Identifying Loss and Waste Hotspots and Data Gaps throughout the Wheat and Bread Lifecycle in the Fars Province of Iran through Value Stream Mapping
Abstract
:1. Introduction
1.1. Problem Statement and Objectives of the Study
1.2. The Background and Implications of Value Stream Mapping
2. Materials and Methods
2.1. Sampling Strategy and Survey Development
2.2. Data Analysis
3. Results and Discussion
3.1. Overview
3.2. Wheat and Bread Lifecycle
“Until 12 years ago, AREEO used to produce certified seeds. Nowadays, AREEO focuses only on research and producing nucleus breeds and delegates the rest of the breeding program to private companies…. We recently received breed 2, from which we produced 60 kg of breed 3 and, finally, 200 kg of the maternal line. Certified seeds are produced by [propagating] maternal seeds.” (Farmer 1)
“We plant certified seeds supplied by AREEO. We purchase the seeds from the local AREEO subsidiary.” (Farmer 4)
“The seed-producing companies sign contracts with some farmers. They give maternal seeds to farmers, and farmers produce certified seeds. The certified seed is used to produce bread wheat.” (Co-op CEO)
“We produce two types of wheat: one for seed using the hybrid cultivars supplied by breeding companies and another for consumption produced from certified seeds.… The price of the seeds is normally 20–25% more than bread wheat” (Farmer 1)
“The cultivation for seed production is executed more carefully compared to bread wheat. For example, AREEO requires farmers to test the soil for efficient fertilization.” (Co-op CEO)
“If the seeds produced by farmers contain high soil and weed dockage or too many broken grains, the companies or AREEO reject them, and farmers sell them as normal wheat.” (GCCS inspector)
“I purchase the certified seeds distributed by the rural cooperative. My father used to reuse the good wheat grains as seeds for the next year’s cultivation. Or if a neighboring farmer had good seeds worth more than bread wheat, my father used to make a deal with them to replace their good batch with bread wheat and get their good seeds for cultivation. The other farmer was selling the bread wheat batch at a normal price, and my father would pay them the difference. The good grains were sprayed with a certain pesticide and stored to be used as seeds in the following year. I do not do that.” (Baker 3)
“I could also produce seeds, but they [breeding companies or AREEO] do not buy them because they [the seeds] include too much soil and weed impurities.” (Farmer 3)
“Farmers usually do not irrigate the field if it rains about 30–40 mm after sowing.” (Co-op CEO)
“We harvest [wheat] in June or July.” (Farmer 3)
“We sell our [wheat] products to the cooperative, and they send them to silos.” (Farmer 2)
“We sell the product directly to silos. Sometimes we sell to the cooperative.” (Farmer 3)
“We deliver the yield to the cooperative.” (Farmer 4)
“The wheat is delivered to the cooperative’s purchasing center. It is weighted here, and the amount is recorded in the online system under the farmer’s name. The online system is connected to the Keshavarzi Bank (Bank of Agriculture), GCCS, and the Ministry of Industry, Mine, and Trade.” (Co-op CEO)
“The cooperative records the yield. They also assess the besatz content to determine the price based on their tables. They give us a receipt with all the details and record everything on a computer.” (Farmer 4)
“Our cooperative has 2000 members (shareholders) from 14 surrounding villages.” (Co-op CEO)
“From the moment producers deliver wheat to us, we are responsible for storing and safekeeping the wheat and later loading trucks and sending it to its designated destiny, which GCCS of Fars [province] determines. The destinations can be a milling factory or a silo…. GCCS uses an online system to tell us where to distribute wheat.” (Co-op CEO)
“The payment takes around two months. I sold my last batch at the end of June 2018. The payment took two to three months.” (Farmer 3)
“Not all the wheat the farmers produce is purchased by the cooperative. Some private buyers pay a negotiated price to the farmers…. These buyers either sell to the milling factories or the silos.” (Co-op CEO)
“Some intermediaries buy [bread] wheat to sell to the livestock feed-producing factories or directly to livestock farms. They normally have storage and weighing facilities.” (Farmer 2)
“They [intermediaries] normally pay less than the government, but they pay right away.” (Co-op CEO)
“[With intermediaries,] there is no waiting time to weigh farmers’ products, and the payment is instant, although at a bit lower price.” (Farmer 2)
“[Currently,] intermediaries pay more than cooperatives or silos…. They sell the wheat for livestock feed at a slightly higher price.” (Farmer 3)
“Normally, farmers sell wheat to silos or the cooperative right after harvest. They also store part of their harvest, which they later sell to intermediaries for livestock feed. Some farmers build a storage room, usually made of cement and isolated with tiles from the inside.” (Farmer 3)
“Almost 90% of the farmers are not able to store their yield. Therefore, they need to sell their product as soon as possible to gain some revenue to compensate for their costs for at least nine months.” (Co-op CEO)
“The advantage of selling to silos or cooperatives is receiving subsidized seeds, fertilizers, and pesticides. Moreover, our personal storage room is limited.” (Farmer 3)
“It is sometimes better to sell to the cooperative [or to silos] because we can buy fertilizer and pesticides with a discount for the next year in proportion to our current harvest amount.” (Farmer 2)
“[Currently,] supplying wheat outside the governmental supply chain is against the law, even to individuals.” (GCCS inspector)
“We receive wheat starting from June 10 until around July 1. We store the wheat (about 6000–8000 tonnes) here, usually around 20–30 days. In rare cases, we store wheat here for up to three months.” (Co-op CEO)
“Wheat remains in silos and will be distributed based on demands throughout the year. The silos are organized by the government.” (Co-op CEO)
“The GCCS of Fars uses the online system to tell us how to distribute wheat. For example, the GCCS of Fars would give us transportation permission for shipping 2000 tonnes of wheat to [company’s name] milling factory.” (Co-op CEO)
“The grains in silos are not threshed and include soil and weed residues or broken grains.” (Farmer 1)
“Milling factories separate the bran from the grains and grade them based on the existing standards. These factories distribute wheat flour to local or industrial bakeries based on quotas designated by GCCS Fars province and the union of bakers.” (Farmer 2)
“The government controls the distribution through an online platform, and bakers receive wheat flour based on their quota.… Our baking factory produces up to one thousand bread pieces per day. This amount is produced from our wheat flour quota.” (Baker 4)
“We order online based on our quota. The milling companies ship flour to each bakery based on online orders. We also pay transportation costs and store flour here.” (Baker 3)
“We order wheat flour via a website. Each bakery has a quota for each month. We store the flour here and prepare the dough, and then bake the bread.” (Baker 1)
“The milling factories supply wheat flour either to the free market via whole sellers or directly to bakers.” (Baker 4)
“The nomadic families and households in small villages also have flour quotas to bake their own bread.” (Farmer 2)
“Our buyers are supermarkets, household consumers, and fast food stores…. We sell bread to supermarkets in dated plastic packs…. Household consumers and fast foods buy fresh bread daily.” (Baker 4)
“We have a contract with an industrial bakery. The bread comes daily in box packs of 40 pieces.” (Foodservice 1)
“We buy our bread from a local bakery…. We use the fresh bread for the day and store the surplus in a freezer.” (Foodservice 2)
3.3. Loss and Waste Hotspots and Data Gaps
“The loss in the cooperative’s purchasing center is minimal. I am personally liable for any loss that may happen here…. Silos have a minimal amount of loss. For example, the nearby Silo in Sivand has a capacity of 70,000 tonnes. When the silo is fully loaded, it can preserve between 69,500 and 69,700 tonnes [about 0.07% loss]. The rest could rot or absorb too much moisture, which is insignificant.” (Co-op CEO)
“Once wheat enters milling factories, there is no loss. All parts of the wheat will be sold. For example, the wheat bran separated to produce white flour for confectioneries will be sold for animal feed.” (Farmer 1)
“The highest loss in storage can happen due to high water content, and because wheat has low water content in Iran, this loss is limited.” (Agri. Mins. Officer)
“Transport loss is limited unless the trucks are not sealed well, which does not happen often.” (Farmer 4)
“We do not experience any flour loss, and we are able to sell all the bread we produce. However, if the dough is ruined, we have to convert it into dried bread and sell it to intermediaries who eventually sell it to livestock farms.” (Baker 1)
“We usually sell 100% of our white bread production, although other bread types may experience some loss. During certain conditions, such as heavy rain or cold weather when we have fewer customers, we may not sell 100% of our production. Consequently, we end up with some unsold bread which we typically dry and sell as breadcrumbs.” (Baker 4)
“The main reasons for bread loss in supermarkets are expiration date and stale bread. Supermarkets typically sell their bread waste to bread waste recyclers, who in turn sell it as livestock feed.” (Baker 4)
“The on-farm loss is due to seed overuse, pests and harvesting.” (Seed producer)
“Bread waste happens in restaurants due to consumers having leftovers or passing expiration dates and staling.” (Baker 4)
“The highest bread waste amount is in households because the consumers do not manage their grocery shopping appropriately.” (Baker 4)
3.4. Material Flow Inventory along the Wheat and Bread Lifecycle
“We sell expired or stalled bread to intermediaries who sell them to animal farms as feed. We also record the amount we sell to them.” (Baker 2)
“We record what we sell to bread recyclers for internal accounting.” (Baker 3)
“We sell bread leftover to bread recyclers. They measure the amount and pay us accordingly.” (Foodservice 1)
The input and output of this purchasing center are accurately recorded. There is weight loss, which is due to losing moisture. We record moisture content both at purchasing time and later at loading time. [In the last measurement], the average moisture content of 12 random samples was 8.9%. The average at the time of loading was 8.1%, which means a 0.8% mass reduction was expected. (Co-op CEO)
3.5. Limitations of the Study and Future Research Directions
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Participant’s ID | Role |
---|---|
Seed producer | The owner of a plant breeding and seed production company. |
Farmer 1 | A farmer with large-sized (over 70 ha) land. |
Farmer 2 | A farmer with small-sized (10 ha) land. |
Farmer 3 | A farmer with small-sized (10 ha) land. |
Farmer 4 | A farmer with small-sized (20 ha) land. |
Co-op CEO | The chief executive officer (CEO) at a local agricultural cooperative and a farmer with medium-sized (50 ha) land. |
GCCS inspector | The technical inspector of Grain Company and Commercial Services (GCCS) of Fars province. |
Agri. Mins. Officer | A high-ranking officer at the Ministry of Agriculture. |
Foodservice 1 | The owner of a fast-food restaurant. |
Foodservice 2 | The head chef at a hotel. |
Baker 1 | The manager of a traditional bread (sangak) bakery. |
Baker 2 | The manager of a traditional bread (lavash) bakery. |
Baker 3 | The manager of a traditional bread (sangak) bakery. |
Baker 4 | The owner of a non-traditional bread bakery. |
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Ghaziani, S.; Dehbozorgi, G.; Bakhshoodeh, M.; Doluschitz, R. Identifying Loss and Waste Hotspots and Data Gaps throughout the Wheat and Bread Lifecycle in the Fars Province of Iran through Value Stream Mapping. Sustainability 2023, 15, 8404. https://doi.org/10.3390/su15108404
Ghaziani S, Dehbozorgi G, Bakhshoodeh M, Doluschitz R. Identifying Loss and Waste Hotspots and Data Gaps throughout the Wheat and Bread Lifecycle in the Fars Province of Iran through Value Stream Mapping. Sustainability. 2023; 15(10):8404. https://doi.org/10.3390/su15108404
Chicago/Turabian StyleGhaziani, Shahin, Gholamreza Dehbozorgi, Mohammad Bakhshoodeh, and Reiner Doluschitz. 2023. "Identifying Loss and Waste Hotspots and Data Gaps throughout the Wheat and Bread Lifecycle in the Fars Province of Iran through Value Stream Mapping" Sustainability 15, no. 10: 8404. https://doi.org/10.3390/su15108404
APA StyleGhaziani, S., Dehbozorgi, G., Bakhshoodeh, M., & Doluschitz, R. (2023). Identifying Loss and Waste Hotspots and Data Gaps throughout the Wheat and Bread Lifecycle in the Fars Province of Iran through Value Stream Mapping. Sustainability, 15(10), 8404. https://doi.org/10.3390/su15108404