Application of Cleaner Production in a Fruit Chips Industry Penerapan Cleaner Production di Industri Keripik Buah

Cleaner production (CP) is one of the sustainable implementations of a comprehensive preventive environmental strategy involving company processes, products, and services. CP plan implementation still faces obstacles, such as the lack of detailed information, tools, and techniques. This study aimed to determine the variables and to select alternative solutions for cleaner production at a fruit chip industry using the Analytical Hierarchy Process (AHP) method. The research was carried out at PT Agrijaya Indotirta in Malang, East Java. The production process at this company generates waste from the consumption of energy, water, materials, and raw materials. Energy and water consumption are disposed directly without preliminary recycling process. Used oil is sold, and the remaining fruit seeds are sold for seeds. Checklists are used for problem identification, while fishbone diagrams and the 5W1H method are used to solve the problem of getting the best solution from the available alternatives. The weighting results of the alternative solutions using the AHP method show that the application of Good Manufacturing Practice (GMP) (with a weight of 0.287080) on the human resource criteria (with a weight of 0.63699) is a suitable alternative solution for the CP application of fruit chips production at PT Agrijaya Indotirta. Cleaner production can be performed by improving the capacity of human resources as production actors and regulators of proper waste management.


INTRODUCTION
The food industry plays an essential role in the Indonesian economy.One of the most developed small and medium enterprises (SMEs) is chips SMEs, especially tourism (Sari & Roza, 2017).Malang City is one of the tourist cities and the largest chips producer in East Java Province, with fruit chips as its typical souvenirs.Other specific Malang food businesses, such as the ones that sell dodol and strudel cake, are competitors for the fruit chip business.The production of fruit chips causes some environmental problems that needed more concern.The accumulation and intensity of pollutants negatively affect environmental pollution (Zein, Lestari, & Aru, 2019).Waste in large quantities is directly discharged into the environment without any treatment, which leads to the environmental pollution (Michael et al., 2013).
Fruit chip SMEs must manage waste properly to create a green industry because every activity in the production process will produce by-products that impact the environment (Suhardi, Laksono, & Fadhilah, 2017).One alternative to deal with environmental impacts is the concept of cleaner production (CP).CP is a comprehensive and preventive environmental management strategy that is continuously implemented to the production process and to the product life cycle to reduce the impact on the environment and humans (Ujianti, 2017).
The concept of CP has been adopted by many economic, environmental, and social welfare activities to provide zero-waste solutions (Lopes Silva et al., 2013).The main principle of CP in the national clean production policy is applied by rethink, reuse, reduce, recovery, and recycle (5R) (Fadilah, Sunarsih, & Faisya, 2014).CP proposes a broader, integrated, and systematic approach because it includes changes and continuous improvement in all aspects of the organization related to production and processes, which are also the goals of quality control management (Novita et al., 2010).This study aimed to determine the variables and select the alternative solutions for the chips cleaner production at a fruit chip industry.

METHODS
The research was conducted at PT Agrijaya Indotirta, Malang, East Java.The data used are qualitative and quantitative primary data and secondary data.The research stage is presented in Figure 1.

Assessment of Cleaner Production Application
The research method at this stage is observation and interviews with an assessment using a cleaner production checklist (Ariyanti, Purwanto, & Suherman, 2014;International Labour Organization, 2013;Avşar & Demirer, 2008).The cleaner production checklist contains the main aspects and activities related to CP application.Fruit chip production activities generally include sorting, peeling, washing, cutting, cooling, frying, draining, packaging, machine maintenance, and waste treatment.The checklist point functions to focus on the point where clean production must be applied (Sirait, Noor, & Ismayana, 2019).
The cleaner production checklists are shown in Table 1.Checklist points are filled in the "YES" and "NO" columns for each activity.The checklist point in the "yes" column means that the activity has implemented the CP concept and the checklist point in the "no" column means that the activity has not implemented the CP concept.The percentage of each aspect is then calculated to determine the aspect that contributes the most to the company's environmental waste pollution problem (Suhardi et al., 2017).

Causes and Effects Determination of Environmental Waste Problems
The assessment results of the CP application were then identified using a fishbone diagram (Lopes Silva et al., 2013).The problem cause is determined through discussions with expert respondents: the company owner and the fruit chip production operator PT Agrijaya Indotirta.The identified problems were analyzed using the What, Where, Why, When, Who, and How (5W1H) methods.These problems are categorized based on human, machine, method, material, and environmental aspects.Cause example in each category are shown in Table 2.

Determination of Alternative Solutions
Brainstorming with expert respondents was used to determine the problems alternative solu-tions.The selection of alternative cleaner production solutions at PT Agrijaya Indotirta was performed based on the Analytical Hierarchy Process (AHP) method priority weights with the rating scale shown in Table 3.The assessment results were then processed using Super Decision software.AHP is a multi-criteria decision-making approach by formulating criteria and alternatives in a hierarchical structure (Saaty, 2008;Srđević, Blagojevic, & Srđević, 2011).Alternative solutions in this study were selected based on technical, economic, and environmental criteria.The alternative solution with the highest weight from the AHP results is chosen as an alternative assessment.The alternative weighting in this study was carried out by expert respondents consist of company owners, production operators, and academics.

Assessment of Cleaner Production Application
The fruit chips production begins with removing dirt from the fruit by washing.Fruit peel is then removed during the peeling process.The fruit seeds are removed then fruit flesh is cut to produce the desired size.The pieces of fruit flesh are then fried in a vacuum fryer using palm oil.Vacuum frying aims to obtain fruit chip products with better quality, color, texture, aroma, and shelf life (Herminingsih, 2017).The frying takes 50 minutes at a temperature of around 85 °C and air pressure of 70 cmHg (Afrozi, Mufarida, & Sofiyah, 2018).Frying duration, temperature, and air pressure depend on the fruit type.Pineapple chips are fried for 60 minutes at 100 °C with 64-68 cmHg air pressure; salak chips are fried for 60 minutes at 77.50 °C with 70 cmHg air pressure; banana chips are fried for 45 minutes at 100 °C with 64-68 cmHg air pressure (Kamsiati, 2010), and mango chips are fried for 60-100 minutes at 80-90 °C with 70 cmHg air pressure (Mufarida, 2019).Condensate water is added in the vacuum frying process as a condenser coolant to condense the water vapor released during the frying process (Wibowo & Nugraha, 2016).The fruit chips from frying were drained using a spinner to reduce the chips' oil content.The fruit chips are then packaged using food-grade aluminum foil packaging.The mass balance for the process of fruit chips production is presented in Figure 2.
The main aspect of the cleaner production checklist includes human resources role, energy used in general, water used in general, materials and chemicals used in general, and pollution and waste prevention in general.The checklist points results based on the CP checklist main aspects at PT Agrijaya Indotirta are shown in Table 4.

Assessment of Environmental Waste Problems Causes
The application of CP in using materials and chemicals has the highest percentage compared to other aspects in general.This high percentage shows that the fruit chip company PT Agrijaya Indotirta has implemented the CP concept in these aspects, such as re-management of discarded water to irrigate plant seeds and utilization of fruit peel and seeds for fertilizer.The aspect that does not apply CP with the most percentage is the human resources role aspect.This statement means that the company has not applied the CP concept to this aspect.A causal analysis diagram (fishbone diagram) was made to identify the problem causes from the discussion results (Fauzi & Defianisa, 2019;Purwani, 2015).Figure 3 shows the results of the discussion.

Determination of Suboptimal Human Resource Role in CP Causes and Effects
Human, material, machine, method, and environmental factors are shown in detail using the 5W1H method (Silva, Medeiros, & Vieira, 2017).The purpose of using the 5W1H method is to obtain detailed and targeted alternative improvement solutions (Alpharianto, Suryadhini, & Astuti, 2015).Information about 5W1H in this problem was obtained based on discussions between researchers, product owners, and operators at PT Agrijaya Indotirta (Suhardi et al., 2017).Table 5 shows the discussion results.
Table 5 shows the causes of the problem and the improvement solutions in detail related to the role of human resources at PT Agrijaya Indotirta (Purwani, 2015).The solution obtained from the 5W1H method can be more detailed and varied, so it can be divided into several alternative solutions that are similar and can solve several problems at once based on workstations.

Selection of Alternative Clean Production Solutions
PT Agrijaya Indotirta has limited resources, so the company cannot apply the alternative solutions from the 5W1H method simultaneously.The AHP method evaluates the selected alternatives based on technical criteria, human resources, and the environment.The evaluation and weighting involved three expert respondents who knew the actual conditions of the fruit chip production process.The expert respondents are company owner, production operators, and academics.Alternative solutions from the 5W1H method are then evaluated based on technical criteria, human resources, and the environment to obtain the proposed alternative solutions shown in Table 6.The weighting results on technical criteria, human resources, and the environment are processed using Super Decision software shown in Table 7.
The weighting results using AHP indicate that the criteria for human resources have the    8.The application of GMP has the highest alternative solution weight value, which is 0.387080.This value shows that the company must focus on implementing GMP in solving the human resources problem, which is not yet optimal in CP.GMP is one of the guidelines for companies related to food safety aspects, including processes, products, and human resources in applying CP to produce high quality, safe, and suitable food for consumption.The purpose of GMP in CP is to provide basic principles of food safety for companies to produce good quality, safe, and zero-waste food products following consumer demands (Ristyanadi & Hidayati, 2012).Humans as perpetrators of GMP are designed to prevent the emergence of quality problems in a food product caused by chemical, biological, and physical factors (food safety problems).GMP is a basic requirement for companies or food product industries before Home Industry Food certification (PIRT).
The role of human resources in maintaining the safety of fruit chip production at PT Agrijaya Indotirta is in line with the implementation of cleaner production (Ratnawulan, Noor, & Suptijah, 2018).This conformity affects the entire fruit chip processing chain, starting from receiving fresh fruit until the finished product that involves handling waste during production to produce safe, zero-waste products (Fadilah et al., 2014).The application of GMP in the fruit chip industry includes aspects of location, production environment, employees, buildings and facilities, production equipment, water facilities, sanitation activities, employees' health, maintenance procedures, storage, process control, food labeling, supervision of waste management by the person in charge, product recalls, documentation records, and employees staff training (Yulianti & Mustarichie, 2017).All of these aspects involve the human resources of the fruit chip company.

CONCLUSIONS
This study shows that the variables affecting the implementation of CP at PT Agrijaya Indotirta are the role of human resources, the use of energy, water, materials, chemicals in general, and pollution and waste prevention in general.The role of human resources is influential in fruit chip processing in order to produce a safe product and to achieve the target of zero waste.The GMP application was chosen to increase the human resource role in the CP application because it affects the processing, product safety, quality aspects, and waste management.A possible further research can be conducted to analyze the effect of GMP application in the CP application.

Figure 1 .
Figure 1.Flowchart of Research Method Framework End

Figure 5 .
Figure 5. Weight of AHP Method Assessment

Table 1 .
Cleaner production checklist

Table 2 .
Examples Suhardi et al. (2017)sing fishbone diagrams Cause Category Example of Primary Cause Cleaner Production Problem Man Lack of skills and knowledge about clean production Machine Machinery and equipment that does not support clean production Method Procedures are not standard and conflict with clean production MaterialThe raw materials quality f standard and negatively impacts the environment Environment Unclean workstations, poor air quality, and other environmental aspects that affect clean production Source:Suhardi et al. (2017)

Table 4 .
Recapitulation of CP checklist Fishbone Diagram Analysis of Suboptimal Human Resource Role in CP

Table 6 .
Group of alternative solutions from the 5W1H method and proposed alternative solutions

Table 7 .
The weight value of technical, human resource, and environmental criteria