modelling

10 11

Base Line

Modelling

• A model is a simplified representation of another system. It focuses on certain

aspects of the system relevant to analysis objectives and necessarily always is an abstraction.

• “‘Model Validation’ is substantiating that the model within its domain of

applicability behaves with satisfactory accuracy consistent with the study

• bjectives. […] ‘Model Verification’ is substantiating that the model is

transformed from one form into another […] with sufficient accuracy”

(Balci, O. (1998), cited in [KKPa2005], p. 197)

Present Data Situation Concise & Detailed Modelling Approach

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Example Modelling

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Example Modelling

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Example Modelling

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Example Modelling

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Example Modelling

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Example Modelling

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Excursus GCP – Overview Process Steps Modelling

Example Modelling

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook (Please note: The data have been modified, so that they do not belong to one of the analysed beneficios) Excursus GCP – Overview Process Steps Modelling

First Evaluation

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

Based on the Plan-Do-Check- Act Cycle of ISO 14031:1999, data source: [DIN1999]

Situation in the Coffee Industry

Situation in Coffee Industry (1)

Generally, prices have significantly fallen because of overproduction The recognized crisis in the coffee market is also due to a structural change The crisis resulted in decrease of quality, in growing levels of poverty, unemployment, bad labour conditions, social violence, critical financial situations and undesired environmental impacts in producer countries International Coffee Agreements (ICA) by the International Coffee Organization (ICO) Since 1989, the market became much more liberalized and volatile, and converted into a buyer-driven commodity chain A vast number of potentially interested parties exists. These groups are focussing on social, economic and ecological aspects of corporate activities within the coffee sector

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Situation in the Coffee Industry

Situation in Coffee Industry (2)

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook Situation in the Coffee Industry

(Data source: see information on last slide)

Conclusions and Outlook

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

Based on the Plan-Do-Check- Act Cycle of ISO 14031:1999, data source: [DIN1999]

Conclusions and Outlook (1)

ISO 14031 framework Material flow net approach Business process models of the ARIS-modelling concept Description of equipment and material flows by application of 3D-CAD- models Concentrated on two beneficios with some similarities, but also differences Only a few functions of the EMIS-System Umberto with focus on application of the material flow nets as its core concept could be evaluated

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

Conclusions and Outlook (2)

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

(Data source: see information on last slide)

Conclusions and Outlook (3)

First statements by individuals about the use of material flow net models and Umberto in beneficios of Costa Rica Evaluation mostly qualitative The coffee market is facing a crisis due to overproduction and structural changes in the coffee market Further research will be needed for application of the EMIS-Software Umberto and its core concept of material flow nets for evaluation of its practical applicability for green coffee processing for provision of sound data for environmental decision-making. This thesis might be taken as a basis for further proceedings

Introduction Foundations Data Collection First Evaluation Conclusions & Outlook

Thank You !

Please Note

To have a full list of the data sources used, you will need to refer to the full example of the diploma thesis. Pictures and drawings with a note in this presentation demonstrate, that they do not base totally upon the authors

• wn elaborations. Many of these have been modified by the author. This is

also valid for the photo collage shown on the first two slides.