PENURUNAN MATERIAL LOSSES PADA INDUSTRI PENGOLAHAN SUSU DENGAN PERBAIKAN SET COUNTER FLUSHING (Studi Kasus di PT. Danone Indonesia, Bekasi, Jawa Barat)

FERI, Dr. Wagiman, STP., M.Si.

2013 | Skripsi | TEKNOLOGI INDUSTRI PERTANIAN

Proses produksi industri pengolahan susu berkomitmen dalam peningkatan produktivitas, kualitas, nutrisi tinggi, dan keamanan produk. Proses produksi pengolahan susu (yoghurt) meliputi mixing, pasteurisasi, filling, sealing, packing dan palletizing. Material losses menjadi salah satu faktor penghambat peningkatan produktivitas perusahaan. Penelitian ini bertujuan mengidentifikasi dan menganalisis tingkat pemborosan dan dampaknya terhadap biaya produksi perusahaan untuk produk Activia yoghurt cup dan Milkuat yoghurt cup. Penelitian ini memetakan masalah dengan pendekatan analisis input-output berdasarkan neraca massa. Total padatan terlarut dalam proses flushing dijadikan salah satu indikator material losses. Analisis kelarutan total padatan terlarut menggunakan metode thermogravimetri pada proses flush to SURGE dari mixing tank menuju ferment tank dan transfer ferment tank menuju storage tank. Selanjutnya, analisis dipertimbangkan dengan hasil neraca massa produksi, jenis produk, jenis bahan baku, material losses per batch, nilai ekonomi per material, serta desain pipa dalam lini produksi. Hasil penelitian menunjukkan material losses yang terjadi sebesar 7% batch size (per 5 ton) dapat direduksi dengan pengaturan flushing (set counter flushing) pada proses transfer produk dari ferment tank menuju storage tank. Usulan perbaikan set counter flushing pada tahap flush to SURGE dengan penambahan air 105 kg dan transfer produk dari ferment tank menuju storage tank kualitas produk hasil perbaikan, TS 20.04% ; 15.3oBrix. Penurunan material losses hasil dari usulan perbaikan sebesar 1,87 % batch size. Saving produk Milkuat yoghurt rata-rata biaya produksi per ton sebesar Rp 674.218, produk Activia sebesar Rp 468.820/ton, dan produk Activia fruit sebesar Rp 780.628/ton.

The process of milk processing industry production is committed in increased productivity, quality, high nutrition, and product safety. The process of production milk processing (yoghurt) involves mixing, pasteurization, filling, sealing, packing and palletizing. Material losses became one of factors that inhibit the increase in company productivity. This research aims to identify and analyze the level of waste and their impact on the company’s production cost for Activia yoghurt cup and Milkuat yoghurt cup products. This research mapped the problem input-output analysis approach which based on mass balance. Total dissolved solids in the process of flushing material used as one indicator of losses. Solubility analysis of total dissolved solids using thermogravimetri method on “Flush to SURGE” process from mixing tank towards ferment tank and ferment transfer tank towards storage tank. Furthermore, the analysis considered with the result mass balance production, type of product, types of raw material, material losses per batch, economic value per material, and pipeline design in the production line. The result of the research showed that the material losses that occur at 7% batch size (per 5 ton) can be reduced with flushing configuration (set counter flushing) on the process of product transfer from ferment tank towards storage tank. Improvement proposed of set counter flushing on the flush to SURGE stage 105 kg water addition and product transfer from ferment tank towards storage tank product quality of improvement outcome, TS 20.04 ; 15.3oBrix. Reduction in material process as the result from improvement proposal by 1.87%. The average saving of production cost Milkuat yoghurt product amounted to Rp 674.218/ton, Activia product by Rp 468.820/ton, and Activia Fruit product by Rp 780.628/ton.

Kata Kunci : Material Losses, Set Counter Flushing, Yoghurt