LAPORAN KEMAJUAN PENELITIAN LABORATORIUM DANA ITS 2020 Kajian Minimisasi Risiko Penggunaan Air Minum Dalam Kemasan (AMDK) oleh Konsumen dengan Menggunaka Metode Hazard Analysis Crytical Point (HACCP) dan Extended Producer Responsibility Tim Peneliti : Ketua : Ir. Mas Agus Mardyanto, MEng., PhD. (Departemen Teknik Lingkungan/FTSPK/ITS) Anggota I : Prof. Dr. Ir. Nieke Karnaningroem, MSc. (Departemen Teknik Lingkungan/FTSPK/ITS) DIREKTORAT RISET DAN PENGABDIAN KEPADA MASYARAKAT INSTITUT TEKNOLOGI SEPULUH NOPEMBER SURABAYA 2020 Sesuai Surat Perjanjian Pelaksanaan Penelitian No: 903/PK/ITS/2020
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LAPORAN KEMAJUAN
PENELITIAN LABORATORIUM
DANA ITS 2020
Kajian Minimisasi Risiko Penggunaan Air Minum Dalam Kemasan
(AMDK) oleh Konsumen dengan Menggunaka Metode Hazard
Analysis Crytical Point (HACCP) dan Extended Producer
Responsibility
Tim Peneliti :
Ketua : Ir. Mas Agus Mardyanto, MEng., PhD. (Departemen Teknik
Lingkungan/FTSPK/ITS)
Anggota I : Prof. Dr. Ir. Nieke Karnaningroem, MSc. (Departemen Teknik
Lingkungan/FTSPK/ITS)
DIREKTORAT RISET DAN PENGABDIAN KEPADA MASYARAKAT
INSTITUT TEKNOLOGI SEPULUH NOPEMBER
SURABAYA
2020
Sesuai Surat Perjanjian Pelaksanaan Penelitian No: 903/PK/ITS/2020
i
Daftar Isi
Daftar Isi .................................................................................................................................................... i
Daftar Tabel .............................................................................................................................................. ii
Daftar Gambar.......................................................................................................................................... iii
Daftar Lampiran ....................................................................................................................................... iv
BAB I RINGKASAN ................................................................................................................................. i
BAB II HASIL PENELITIAN ................................................................................................................... 6
BAB III STATUS LUARAN…………………………………………………………………………………….142
BAB IV PERAN MITRA (UntukPenelitian Kerjasama Antar Perguruan Tinggi) ......................143
BAB V KENDALA PELAKSANAAN PENELITIAN..............................................................144
BAB VI RENCANA TAHAPAN SELANJUTNYA .................................................................145
BAB VII DAFTAR PUSTAKA ................................................................................................146
BAB VIII LAMPIRAN .............................................................................................................150
LAMPIRAN 1 Tabel Daftar Luaran ..........................................................................................151
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DAFTAR TABEL
Halaman
Tabel 2.1 Hasil Analisa pH pada Titik Sampling 23
Tabel 2.2 Hasil Analisa TDS pada Titik Sampling 27
Tabel 2.3 Hasil Analisa Kekeruhan pada Titik Sampling 30
Tabel 2.4 Hasil Analisa Kadar Sisa Ozon pada Produk 35
Tabel 2.5 Hasil Analisa Mikrobiologi Bakteri E. Coli Titik Sampling 38
Tabel 2. 6 Pembobotan Kepentingan Resiko 51
Tabel 2.7 Pembobotan Entitas 51
Tabel 2.8 Kategori dan Peringkat Severity 55
Tabel 2.9 Deskripsi Skala Besar Resiko dan Kondisi Lingkungan 56
Tabel 2.10 Nilai Severity Kualitas Air Baku 60
Tabel 2.11 Nilai Severity Jarak Sumber Air Baku dengan Pabrik 62
Tabel 2.12 Nilai Severity Kualitas Pompa 64
Tabel 213 Nilai Severity Media Penggantian Pasir Silika 66
Tabel 2.14 Nilai Severity Media Pencucian Pasir Silika 68
Tabel 2.15 Nilai Severity Ukuran Media Pasir Silika 70
Tabel 2.16 Nilai Severity Penggantian Media Gravel 72
Tabel 2. 17 Nilai Severity Pencucian Media Gravel 74
Tabel 2. 18 Nilai Severity Ukuran Media Gravel 76
Tabel 2.19 Nilai Severity Penggantian Media Karbon Aktif 78
Tabel 2 20 Nilai Severity Pencucian Media Karbon Aktif 80
Tabel 2. 21 Nilai Severity Jenis Media Karbon Aktif 82
Tabel 2.22 Nilai Severity Penggantian Catridge pada Mikro Filter 84
Tabel 2. 23 Nilai Severity Pencucian Membran catridge Mikrofilter 86
Tabel 2.24 Nilai Severity Ukuran Catridge pada Unit Mikro Filter 88
Tabel 2. 25 Nilai Severity Penggantian Ozone Generator 90
Tabel 2. 26 Nilai Severity Kadar Ozon 92
Tabel 2. 27 Nilai Severity Penggantian Lampu UV 95
Tabel 2. 28 Nilai Severity Spesifikasi Lampu UV 97
Tabel 2. 29 Nilai Severity Waktu Kontak Lampu UV 99
Tabel 2. 30 Nilai Severity Analisa Kualitas Air 101
Tabel 2. 31 Nilai Severity Titik Analisa Kualitas Air 103
Tabel 2. 32 Nilai Severity Sanitasi Pekerja 106
Tabel 2. 33 Nilai Severity Sanitasi pada Unit Pengolahan AMDK 108
Tabel 2.34 Nilai Severity pemahaman pekerja mengenai kualitas air sesuai
SNI 3553:2015
111
Tabel 2. 35 Nilai Severity Wawasan Pekerja terkait Operasional Pabrik
sesuai
PERMEPERINDAG No. 705 Tahun 2003
114
Tabel 2. 36 Nilai Severity pelatihan mengenai sistem manajemen kualitas air
minum sesuai SNI 01-4852-1998
117
Tabel 2. 37 Peringkat Severity 118
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Tabel 2. 38 Penilaian Occurance 121
Tabel 2. 39 terkait Penilaian Occurance Air Baku 122
Tabel 2. 40 terkait Penilaian Occurance Unit Karbon Filter 123
Tabel 2. 41 terkait Penilaian Occurance Unit Mikro Filter 125
Tabel 2. 45 Penilaian Occurance pada Wawasan Pekerja 130
Tabel 2. 46 Penliaian Detection 133
Tabel 2. 47 Penilaian Detection pada Air Baku 134
Tabel 2. 48 Penilaian Detection pada Unit Karbon Filter 136
Tabel 2. 49 Penilaian Detection pada Unit Mikro Filter 138
Tabel 2. 50 Penilaian Detection pada Unit Injeksi Ozon 139
Tabel 2. 51 Penilaian Detection pada Unit Lampu UV 141
DAFTAR GAMBAR
Halaman
Gambar 2.1 Produk Gelas, botol, dan Galon Toyamilindo Mountoya 6
Gambar 2.2 Unit Ground Tank Air Baku Toyamilindo Mountoya 7
Gambar 2. 3 Unit Karbon Filter AMDK Toyamilindo Mountoya 8
Gambar 2. 4 Unit Mikro Filter AMDK Toyamilindo Mountoya 10
Gambar 2. 5 Unit Injeksi Ozon AMDK Toyamilindo Mountoya 11
Gambar 2.6 Unit Tangki Mixing AMDK Toyamilindo Mountoya 11
Gambar 2.7 Unit Penyinaran UV AMDK Toyamilindo Mountoya 12
Gambar 2.8 Unit Reservoir Product AMDK Toyamilindo Mountoya 13
Gambar 2.9 Unit Filling Machine AMDK Toyamilindo Mountoya 14
Gambar 2.10 Proses Packing Bagian Produksi AMDK 15
Gambar 2.11 Titik-titik Sampling Unit Pengolahan AMDK 20
Gambar 2. 12 Hasil Grafik Analisa pH pada Titik Sampling 25
Gambar 2. 13 Hasil Analisa TDS pada Titik Sampling 29
Gambar 2.14 Hasil Grafik Analisa Sisa Kadar Ozon pada Produk 36
Gambar 4. 15 Diagram Fishbone Analysis 42
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DAFTAR LAMPIRAN
Halaman
DAFTAR PUSTAKA 148
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DAFTAR LAMPIRAN
Halaman
Luaran Wajib:
Lampiran 1 Artikel Jurnal Q2
152
Luaran Tambahan Lampiran 2 :Artikel Konferensi
152
Luaran Tambahan Tugas Akhir yang dihasilkan 153
“Sustainability and Resilience of
Coastal Manajemen”
Penyelenggara : Pusat Penelitian
ITS, 30 Nopember 2020
Quality Control Of Mineral Water Production By Using Hazard Analysis Critical Control Point (Haccp) And Extended Producer Responsibility (Epr) Methods (Case Study : Toyamilindo Mountoya Company)
156
“Sustainability and Resilience of
Coastal Manajemen”
Penyelenggara : Pusat Penelitian
ITS, 30 Nopember 2020
Study Of Water Quality Status Of Surabaya River Water At Gunungsarijagir Segment Wit Pollutant Index (IP) And Total Pollutant Load Control System (TPLCS)
156
Lampiran Materi Jurnal Yang
Direncanakan Akan Dipublish
Study Of Mineral Water Production By Using Hazard Analysis Critical Control Point (Haccp) And Extended Producer Responsibility (Epr) Methods (Case Study : Toyamilindo Mountoya Company)
158
BAB I RINGKASAN
Ringkasan penelitian berisi latar belakang penelitian,tujuan dan tahapan metode penelitian, luaran
yang ditargetkan, kata kunci
Permintaan akan Air Minum di Kota kota besar di Indonesia semakin meningkat tidak sebanding
dengan kapasitas penyediaan air minum yang oleh PDAM setempat. Sebagai contoh kasus adalah Kota
Cirebon yang mana merupakan kota yang hanya memiliki satu sumber mata air yaitu berasal dari
Gunung Ciremai yang terletak di Desa Cipanis, Kabupaten Cirebon, Provinsi Jawa Barat. Debit sumber
mata air tersebut dan dengan proses produksinya yang menghasilkan air minum dalam kemasan
(AMDK) diharapkan masih tetap layak dikonsumsi oleh masyarakat sekitarnya ( Provinsi Jawa Barat)
sebagai pemenuhan kebutuhan air minum yang salah satunya adalah perusahaan AMDK PT.
Toyamilindo Mountoya.
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Agar AMDK tersebut diwajibkan tetap menghasilkan produk air minum atau mutu AMDK yang
berkualitas air minum, maka perlu dilakukan pengawasan terhadap penjaminan mutu kualitas
produksinya dengan menerapkan metode HACCP. HACCP (Hazard Analysis Critical Control Point),
adalah sebuah sistem analisa resiko dengan menetapkan pengendalian dan pengawasan yang tepat
untuk menghindari penyimpangan produk. Metode HACCP dapat diterapkan pada seluruh proses
produksi, seperti salah satunya contohnya produk AMDK yang prosesnya dimulai dari penyediaan air
baku hingga dihasilkan air minum hasil pengolahan.
Perusahan AMDK Toyamilindo Mountoya yang merupakan salah satu perusahaan yang memproduksi
AMDK tentunya mempunyai kekurangan dan kelebihan dalam proses produksi air minumnya.
Olehkarena itu, dalam pengelolaannya dilakukan sebuah manajemen kontrol dan dengan
menggunakan HACCP dalam mempertahankan dan meningkatkan kinerja setiap unit Water Treatment
Plant Sedangkan guna menjaga kelengkapan dari Standard Operating Procedure (SOP), untuk
memudahkan pekerja dalam melakukan maintenance perusahaan atau pabrik, serta meningkatkan
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wawasan pekerja maka upaya yang dilakuka yaitu dengan melalui beberapa pelatihan tentang
manajemen operasional pabrik.
Selain memperhatikan sistem produksi dan sumber daya manusia di Perusahaan AMDK, perlu juga
diperlukan pengawasan terhadap kualitas produk jadi baik yang dikemas dalam produk gelas, botol
ataupun galon. Selain itu permasalahan kualitas produk air minum dalam kemasan yang sampai
kekonsumen atau didistributor perusahaan atau pabrik masih juga perlu dikontrol kualitasnya. Hal ini
juga masih menjadi salah satu perhatian dan tanggung jawab pihak produsen atau perusahaan. Oleh
karena itu, pihak produsen juga masih harus bertanggung jawab atas produk air minum kemasan yang
diolahnya. Salah satu metode yang dapat diterapkan pabrik produksi Air Minum dalam Kemasan
seperti perusahaan AMDK Toyamilindo Montoya adalah metode Extended Producer Responsibility
(EPR).
Kata Kunci : Perusahaan Toyamilindo Mountoya, Metode HACCP, Metode EPR, AMDK. Kualitas
Produksi.
5
Ringkasan penelitian berisi latar belakang penelitian,tujuan dan tahapan metode
penelitian, luaran yang ditargetkan, kata kunci
6
BAB II HASIL PENELITIAN
Hasil penelitian berisi kemajuan pelaksanaan penelitian, data yang diperoleh, dan analisis yang
telah dilakukan
2.1. Proses Produksi dan Kondisi Eksisting AMDK
Berdasarkan pada Peraturan Menteri Perindustrian Republik Indonesia Nomor 96 Tahun 2011 tentang Persyaratan Teknis Air Minum dalam Kemasan, perusahaan AMDK Toyamilindo Mountoya dilakukan beberapa proses rangkaian water treatment, yaitu ground tank reservoir, unit karbon filter, unit mikrofilter 5 µm, unit mikrofilter 1 µm, unit mikrofilter 0,45 µm, unit injeksi ozon, unit tangki mixing, unit lampu UV, dan lalu disimpan ke tangki produk jadi sebelum memasuki bagian filling pada masing-masing produk. Berikut merupakan proses produksi perusahaan AMDK Toyamilindo Mountoya dan kondisi eksisting AMDK dari bahan baku sampai menjadi produk jadi. Rangkaian proses pengolahan airnya dapat dilihat berikut ini :
1.Bahan Baku dan Bahan Pengemas
Untuk memenuhi syarat standar mutu Perusahaan Toyamilindo Mountoya menerapkan standar mutu air minum dalam kemasan yang berlaku yaitu Standar Nasional Indonesia (SNI) terbaru untuk AMDK yaitu SNI 3553:2015 Kemasan primer merupakan wadah yang digunakan untuk mengemas produk AMDK yang bersentuhan langsung dengan produk air minum dalam kemasan. Perusahaan Toyamilindo Mountoya menghasilkan produk air minum dalam kemasan berupa produk cup 240 ml, botol 330 ml dan 600 ml, serta produk galon 19 liter. Berikut Ini merupakan contoh Gambar 2.1 macam-macam produk AMDK di perusahaan atau pabrik Toyamilindo Mountoya
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Gambar 2.16 Produk Gelas, botol, dan Galon Toyamilindo Mountoya
2.Unit Ground Tank Air Baku
Air yang digunakan sebagai bahan baku pengolahan AMDK ini yaitu merupakan air alami yang berasa dari sumber mata air Cipaniis yang berada di lereng pegunungan Ciremai, Kabupaten Kuningan, Provinsi Jawa Barat yang sebelumnya telah diolah Perusahaan Daerah Air Minum (PDAM) Kabupaten Cirebon. Air dari PDAM dialirkan melalui pipa tertutup dengan pipa induk dari PDAM yang diteruskan melalui pipa penyambung. Jarak pabrik dari sumber mata air adalah 14 kilometer. Volume air baku yang dibutuhkan dalam 1 kali produksi adalah 200.000 liter yang ditampung dalam ground tank dengan kapasitas 267.000 liter..Berikut ini Gambar 2.2 unit penyimpanan air baku atau ground tank Perusahaan Toyamilindo Mountoya
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Gambar 2.17 Unit Ground Tank Air Baku Toyamilindo Mountoya
3.Unit Karbon Filter
Air yang berasal dari ground tank reservoir dialirkan melalui pipa tertutup dengan menggunakan dorongan pompa ke water treatment. Proses awal water treatment adalah penyaringan karbon aktif (activated carbon filter). Penyaringan karbon menggunakan karbon aktif, gravel, serta pasir silika sebagai media filter, yang terdiri atas susunan dari paling atas yaitu pipa inlet untuk air, karbon aktif sebanyak 600 kg, pasir silika dengan ukuran 8 – 14 mm sebanyak 1100 kg, gravel dengan ukuran 3 – 6 mm sebanyak 275 kg, gravel dengan ukuran 6 – 12 mm sebanyak 275 kg, dan pipa outlet untuk air. Gambar 2.3 merupakan unit Karbon Filter yang digunakan Perusahaan Toyamilindo Mountoya
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Gambar 2. 18 Unit Karbon Filter AMDK Toyamilindo Mountoya
4.Unit Mikrofilter Air dari unit karbon filter dialirkan menuju mikrofilter yang berbentuk catridge microfilter guna dilakukan pemisahan partikel berukuran mikron dan submikron. Mikrofilter berfungsi untuk memisahkan padatan terlarut atau koloid yang ada dalam air. Perusahaan Toyamilindo Mountoya menggunakan 3 tangki penyaringan mikro dengan ukuran 5 µm1 µm, dan 0,45 µm dengan bahan dasar saringan adalah polypropylene dan seal material yaitu silikon. Berikut Gambar 2.4 Unit Mikro Filter yang digunakan pada Perusahaan Toyamilindo Mountoya
10
Gambar 2. 19 Unit Mikro Filter AMDK Toyamilindo Mountoya
5. Unit Injeksi Ozon
Ozonisasi pada air minum memiliki fungsi antara lain membunuh kuman, bakteri dan jamur, mengawetkan air, serta memberi rasa segar pada air. Selain itu, ozon ini berfungsi sebagai desinfektan pada air dan tidak mengganggu keberadaan mineral pada air. Injeksi ozon terjadi di pipa pencampuran ozon. Kadar residu ozon sesaat setelah pengisian berkisar antara 0,1 – 0,5 ppm. Perusahaan Toyamilindo Mountoya ini ozon menggunakan jenis alat ozon generator yang dapat merubah oksigen udara bebas menjadi ozon dengan cara melewatkan oksigen melalui percikan bunga api yang terjadi antara dua lempengan kutub listrik bertegangan sangat tinggi. Berikut ini Gambar 2.5 Unit injeksi ozon atau ozone generator pada Perusahaan AMDK Toyamilindo Mountoya
Gambar 2. 20 Unit Injeksi Ozon AMDK Toyamilindo Mountoya
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6. Unit Tangki Reaktor
Tangki reaktor atau tangki mixing berfungsi sebagai penampungan setelah proses ozonisasi juga berfungsi untuk penghomogenan ozon pada air sehingga dapat secara optimum dalam membunuh mikrooganisme yang ada dalam air. Tangki reaktor / reactor tank memiliki kapasitas sebesar 9 m3. Selanjutnya air dari tangki reaktor tersebut dialirkan menjadi dua arah yaitu menuju unit sterilisasi UV dan menuju tangki penampungan galon. Berikut ini merupakan Gambar 2.6 unit tangki mixing Perusahaan AMDK Toyamilindo Mountoya
Gambar 2.21 Unit Tangki Mixing AMDK Toyamilindo Mountoya
7. Unit UV Sterilizer Perusahaan Toyamilindo Mountoya menerapkan desinfeksi tidak hanya dengan proses ozonisasi tapi juga menggunakan unit sterilisasi UV yang berfungsi untuk membunuh mikroorganisme. Alat sterilisasi UV mengguanakan 4 lampu dengan intensitas 400 watt dengan dosis UV maksimal adalah 30.000 µws/cm2. Berikut ini Gambar 2.7 unit penyinaran UV Toyamilindo Mountoya
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Gambar 2.22 Unit Penyinaran UV AMDK Toyamilindo Mountoya
8. Unit Reservoir Product
Air yang sudah melewati seluruh proses water treatment air akan dialirkan menuju tangki
penyimpanan yang berbeda. Tangki penyimpanan dibagi menjadi 2 yaitu tangki cup dan botol
1 tangki dan untuk galon 3 tangki. Kapasitas untuk setiap tangki penampungan adalah 1000
liter. Gambar 2.8 Unit Reservoir Product AMDK Toyamilindo Mountoya
Gambar 2.23 Unit Reservoir Product AMDK Toyamilindo Mountoya
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9.Unit Filling Machine
Filling machine terbagi menjadi 3, yaitu filling cup machine, filling bottle machine, dan filling
gallon machine dengan mesin yang berbeda-beda. Masing-masing mesin merupakan mesin
yang berkerja secara otomatis. Filling machine ditempatkan pada ruangan yang berbeda-beda
dimana setiap ruangan dibatasi oleh dinding kaca. Pada rangkaian mesin cup, pengisian akan
berjalan secara otomatis pengisian air dan juga penempelan lid pada cup, begitu juga dengan
mesin botol dan galon dengan pemberian tutup secara langsung dalam satu rangkaian ketika air
telah terisi. Setelah jadi produk akan melewati conveyor dan akan dilihat kualitas produk jika
tidak sesuai produk akan di reject. Kemudian dilakukan caping untuk memberikan tanggal
kadaluarsa, pada produk cup tanggal kadaluarsa berada di lid dan pada produk botol dan juga
produk galon berada pada tutup, setelah itu di cek kembali apakah produk sudah sesuai. Berikut
Gambar 2.9 mesin filling Perusahaan Toyamilindo Mountoya
Gambar 2.24 Unit Filling Machine AMDK Toyamilindo Mountoya
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10.Visual Control, Packing, Storage, dan Delivery
Proses visual control dilakukan oleh staf quality control setelah proses pengemasan primer pada
produk. Pengemasan sekunder dilakukan dengan menggunakan kardus/karton bergelombang
untuk produk cup 240 ml, botol 330 ml, dan botol 600 ml, sedangkan untuk produk galon 19
liter tidak ada kemasan sekunder. Proses pengepakan ke dalam dus dilakukan secara manual.
Untuk 1 kardus cup 240 ml berisi 48 cup, 1 kardus botol 330 ml berisi 24 botol, dan 1 kardus
botl 600 ml berisi 24 botol. Berikut Gambar 2.10 proses packing produk yang akan diberi kode
produksi dan expired date yang dilakukan oleh bagian produksi Perusahaan Toyamilindo
Mountoya
Gambar 2.25 Proses Packing Bagian Produksi AMDK
Produk jadi yang telah dikemas disimpan di dalam gudang penyimpanan. Lama penyimpanan
di gudang adalah 1 x 24 jam. Hal ini dilakukan untuk menghilangkan residu ozon. Gudang
penyimpanan dibuat terpisah dan dibuat tertutup dan terhindar dari sinar matahari serta
dijauhkan dari benda yang beraroma tajam. Dus ataupun galon yang disimpan di gudang tidak
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boleh bersentuhan langsung dengan lantai untuk menghindari terjadinya kelembaban agar
produk tidak ditumbuhi lumut. Produk yang siap didistribusikan dipindahkan ke dalam truk dan
siap untuk di distribusikan ke wilayah Kota dan Kabupaten Cirebon. Proses distribusi produk
dilakukan dengan menggunakan truk. Produk Toyamilindo Mountoya didistribusikan sebagian
besar di wilayah Cirebon dan Jawa Barat lainnya.
Tenaga Bagian Produksi
Jumlah pekerja bagian produksi pada Perusahaan Toyamilindo Mountoya adalah sebanyak 30
orang pegawai produksi. Pekerja bagian produksi pada Perusahaaan Toyamilindo Mountoya
dibawah terdiri dari Head of SCM, Head of Production, Supervisor Production, Leader
Production, Helper Production, Transporter Production, Head of QC / QA, Co. Head of QC /
QA, QC Inspector, QC Officer, Supervisor Gudang, Head of Maintanace, Head of Purchasing,
dan staff lainnya. Struktur organisasi pekerja bagian produksi pada Perusahaan Toyamilindo
Mountoya dapat dilihat lebih lengkap pada lampiran 1. Waktu yang dibutuhkan dalam satu kali
proses produksi adalah 7-8 jam (1 shift). Terdapat 15 pekerja yang berkerja dalam 1 shift. Rata-
rata pendidikan terakhir pada pekerja bagian produksi perusahaan Toyamilindo Mountoya
adalah minimal tingkat SMA atau SMK untuk maintanance dan produksi serta S1 untuk bagian
quality control / quality assurance. Pelatihan-pelatihan yang sudah didapatkan para pekerja
adalah peningkatan kualitas produk, pelatihan ISO 22000 : 2018 Sistem Manajemen Keamanan
Pangan, dan pelatihan hygene sanitasi.
Para pekerja bagian produksi perusahaan Toyamilindo Mountoya juga harus mengikuti
prosedur standar yang berlaku di perusahaan AMDK yang biasanya sudah tercantum dalam
16
Standard Operating Procedure (SOP), intruksi kerja, ataupun petunjuk pelaksanaan lainnya.
SOP pada perusahaan Toyamilindo Mountoya yaitu yang mengatur jalannya operasi secara
keseluruhan, intruksi kerja yaitu intruksi jalannya sebuah proses, sedangkan petunjuk
pelaksanaan adalah langkah-langkah detail yang perlu diperhatikan dalam operasi. Contoh
Standard Operating Procedure (SOP), intruksi kerja, dan petunjuk pelaksanaan yang terdapat
pada Perusahaan AMDK Toyamilindo Mountoya adalah :
- Intruksi kerja sanitasi tangki reaktor dan OH reservoir
- Intruksi kerja pencucian ground tank.
- Intruksi kerja sanitasi ruang produksi.
- Standard Operating Procedure (SOP) menjalankan mesin water treatment.
Berisi uraian realisasi kerjasama dan realisasi kontribusi mitra, baik in-kinddan in-cash
“Penelitian Ini tidak termasuk kedalam “Penelitian Kerjasama Antar Perguruan Tinggi “
akan tetapi Termasuk Dalam “Penelitian Laboratorium” yang didanai dari Dana Lokal ITS
2020”
142
BAB V KENDALA PELAKSANAAN PENELITIAN
Kendala Pelaksanaan Penelitian berisi kesulitan atau hambatan yang dihadapi selama melakukan penelitian
dan mencapai luaran yang dijanjikan
KENDALA KENDALA DALAM PELAKSANAAN PENELITIAN LABORATORIUM :
1. Pertanggung jawaban laporan penelitian untuk pelaporan kemajuan mengalami kendala seperti pada
permasalahan waktu dalam perolehan data primer dan sekunder di AMDK Montoya yang berada di
Wilayah Propinsi Jawa Barat tepatnya Kota Cirebon.
2. Dikarenakan terjadinya pandemic Covid 19 di dunia yang menjadi penyebab sulitnya dalam
pelaksanaan pengambilan sample dan analisa kualitas sumber air yang digunakan sebagai air baku
AMDK .
3. Karena pandemic yang saat ini masih terjadi di kota Surabaya untuk memerintahkan tim peneliti
turun berangkat survey ke lokasi objek menjadi suatu pertimbangan yang sangat sulit. Hal ini
disebabkan risiko besar yang harus dihadapi oleh tim peneliti. Sehingga sementara waktu untuk
pelaporan kemajuan masih digunakan data sekunder.
143
BAB VI RENCANA TAHAPAN SELANJUTNYA
Rencana Tahapan Selanjutnya berisi tentang rencana penyelesaian penelitian dan rencana untuk mencapai luaran
yang dijanjikan.
RENCANA TAHAPAN SELANJUTNYA UNTU PENYELSAIAN PENELITAN DAN UNTUK
MENCAPAI LUARAN YANG DIJANJIKAN :
1. Dilakukan sampling kualitas air baku dan air produksi AMDK sesuai objek penelitian, yaitu :
Secara paralel dengan pembuatan laporan kemajuan juga dilaksanakan ;
o sesuai kontrak dengan kontrak maka dilakukan Kembali sampling pada lokasi area
perusahaan AMDK Montouya mulai dari air baku sampai dengan air produksi serta air yang
telah diterima di distributornya dengan memakai tenaga lokal PT Mountoya.
o Sampling untuk kualitas air produksi digunakan pendekatan sampling pada
pelanggan/distributor sebanyak 3 tempat.
2. Menyusunkan menyempurnakan laporan akhir penelitian dan menyelesaikannya
3. Menyusun laporan Logbook untuk tahap II dan dikombinasi atau disatukan dengan logbook tahap I
seperti pada laporan kemajuan
4. Menyusun laporan keuangan taotal dari mulai 02 April 2020 (saat penenda tangganan kontrak)
sampai terselesaiannya laporan akhir penelitian ini bulan Nopember 2020.
5. Melanjutkan laporan akhir dengan menambahkan metode Extended Produser Responsibility (EPR)
untuk memperoleh penjaminan mutu produk dalam upaya penyelesaian penelitian ini.
6. Menyertakan 2 (dua) mahasiswa yang ikut dalam tim penelitian ini mengikuti kegiatan seminar
penelitian yang akan dilaksanakan pada tanggal 30 Nopember Tahun 2020
7. Dan diprediksi semua tugas dan kwajiban selesai pada bulan Nopember 2020. 8. Kendala yang lain untuk pemenuhan publish Jurnal Q2 membutuhkan waktu yang lama akan tetapi
diakhir bulan Maret mendatang ditetapkan oleh Puslit ITS harus sudah di publish. Peneliti dan tim
berusaha untuk memenuhi persyaratan tersebut dan oleh karena itu tim berusaha untuk melakukan
submitted materi penelitian di akhir bulan September ini.
144
145
BAB VII DAFTAR PUSTAKA
Daftar Pustaka disusun dan ditulis berdasarkan sistem nomor sesuai dengan urutan pengutipan.
Hanya pustaka yang disitasi pada laporan kemajuan yang dicantumkan dalam Daftar Pustaka.
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149
BAB VIII LAMPIRAN
Lampiran berisi tabel daftar luaran (Format sesuai lampiran 1) dan bukti pendukung luaran wajib dan luaran tambahan (jika ada)
sesuai dengan target capaian yang dijanjikan
Tabel Daftar Luaran
PROGRAM : PENELITIAN LABORATORIUM DANA ITS TAHUN
2020
Nama Ketua Tim : Mas Agus Mardyanto
Judul : Kajian Minimisasi Risiko Penggunaan Air Minum Dalam
Kemasan (AMDK) oleh Konsumen dengan Menggunaka
Metode Hazard Analysis Crytical Point (HACCP) dan
Extended Producer Responsibility.
1.Artikel Jurnal
No Judul Artikel Nama Jurnal Status
Kemajuan*)
1 Study Of Mineral Water
Production By Using Hazard
Analysis Critical Control Point (HACCP) And Extended
*) Status kemajuan: Persiapan, submitted, under review, accepted, published
2. Artikel Konferensi
No Judul Artikel Nama Konferensi (Nama
Penyelenggara, Tempat,
Tanggal)
Status Kemajuan*)
Quality Control Of Mineral Water Production By Using Hazard Analysis Critical Control Point (Haccp) And Extended Producer Responsibility (Epr) Methods (Case Study : Toyamilindo Mountoya Company)
“Sustainability and
Resilience of Coastal
Manajemen”
Penyelenggara : Pusat
Penelitian ITS, 30
Nopember 2020
Persiapan
Study Of Water Quality Status Of
Surabaya River Water At
Gunungsarijagir Segment Wit
Pollutant Index (IP) And Total
Pollutant Load Control System
(TPLCS)
“Sustainability and
Resilience of Coastal
Manajemen”
Penyelenggara : Pusat
Penelitian ITS, 30
Nopember 2020
Persiapan
*) Status kemajuan: Persiapan, submitted, under review, accepted, presented
*) Status kemajuan: Persiapan, submitted, under review
4. Buku
No Judul Buku (Rencana) Penerbit Status Kemajuan*)
*) Status kemajuan: Persiapan, under review, published
5. Hasil Lain
No Nama Output Detail Output Status Kemajuan*)
*) Status kemajuan: cantumkan status kemajuan sesuai kondisi saat ini
6. Disertasi/Tesis/Tugas Akhir/PKM yang dihasilkan
No Nama Mahasiswa NRP Judul Status*)
1 Adhitia Satria Pradana
03211640000095
Kajian Produksi Air Minum Dalam
Kemasan Dengan Menggunakan
Metode Hazard Analysis Critical
Control Point (HACCP) Dan
Extended Producer Responsibility
(EPR)
(Studi Kasus : Perusahaan
Toyamilindo Mountoya)
Sudah Selesai
(Lulus 2020)
2 Alysia Safi Damayanti
03211640000069 Kajian Status Mutu Air Kali
Surabaya Pada Segmen Gunungsari
– Jagir Dengan Metode Indeks
Pencemaran (IP) Dan Total
Pollutant Load Control System
(TPLCS)
Sudah Selesai
(Lulus 2020)
*) Status kemajuan: cantumkan lulus dan tahun kelulusan atau in progress
LAMPIRAN JURNAL
155
STUDY OF MINERAL WATER PRODUCTION BY USING HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP) AND
EXTENDED PRODUCER RESPONSIBILITY (EPR) METHODS
(CASE STUDY : TOYAMILINDO MOUNTOYA COMPANY)
Abstract
The demand for drinking water in Cirebon City is increasing and is not proportional to the drinking water supply capacity of DWTP
Cirebon City. So the Toyamilindo Mountoya Company was established, which is engaged in bottled drinking water (BDW), whose
production rate continues to increase. The need for quality control methods to improve the quality of bottled drinking water
products that can affect the quality of products consumed by customers. So BDW Toyamilindo Mountoya applies the HACCP and
EPR methods which aim to evaluate the performance of the BDW production processing unit in planning quality control with the
HACCP method, determine the quality control of bottled drinking water products to minimize negative risks to consumers with
the EPR method, and compare the quality of freshly produced bottled water with products that consumers accept. Based on the
analysis of existing conditions on the Toyamilindo Mountoya BDW, the poor performance of the processing unit and the need for
quality control monitoring is caused by replacing the membrane, cartridge micro filter and ozone generator, the ozone injection
unit that exceeds the usage limit, poor quality of raw water pumps and backwash scheduling of carbon filter media affect the
quality of production water and products. Quality control using the EPR method is carried out on the use of raw materials,
production processes, finished products, product storage and distribution, sanitation and waste treatment, and product quality to
consumers. Changes and decreases in product quality are due to the distance between the delivery to the store, the shipping or
transportation process, the method of storage, and the length of time the product is stored.
Keywords : Bottled Drinking Water, Extended Producer Responsibility, Hazard Analysis Critical Control Point, Quality Control,
Toyamilindo Mountoya Company.
1. INTRODUCTION
The demand for drinking water in Cirebon City is increasing and is not proportional to the drinking water supply capacity
of the DWTP.Cirebon city has the potential for vulnerability to the availability of drinking water because it depends on water
sources from Kuningan Regency, West Java. DWTP Cirebon City services reach 78% of total population of Cirebon City, while
the demand for drinking water has increased and has become a problem because people need drinking water (DWTP Cirebon City, 2014). To overcome this, people choose bottled drinking water for their daily needs. But it is necessary to be aware of namely, the
quality of water from the bottled water products used by the community, whether it meets the applicable drinking water quality
requirements and is listed in the Indonesian National Standard Number 3553 of 2015 and Regulation of the Minister of Industry
of the Republic of Indonesia Number 78 of 2016. So, the need for monitoring and controlling the results of the production process
so that it is suitable for consumption and reducing the negative risk of bottled drinking water (Dahlan and Wahyunus, 2016).
Therefore, the bottled drinking water (BDW) Toyamilindo Mountoya company, located in Cirebon City, seeks to apply the
method Hazard Analysis Critical Control Point to fulfill monitoring and control measures, as well as to reduce the negative risk of
bottled water products using the method Extended Producer Responsibility.
2. METHODS
Collecting laboratory research data to support HACCP and EPR methods, conducted interview surveys and questionnaires
containing aspects of production and aspects of human resources aimed at 6 expert judgments, namely Head of production, Head
and Co. Head of QA / QC, Head of Management Representative, Head of Maintenance, and Head of PPK. Meanwhile, to support
the EPR method, a questionnaire survey was obtained from 4 shops selling complete bottled drinking water, namely the Bayu shop,
Jaguar 99, Jembar Agung, and 100 mundu. The research area was carried out at the Toyamilindo Mountoya BDW Company which
is located on Jalan Pangeran Cakrabuana, Wanasaba Kidul Village, Talun District, Cirebon City, West Java Province.
STUDY OF MINERAL WATER PRODUCTION BY USING HAZARD ANALYSIS CRITICAL CONTROL
POINT (HACCP) AND EXTENDED PRODUCER RESPONSIBILITY (EPR) METHODS
(CASE STUDY : TOYAMILINDO MOUNTOYA COMPANY)
Nieke Karnaningroem, Mas Agus Mardianto, dan Adhita Satria Pradana
Nieke Karnaningroem, Mas Agus Mardianto, dan Adhita Satria Pradana
156
Figure 1. Location of Research Area, BDW Company Toyamilindo Mountoya
Pre-requisites method, namely the initial procedure to support risk analysis and preparation of critical points which aims
to facilitate the identification of the causes of failure and the impact of the production process using the method fishbone
analysis and Failure Mode and Effect Analysis. Fishbone analysis can find the root causes of problems based on questionnaires
sourced from expert judgments, surveys of the existing conditions of the production process and can be used as problems to be
analyzed (Suryani, 2018). Identify potential failures in FMEA to assess aspects of failure based on incidence rate, severity, and
detection, then obtain the RPN value for failure prevention efforts so that companies focus on dealing with problems identified as
critical points, so as to reduce costs and increase the effectiveness of time and energy in solve problems (Sari, et al, 2011). These two methods consider the Indonesian government program regarding the appeal for HACCP implementation and as a method pre-
requisite to guarantee the quality of bottled drinking water products based on SNI 01-4852-1998, ISO 9001 series, and ISO series
22000 (Fitrianti, 2016). HACCP is a quality assurance method that not only guarantees the safety of bottled drinking water without
risk, but this method is based on the anticipation of hazards and supervision that prioritizes preventive measures rather than
emphasizing final product testing with control measures to minimize negative risks and the occurrence of hazards (Daulay, 2014).
The application of the HACCP method consists of 5 principles, namely risk and hazard analysis with the method pre-
requisite, identification and determination of critical control points, determination of critical limits from critical control points,
preparation of monitoring systems, and determination of corrective actions (SNI 01-4852, 1998).
EPR or producer responsibility for its products is a form of producer responsibility in producing and distributing its
products, as well as monitoring the use of raw materials, production processes, distribution, product quality, and so on, to minimize
the risk of negative products to consumers or distributors and reduce the potential risk of defects. products and decreased product
quality (Law Number. 8 of 1999). After the production process produces a product, an inspection is carried out which includes
two things, namely checking the conformity of the product with product quality standards and checking the conformity of the
product with consumer requirements. From this examination, it is known whether the product can be marketed to consumers or
whether it has to be reprocessed because it is not by customer needs, so quality control is needed from the beginning of the
production process to become bottled water (Nugroho, et al, 2012).
3. RESEARCH RESULTS AND DISCUSSION
a. Identification of Risks and Hazard Cause of Failure
Sampling was conducted once a day for 7 working days, starting on Monday, 17 February 2020 to Monday, 24 February
2020 which is a time series. Sampling in this study was carried out using a 250 mL beaker glass with the top covered with aluminum
foil, while for the microbiological analysis of bacteria Escherichia Coli using a 140 ml glass bottle. Following are the results of
the analysis carried out at the Laboratory Quality Control of the Toyamilindo Mountoya BDW Company :
1. pH Analysis, Total Dissolved Solids, Turbidity, Ozone Remaining Levels, and E. Coli Microbiology
The pH analysis results obtained the highest pH value of 7.54 and the lowest of 6.99. These results are still by the quality
standards in SNI 3553: 2015, namely 6.0 to 8.5. The results of TDS analysis obtained the highest TDS value of 184 mg / L and the lowest value of 177 mg / L. These results are still by the quality standards stipulated in SNI 3553: 2015, namely a maximum of
500 mg / L. The results of the analysis of the highest turbidity were 0.86 NTU and the lowest was 0.45 NTU. These results are still
by the quality standards in SNI 3553: 2015, namely a maximum of 1.5 NTU. However, it was found irregularities in the fluctuation
of the turbidity value on all laboratory analysis days. The increase in turbidity value is always in the carbon filter effluent, which
should function to reduce turbidity, but there is an increase in the turbidity value of the carbon filter effluent. This requires further
analysis related to problems that occur in the carbon filter unit. These problems can be caused by replacing filter media and carbon
filter membranes that are not by the SOP, washing the media that is not based on the sanitation procedure of the carbon filter unit
which is not routine, or the lack of supervision and control of water quality by the production department (Permenperin Number
96 of 2011). The results of the analysis of ozone levels in bottled drinking water products obtained the value of residual ozone
levels of 0.1 ppm or constant for all the products tested with UV irradiation unit contact time for 14 - 16 hours divided into
2 shifts work. The results of the analysis are still by the quality standards stipulated in the Regulation of the Minister of Industry
of the Republic of Indonesia Number 78 of 2016, which is between 0.05 - 0.3 ppm. The results of the analysis of bacteria Escherichia Coli at the sampling point obtained that the bacteria content Escherichia Coli was negative or not detected
(TTD). The negative results of the MPN analysis of the bacteria Escherichia Coli in the sample stated that the bacteria
were Escherichia Coli not detected in the sample water. These results are by the quality standards stipulated in SNI 3553 : 2015,
namely the absence of bacteria Escherichia Coli in the results of each sampling point.
2. Fishbone Analysis
In the preparation of fishbone analysis is based on a questionnaire sheet is divided into two, namely the questionnaire
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sheet and the technical part of human resources. The technical section questionnaire sheet includes questions about raw water
quality, carbon filter, microfilter, ozone injection, mixing tank, and ultraviolet light. Meanwhile, the human resources section of
the questionnaire sheet includes questions about worker behavior and worker insights. From the diagram fishbone, it is that found
there are problems in the BDW production process such as the burning of raw water intake pumps, rotating blackouts by DWTP,
washing media and replacing ozone generators that are not according to schedule and SOP as well as excessive use of the
membrane cartridge in the microfilter processing unit.
Figure 2. Fishbone Diagram Analysis
3. Failure Mode and Effect Analysis (FMEA) Method Weighting is adjusted to fishbone analysis and entity weighting aims to make it easier to determine the priority of HACCP
critical points if there is the same RPN calculation (Wahyuningsih, 2018). Then, determining the value severity or the level of
seriousness of the impact, the more severe the impact, the higher the value severity. The limitation of the value of
the severity analysis is 1 - 5. Furthermore, each scale of environmental conditions is described to ensure consistency in risk analysis
(Fitrianti, 2016). Then the results of the estimation of the existing conditions can be known the value severity of each entity is
equation (1) below and then in Table 1 is the result of the ranking severity of each entity
Severity = Ideal Scale Value−Existing Scale Value
Ideal Scale Value x 100% (1)
Table 1. Rangking of each Entitity
Occurance or the rate of failure of the processing unit illustrated the number of events in 1 year, where the probability of
failure was based on a scale of 1-5. A value of 5 means the level of high impact frequency or the number of frequent occurrences
and a value of 1 means that the level of impact frequency is low or the number of events rarely occurs. Detection or the value of
the ability to control failure associated with that control based on the frequent failure occurs or a value occurrence performed
because the number of failures became more frequent if less effective methods of prevention do. Assessment Detection has a scale
range of 1 - 5. Scale 5 explains that the ability of the control device to detect the causes of failure is low (undetected) and scale 1,
namely the control device can detect failure easily and with a certainty of detection (Wahyuningsih, 2018).
In Table 2, the results of the Risk Priority Number are the multiplication of assessments severity,
occurrence, and detection, to determine the potential failure that occurs and the critical point for the HACCP method. The RPN
values are sorted from largest to smallest value. The largest RPN value is that the type of failure has a significant effect, has a high
risk, requires handling, and a monitoring method to repair failure. The smallest RPN value is that the type of failure never occurs,
the risk of danger does not have the potential to arise, and does not need it but is still given a monitoring method to minimize the
potential for failure. This type of failure has a significant and high-risk influence which is included as a critical control point whose
RPN value is above 10, because it indicates that failure can disrupt the production process so that it affects the characteristics or
quality of production water directly, such as laboratory analysis results that exceed quality standards. The results of the RPN
analysis obtained ratings of 1 to 27 identified hazards and not all types of hazard failures can be used as critical control points.
Determination of critical control points is only rated 1 - 6 which is controlled because it has a large RPN number or above 10 which
can disrupt the production process, while ratings 7 - 27 do not need to be put into a critical control point because the RPN value is
small and does not have the potential to cause failure in the production process. Potential failure occurs due to replacing the membrane cartridge in the microfilter unit and the ozone generator in the ozone injection unit which exceeds the period of use,
the quality of the pump for raw water transportation that is often damaged, backwash media for silica sand, gravel, and activated
carbon in the carbon filter unit that is not suitable with the applicable schedule or SOP. Then the above failures will be identified
at the critical control point.
Table 2. Result of Calculation Risk Priority Number
b. Hazard Analysis Critical Control Point Method
After analyzing the risks and hazards, the second principle is the determination of a critical control point or a hazard
prevention procedure that has been missed from the control, resulting in the emergence of a negative risk to BDW. Then, a critical
limit can be determined to facilitate risk control as the third principle (Hassan and Masduqi, 2016). The critical limit is a criterion
that separates acceptable and unacceptable conditions for each critical control point so that it is not exceeded to avoid loss of
control in corrective efforts based on legislation, safety standards, and scientifically tested values. (Sudarmaji, 2015). Arrangement
of a monitoring system as the fourth principle to provide information before any deviation occurs so that corrective action is taken
and does not affect the entire BDW production system (SNI 01-4852, 1998). Monitoring activities include determining the person
in charge for each production process, checking the critical control point handling procedure, testing the effectiveness of the critical
control point control handling procedure, and determining critical limits to ensure that it is still on a safe level. The fifth principle
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is the establishment of corrective actions for each critical control point to deal with deviations that occur so as not to affect
production results. If the critical limit is not within a tolerable level, corrective action is needed depending on the level of risk in
each product production process to ensure that the product production process does not cause new potential hazards (Daulay,
2014). After all the principles of the HACCP method have been carried out, all the results of the analysis are entered in Table 3
Table 3. Result of Hazard Analysis Critical Control Point Method
c. Analysis of Extended Producer Responsibility Method
Supervision and quality control are carried out as a whole from the production process, finished product, storage form,
process transportation, sanitation, waste treatment, and consumer products. Good quality of drinking water products will increase
consumer satisfaction and minimize the occurrence of contamination and product damage and maintain product quality to remain
good for consumers (Batarfie, 2006).
1. Quality Control of Production and Finished Products
Toyamilindo Mountoya BDW Company carries out a program hold and release, namely if there are raw materials or final
products that do not comply with the specified specifications after testing, the QC section provides information on parts of raw
material and finish goods to separate these raw materials or products and provide a clear identity. There are 3 types of identities
used in the implementation, namely quarantine, reject, and QC passed. Products that meet the specifications are given the status
of QC passed. The finished product is checked against the specifications of each product, such as checking the volume, expiration
date, foreign matter, appearance of the packaging. Control of the quality of the packaging process by checking the condition of the
product again if anything has been missed from the previous process, gluing the box, and also the expiration date on the packaging
box. Product withdrawal is carried out if discrepancies are found during the production process that can endanger consumers in
terms of food safety and the product has been sent to consumers. The product recall mechanism has been documented in the form
of a procedure by performing mock recall at least once a year. The process of controlling rework is the implementation
of repacking of products that occur due to imperfections during the packaging process, storage in finished goods warehouses, or
during transportation.
2. Quality Control of Storage and Transportation
Storage of finished products is used in special warehouses to prevent damage to materials which must comply with procedures QC
passed, to prevent users that are not by health requirements. The storage area must be clean and no scattered material stored in a
special area with a storage area air circulation system that is formed to prevent unwanted things from affecting the
product. Stacker and hand pallets as a means of transfer and unloading in the finished goods warehouse to the distribution
equipment are maintained so that contamination does not occur. Warehouses and General Affairs must regulate the traffic of
vehicles used for the transportation of raw materials, process auxiliary materials, packaging materials, and final products. The
General Affairs arranges vehicles for garbage collection and waste disposal. The supervisor warehouse arranges for container truck
inspections for product delivery to run properly and according to the SOP. Inspection for vehicles is carried out to see that the
vehicle used meets the specifications set by QC and security to ensure that no product is damaged or dirty during the
process loading.
3. Sanitation and Waste Management
The company performs environmental sanitation before, during, and after processing. Production room sanitation is
carried out before and after the production process as well as thorough cleaning every 2 weeks. Equipment sanitation is carried out
to avoid quality changes that occur in the BDW processing process.sanitation is a Ground reservoir carried out every 1 month,
using food grade soap. Sanitation of the carbon filter is carried out every 1 month with backwash repeatedly until the water is not
cloudy. To maintain the effectiveness of activated carbon, it is replaced every 6 months.sanitation is Microfilter carried out every
1 week with a physical wash. Cleaning the holding tanks and filling machines is done by soaking using food grade soap and rinsing
thoroughly. Sanitation for production workers uses equipment, namely uniforms and other equipment, namely hairnet, masks,
boots, gloves, and is sprayed with alcohol every 5 minutes. Waste from the BDW processing process is in the form of liquid and
solid waste. For liquid waste, namely water from washing bottles and gallons and water wasted from filling. Solid waste is activated
carbon, bottle caps, and gallons. For liquid waste, it is disposed of into a sewer that is connected to the irrigation of the population
because the wastewater that is disposed of is not dangerous because when washing the gallon it uses soap food grade. Solid waste
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in the form of activated carbon is sprinkled on the ground so that it will decompose, while waste for the production
of cups, damaged bottles, and gallons is collected and then sold to collectors.
4. Quality Control of Product for Consumers
Supervision of product quality for consumers is carried out in 3 ways, the first is to identify and trace products based on
monitoring and measurement of each stage of the production process. For finished products, the status identity is given after the last stage of the process. Tracing is maintained by implementing the use and filling of forms in each company department. Second,
establish and implement a non-conformance control system, especially for potentially unsafe products, by establishing corrective
and preventive action procedures and product recall procedures. This corrective and preventive action procedure regulates the
handling if a non-conformity is identified from the results of internal or external audits of customer complaints. Third, validation
of the ozonation process, where the company has regulations to determine the level of injected ozone to ensure the product is by
specifications and records the results of ozonation to re-validate the quality and safety of bottled water products according to
quality standards every 6 months to ensure the suitability of the products produced
5. Analysis Quality Product BDW for Consumer
The purpose of comparing product quality to consumers with product quality data when it is newly produced is to maintain
the quality of the product that has been produced and to detect a decrease in product quality when it is in the hands of consumers
because it can endanger consumer health. Factors that cause a decrease in the quality of bottled water products, for example, are the influence of the distance of the delivery process from the company to the store, damage during the product transportation
process to distributors or consumers, the wrong way to store products, and also the length of product storage. The BDW
Toyamilindo Mountoya company as a producer is not only responsible for the production process but is also obliged to monitor
the quality of its products in the hands of consumers or distributors by the Minister of Industry Regulation Number 96 of 2011.
Based on the results of analysis from 4 stores, changes in the quality of bottled drinking water products are caused by product
delivery, product storage, product storage time, and contamination from outside the product as evidenced by a significant change
in the pH number in glass and bottled products which can cause changes in the taste of the product. For the turbidity parameter,
there is an increase in the value of turbidity in bottled and gallon products which can affect the physicality of the product. In one
shop, moss was also found in gallons due to the lack of cleanliness of washing and improper storage due to direct exposure to
sunlight. Meanwhile, for TDS parameters, residual levels of ozone, and Escherichia coli bacteria, there was no change in the
quality of the product..
4. CONCLUSION
Based on the results of the analysis of the existing conditions at the Toyamilindo Mountoya bottled water, the poor
performance of the processing unit and the need for quality control monitoring is due to the replacement of the
membrane cartridge on the microfilter and the ozone generator on ozone injection that exceeds the usage limit, the poor quality
of the raw water transportation pump and backwash carbon filter media(silica sand, gravel, and activated carbon) that are not on
the schedule. Quality control using the EPR method is applied by quality control on the use of raw materials, production processes,
finished products, product storage, product distribution, sanitation and waste treatment, and product quality to consumers. The
results of the comparison of the quality of bottled drinking water for consumers with the quality of products that have just come out of the production process, there are changes or decreases in quality caused by the distance of product delivery to the store, the
product delivery process, how the product is stored, and also the length of storage for bottled water products.
REFERENCES
Batarfie, M. U. A. 2006. “Analisis Pengendalian Mutu pada Proses Produksi Air Minum Dalam Kemasan (AMDK) SBQUA”.
Departemen Manajemen, Fakultas Eknomi dan Manajemen. Institut Pertanian Bogor.
Dahlan, A., dan Wahyunus. 2016. “Rencana HACCP Pengolahan Kecap”. Skripsi. Institut Pertanian Bogor.
Daulay, S. 2014. “Hazard Analysis Critical Control Point dan Implementasinya dalam Industri Pangan”. Jakarta.
Fitrianti, N. 2016. “Analisis Penurunan Kualitas Air Produksi Instalansi Air Minum (IPAM) X dengan Metode Failure Mode and
Effect Analysis (FMEA)”. Institut Teknologi Sepuluh Nopember : Surabaya
Hassan, F. dan Masduqi, A. 2016. “Application of Hazard Analysis Critical Control Point (HACCP) in The Drinking Water
Company”. The 1st International Seminar on Management Technology, Surabaya.
Nugroho, M. S., Bisri, M. dan Anwar, M. R. 2012. “Kajian Terhadap Implementasi Manajemen Mutu pada Pengelolaan Proyek
Perumahan”. Jurnal Teknik Sipil, Universitas Brawijaya, Vol. 6 No. 2 Malang.
Peraturan Menteri Perindustrian RI No. 96 Tentang Persyaratan Teknis Industri AMDK Tahun 2011. Perusahaan Daerah Air Minum (PDAM) Kota Cirebon Tahun 2014.
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Sari, D., Rosyada, Z., dan Ramadhani, N. 2011. “Analisa Penyebab Kegagalan Produk Woven dengan Menggunakan Metode
Failure Mode and Effect Analysis”. Jurnal Teknik Industri 1,6:6-11.
Standar Nasional Indonesia (SNI). No. 01-4852 Tentang Sistem Analisa Bahaya dan Pengendalian Titik Kritis (HACCP) serta
Pedoman dan Penerapannya Tahun 1998.
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Suryani, F. “Penerapan Metode Diagram Sebab Akibat (Fishbone Diagram) dan FMEA dalam Menganalisa Resiko Kecelakaan
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Figure 1. Location of Research Area
List of Figures
Figure 2. Fishbone Diagram Analysis
List of Tables
Table 1
Rangking of Severity
Entity Value
Severit
y
Rating
Raw Water
Quality of raw water 0% 1
Distance of raw water source to
factory
0% 1
Quality of pumps for water
transportation
60% 3
Carbon Filter
silica sand replacement 0% 1
Washing silica sand 40% 3
Size silica sand 0% 1
Replacement gravel media 0% 1
Washing gravel media 40% 3
size Gravel media 0% 1
Replacement activated carbon 0% 1
Washing activated carbon 40% 3
type active carbon 0% 1
Micro Filter
Replacement membrane cartridge 80% 4
Wash membrane cartridge 0% 1
The size of the membrane cartridge 0% 1
Injection ozone
Replacement ozone generator 80% 4
levels of ozone 0% 1
UV Lamp
Replacement Lamp UV 0 % 1
UV Lamp Specifications 0% 1
UV Contact Time 0% 1
Worker Behavior
Water Quality Analysis 0% 1
Water Quality Analysis Point 0% 1
Worker Sanitation 0% 1
Sanitation BDW Treatment Units 0% 1
Worker Insights Workers'
understanding of quality of water
according to SNI 3553: 2015
0% 1
Insights of workers related to
factory operations in accordance
with PERMENPERINDAG
Number. 705 of 2003
0% 1
Training on drinking water quality
management system according to
SNI 01-4852-1998
0% 1
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Tablel 2
Results Calculation of Risk Priority Number
Source Type of
Failure
S O D RP
N
Priority for
handling
Raw
Water
Quality of raw
water
1 1 1 1 23
Distance
source of raw
water with
factory
1 1 1 1 24
Pump quality 3 3 3 27 3
Carbon
Filter
Replacement
of silica sand
1 1 1 1 14
backwash
Silica sand
3 2 2 12 4
Size of silica
sand
1 1 1 1 17
Replacement
of media
gravel
1 1 1 1 15
Backwash
media gravel
3 2 2 12 5
media size
Gravel
1 1 1 1 18
Carbon
Filter
Replacement
activated
carbon
1 1 1 1 16
backwash
Activated
carbon
3 2 2 12 6
Types of
activated
carbon
1 1 1 1 19
Micro
Filter
Replacement
cartridge
microfilter
4 3 3 36 1
Backwash
membrane
cartridge
1 1 1 1 20
Size membran
catridge
1 1 1 1 21
Ozone
injectio
n
Replacement
of ozone
generator
4 3 3 36 2
Ozone levels 1 1 1 1 22
UV lamp
Replacement
of UV lamp
1 1 1 1 25
UV lamp
specifications
1 1 1 1 26
UV Contact
Time
1 1 1 1 27
Worker
behavi
or
Water quality
analysis
1 1 1 1 10
Water quality
analysis points
1 1 1 1 11
Worker
sanitation
1 1 1 1 12
Sanitation
treatment units
1 1 1 1 13
insight
s
Worker
s'
Understanding
water quality
workers SNI
3553: 2015
1 1 1 1 7
Insights
PERMENPER
INDAG.
factory
operational
workers
Number. 705
2003
1 1 1 1 8
training water
SNI 01-4852-
1998
1 1 1 1 9
162
Table 3
Result of Hazard Analysis Critical Control Point Method
Type Failure
Critical Control Point Critical Limits Monitoring System