LEMBAGA MINYAK SAWIT MALAYSIA MALAYSIAN PALM …palmoilis.mpob.gov.my/publications/POEB/poeb94.pdf · LEMBAGA MINYAK SAWIT MALAYSIA MALAYSIAN PALM OIL BOARD ... It has been a year

PALM OIL ENGINEERING BULLETIN NO. 94 1

ISSUE NO. 94 (Jan. - Mar. 2010)

LEMBAGA MINYAK SAWIT MALAYSIAMALAYSIAN PALM OIL BOARD

KEMENTERIAN PERUSAHAAN PERLADANGAN DAN KOMODITI MALAYSIAMINISTRY OF PLANTATION INDUSTRIES AND COMMODITIES, MALAYSIA

Website: www.mpob.gov.my


CONTENTS

Editorial

RECENT EVENTS

FORTHCOMING EVENTS 2010 MPOB Training Programme

2010 MPOB Conferences/Seminars

FEATURE ARTICLES

COP 15

Challenges Facing the Palm Oil Industry

REACH and the Malaysian Palm Oil Industry

Tilting Sterilizer

Mongana Basics: Part 20 - Processing of Nut

DATASHEET Approved Oil Palm-based Renewable EnergyProjects in Malaysia

1

3

13

15

17

EDITORIAL BOARD

ChairmanDatuk Dr Mohd Basri Wahid

• Datuk Dr Choo Yuen May• Dr Lim Weng Soon• Dr Ma Ah Ngan

• Ab Aziz Md Yusof • Ir N P Thorairaj

SecretaryIr N Ravi Menon

Malaysian Palm Oil BoardMinistry of Plantation Industries and Commodities,

MalaysiaP. O. Box 10620, 50720 Kuala Lumpur, Malaysia

Tel: 603-8769 4400Fax: 603-8925 9446

Website: www.mpob.gov.my

© Malaysian Palm Oil Board, 2010All rights reserved.

No part of this publication may be reproduced, stored in a retrieval system, in any form or by any means, electronic,

mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

Products and services advertised in thisPalm Oil Engineering Bulletin do not

connote endorsement by MPOB.

HEditorial

see page 2

25

19

43

53

ow time flies. MPOB (PORIM then) is already 30 years old. It has grown from a skeleton

number of staff on its inception in 1979 to close to 2000 staff in 2010. Malaysian palm oil industry has also grown by leaps and bounds to have more than 4.4 million hectares of land under oil palm cultivation. Naturally, the peripheral palm oil – link industries like palm oil mills, refineries, palm kernel crushers, oleochemicals manufacturers and lately palm biodiesel factories, have also grown in tandem with the industry.

Globally, the oils and fats have grown rapidly to meet the demand of the growing world population coupled with the improving purchasing power in developing and emerging economies. However, much to our dismay, Malaysia has lost her position as the world’s largest palm oil producing country due to limitation of suitable land for oil palm cultivation. The palm oil industry has also been beset by such adversities like global warming, climate change, environmental degradation, deforestation, etc. It is time to look closely at our industry on how we can address all these adversities.

Palm oil mills have long been singled

out as one of the chief contributors to our environmental pollution in terms of black smoke emission, water pollution and lately the greenhouse gas emissions. Even though the impact of pollution has been very much reduced, the general scenario remains much the same. Over the last three decades, there had been very little changes in the palm oil extraction process, except that the individ-ual mill capacities have become bigger. The whole palm oil extraction process still re-quires massive heavy machinery and large building footprint. The working environ-ment has not improved much either. Though there were incremental improvements in some of the unit operations, there were no revolutionary changes. The only noticeable change is in the sterilization process. There are now a few options available to sterilize

29

PALM OIL ENGINEERING BULLETIN NO. 942

from page 1

CALL FOR ARTICLESThe millers are requested to send in articles of relevance to the palm oil industry in Malaysia for publication in Palm Oil Engineering Bulletin. By sharing your expertise you will be helping the industry and the nation as a whole. The topics of interest are:

1. Plant modifications done in your mill that resulted in improvements in milling operation or maintenance.

2. Innovations done in your mill that produced improvements in the operation of the mill and that you are willing to share them with others.

3. Any special work done in your mill that directly resulted in improvements in OER and product quality.

Please submit your article to us and we shall be pleased to publish them in Palm Oil Engineering Bulletin. Feel proud to have your articles published in this Bulletin that is circulated throughout the industry and MPOB offices worldwide.

the fresh fruit bunches (FFB). In fact, being me-chanical process, it is difficult to have any drastic changes in the oil extraction process. It has been mentioned many times that if the palm oil mills continue to process the FFB in the present form, there can hardly be any change in the process. The milling process will be drastically simplified if the mills only receive and process loose fruits. Some discussions are presented in this issue.

The palm oil industry is also very conserva-tive in adopting new technology. For example, most of the palm oil mills, even the new ones are still using ponding system for their efflu-ent treatment, even though there are many new treatment systems available. The ponding sys-tem was developed some 30 years ago to meet the first generation environmental standards. They are very empirical and require large land area. It is high time that the industry invest in new technologies to meet the environmental challenges.

The palm oil industry has been accused of contributing to deforestation leading to global warming. The government through its various/relevant ministries has set up various committees in a bid to accelerate the development of new energy technologies needed to address climate change, energy security and food demand.

Four or five years ago, palm biodiesel was the buzzword lighting up the palm oil industry. It was seen as the perfect safety net to stabilize the palm oil price should there be an overproduction leading to high stock. Also, with crude petroleum oil price soaring, palm oil producers saw huge

opportunities as countries seek vegetable oils to produce environmental-friendly biodiesel. Palm oil producers should be the big winner since it is the cheapest of the vegetable oils. However, things have changed. Biofuels, particularly palm biodiesel has been touted as the contributor to global warming and climate change. Much has to be done to resolve the issue. Government’s support is much needed to make it a viable project.

Since 2008, Malaysia has lost its status as the world’s leading palm oil producing country to Indonesia. MPOB has come a long way to be the leading R&D institution in oil palm and palm oil. MPOB should strive to maintain its leading position in order to have a competitive edge over other palm oil producing countries. To be competitive requires constant innovation. Companies wishing to remain long-term have to invest in innovation.

In this issue, there are a few thought provok-ing articles relating to the challenges ahead for Malaysia palm oil industry to ponder over. We welcome comments and suggestions so that MPOB can initiate a star-war R&D programme to lead the way forward to address such issues as environmental pollution, climate change, glo-bal warming, energy security and food demand as well as sustainability.

It has been a year of big green announcement as the Malaysian government brings policies into line with its commitments on climate change. In order to achieve this, we need to chart our action plan and a strong political will to implement it. In short, we have to walk the talk.


Recent Events Contributed by: Noor Asmawati Abd Samad*

* Malaysian Palm Oil Board, P. O. Box 10620, 50720 Kuala Lumpur, Malaysia.

Anugerah Q 2009 (Quality Award 2009)

Datuk Dr Mohd Basri Wahid, the Director-General of MPOB, presented quality awards under various categories to more than 200 staff on 22 January during the Quality Award 2009 event.

Annual Dinner

Two projects entitled Emulsion in Water (EW) Insecticide Formulation Based on Inno-vative Palm Inert Ingredients for Crop Care and Public Health Importance led by Dr Ismail Ab Raman and NoveLin – A New Innovative Oil for Health and Cold Stability led by Dr Siew Wai Lin were chosen to receive the Anuge-rah Emas Penyelidikan MPOB 2009, during the Annual Dinner and Award Presentation Night at Equatorial Hotel, Bangi on 22 Janu-ary 2010.

In addition, the project Life Cycle Assessment of the Production of Crude Palm

Oil led by Dr Vijaya Subramaniam and another project entitled Ester Kuarterner Trietanolamina Berasaskan Oleokimia Sawit untuk Bahan Penjagaan Fabrik led by Dr Zainab Idris were chosen for Anugerah Kecemerlangan Sains Piala Pusingan Ketua Pengarah 2009.

Mr N Balu and Dr Ainie Kuntom were awarded the Anugerah Kecemerlangan Pengu-rusan Piala Pusingan Ketua Pengarah 2009 for their projects Portal Palm Tariff Information and MPOB Codes of Practice, respectively.

Thirty-three publications were given awards for the best publication but Dr Umi Salamah Ramli was chosen as the overall winner for her publication The Use of Meta-bolic Control Analysis to Give Quantitative In-formation on Control of Lipid Biosynthesis in the Important Oil Crop, Elaeis guineensis (oil palm). Tan Sri Bernard Dompok, the Minis-ter of Plantation Industries and Commodi-ties, presented the awards.


Recent Events

Farm Mechanization Operator Course

A total of 47 candidates participated in the 7th Farm Mechanization Operator’s Course, which was conducted from September 2009 until February 2010. Datuk Dr Mohd Basri Wahid, the Director-General of MPOB, pre-sented certificates to the successful candi-dates on 11 February 2010 in a function held at Equatorial Hotel, Bangi.

Three participants namely, Mohd Sai-ful Shafie, Juneo Sinood and Mohd Yuan Fitri Khan Mohd Yusof, who were voted as the best participants, also received their re-wards during this function.

MPOB Presented Scheme to Help Smallholders in Kota Marudu, Sabah

A total of 45 smallholders were offered vari-ous schemes under the Ninth Malaysia Plan by Tan Sri Bernard Dompok, the Minister of Plantation Industries and Commodities, on 30 January 2010 at Kota Marudu, Sabah.

The schemes covered supply of good quality oil palm seedlings to poor smallholders, crop and livestock integration, and oil palm replanting exercise. There was also the Second Economic Stimulus Package (PRE2) to plantation companies and small-holders.

The event was also attended by Dato’ Sabri Ahmad, the Chairman of MPOB; Datuk Dr Mohd Basri Wahid, the Direc-tor-General of MPOB; and Tuan Haji Idris Omar, the Director of Integration Research and Extension Division.


Recent Events

PILIPS Workshop 2010The Workshop on Palm Industry Labour: Issues, Performance and Sustainability (PILIPS) 2010, organized by MPOB was held on 8 February 2010 at the Le Meridien Ho-tel, Kota Kinabalu, Sabah. Tan Sri Bernard Dompok, the Minister of Plantation Indus-tries and Commodities, officially opened the Workshop.

The objective of the Workshop was to provide a forum to deliberate and address concerns related to reducing labour supply that could have an impact on the formula-tion of appropriate and practical strategies in handling labour issues. Participants were also encouraged to share the experiences, knowledge, as well as acquire new tech-niques in managing human resources to ensure the long-term sustainability of the Malaysian palm oil industry.

More than 120 participants from the in-dustry and related government agencies at-tended the Workshop.

Tan Sri Bernard Dompok; Dato’ Sabri Ahmad, the Chairman of MPOB; and Mr M Nagarajan, the Under Secretary, Vegeta-ble Oils, Fats and Sago Division, Ministry of Plantation Industries and Commodities, witnessed an agreement signing ceremony between MPOB and Fancy Power Sdn Bhd for the production and marketing of Oil Palm Motorized Cutter (Cantas™). Datuk Dr Mohd Basri Wahid, the Director-General, represented MPOB while Mr Kam Pau Siong, the Managing Director represented Fancy Power.

MPOB Presented Schemes to Help Smallholders in

Saratok, SarawakTan Sri Bernard Dompok, the Minister of Plantation Industries and Commodities, accompanied by Dato’ Sabri Ahmad, the Chairman of MPOB; Datuk Dr Mohd Basri Wahid, the Director-General of MPOB; and Mr Danial Supit, the Saratok District Officer presented schemes to 40 smallholders. The schemes offered supply of good quality oil palm seedlings, integration of crops


Recent Events

and livestock and agricultural inputs such as MPOB F1 Fertilizer to smallholders at Dewan Masyarakat Saratok, Saratok, Sarawak on 1 March 2010.

Earlier, MPOB organized a seminar to disseminate information on good agricul-tural practices in oil palm plantation for the smallholders. More than 400 smallholders attended the seminar.

SERU_Ling 1 MalaysiaDatuk Dr Mohd Basri Wahid, the Director-Genaral of MPOB, attended the SERU_Ling 1 Malaysia Programmes organized by MPOB on 6 March 2010 at Dewan Serbaguna Kampung Lalang, Baling, Kedah. The programmes were hosted by Senator Dato’ Dr Mashitah Haji Ibrahim, the Deputy Minister at the Prime Minister’s Office. Among the activities organized during the event were cooking demonstration, colouring contest and exhibition related to palm oil industry.

POSREP SeminarThe Palm Oil Small Renewable Energy Pro-gramme (POSREP) Seminar was held on 11 March 2010 at Promenade Hotel, Kota Kina-balu, Sabah. Tan Sri Bernard Dompok, the Minister of Plantation Industries and Com-modities, officially launched the seminar.

The Seminar was specifically organ-ized to disseminate the latest development in Small Renewable Energy Programme (SREP) in the palm oil industry and to ad-dress all barriers and concerns. This was


Recent Events

expected to increase awareness related to SREP and the industry’s role as the major player in renewable energy development in Malaysia.

More than 250 participants participated in this Seminar. Experts from various agen-cies and companies presented a total of eight papers in two different sessions enti-tled SREP in the Palm Oil Industry - The Sta-tus and Issues, Challenges and Way Forward.

The opening ceremony was attended by Datuk Raymond Tan, the Minister of Indus-trial Development, Sabah; Datuk Dr Ewon Ebin, the Minister of Rural Development, Sabah; Dato’ Sabri Ahmad, the Chairman of MPOB; and Datuk Dr Mohd Basri Wahid, the Director-General of MPOB.

Launching of IMPACTan Sri Bernard Dompok, the Minister of Plantation Industries and Commodities launched the Institute of Malaysia Planta-tions and Commodities (IMPAC) located at Keratong, Pahang at MPOB Head Office on 16 March 2010.

The objective of IMPAC is to be the one-stop centre for all agencies under the min-

istry to organize the general and specific training and courses related to the planta-tion and commodities industry. This will produce knowledgeable personnel work-ing in the commodities sector.

The minister also presented diplomas and certificates to participants who had completed training and courses organized by agencies under the ministry.

Datuk Wira Ismail Saleh, the Secretary-General of the Ministry of Plantation In-dustries and Commodities (MPIC); Mohd Aminuddin Hashim, the Deputy Secretary-General II of MPIC; senior officers of MPIC; Director-Generals of agencies and chief executives of councils under MPIC also at-tended the event.


Forthcoming Events

CODENO.

TITLE DATE VENUE

A COURSES1 OIL PALM

A1.1 Kursus Kemahiran Menggred Buah SawitBil. 1: Wilayah Sabah 23–25 Mac Hotel Sunbay,

Sandakan, Sabah

Bil. 2: Wilayah Sarawak 27–29 Apr Hotel Plaza, Bintulu,

SarawakBil. 3: Wilayah Tengah 18–20 Mei Nilai Supreme,

Nilai, Negeri Sembilan

Bil. 4: Wilayah Utara 8–10 Jun Orient Star, Lumut, Perak

Bil. 5: Wilayah Selatan (Permintaan Industri) 20–22 Jul Hotel Desaru,Johor

Bil. 6: Wilayah Timur (Permintaan Industri) 3–5 Ogos MPOBKuantan, Pahang

A1.1. (b)

Peperiksaan Kemahiran Menggred Buah SawitBil. 16: Sarawak Okt. *Bil.17: Semenanjung Dis. *

A1.2 12th Intensive Diploma in Oil Palm Management & Technology (IDOPMT)Semester IEstate AttachmentSemester IIEstate AttachmentSemester III

12 Apr–7 May10–21 May

24 May–18 June21 June–2 July

5–30 July

MPOB HQ****

A1.3 Kursus Operator Mekanisasi Ladang Mac-Ogos MPOB UKM

2010 MPOB TRAINING PROGRAMME SCHEDULE


A1.4 Kursus Pengurusan dan Penyelenggaraan Tapak Semaian SawitBil. 1: Wilayah Tengah 16–17 Mac Hotel Seri

Malaysia, Bagan Lalang,

Selangor Bil. 2: Wilayah Selatan 13–14 Apr Hotel Legend

& Golf Resort, Kulai, Johor

Bil. 3: Wilayah Timur 18–19 Apr FELDA Sg Tekam, Jerantut,

PahangBil. 4: Wilayah Sabah 8–9 Jun Sandakan,

SabahBil. 5: Wilayah Sarawak 13–14 Jul Miri, SarawakBil. 6: Wilayah Utara 28–29 Sep Teluk Intan,

PerakA COURSES 2 PALM OIL

A2.1 Diploma in Palm Oil Milling Technology and Management (DIPOM)Semester I Semester IISemester IIIExam. Semester III

15–25 Mar10–20 May28 Jun–6 Jul9–10 Aug

PLASMALahad Datu,

Sabah

A2.2 The 23rd MPOB Oil Palm Products Surveying Examination

The 22nd MPOB Oil Palm Products Surveying Course

*

21–25 Jun

*

Vistana Hotel, Kuantan, Pahang

A2.3 Kursus Bengkel Kilang Minyak Sawit 12–16 Apr MPOB PLASMALahad Datu

A2.4 Kursus Drebar Enjin 21–25 Jun MPOB PLASMALahad Datu

A2.5 Cosmetic Course 9–13 Aug MPOB HQ/AOTD

A2.6 Introductory Course on Palm Oil Trading and Marketing

9–13 Aug *

A2.7 Diploma in Olecohemical Technology Semester ISemester IISemester IIIPractical and Factory Visit

****

MPOB HQ

Forthcoming Events


Note: * To be confirmed.

For enquiry or further information, please contact:

HRD & Conference Management UnitTel. No. : 03-8769 4400 ext. 4865, 4860, 4867Fax No. : 03-8925 7549E-mail : [email protected]’s website : http://www.mpob.gov.my

2010 MPOB CONFERENCES/SEMINARSCODENO.

TITLE DATE VENUE

B CONFERENCES/SEMINARS1. Palm Industry: Issues, Performance and Sustainability

(PILIPS) Workshop8 February Le Meredian

Hotel, Kota Kinabalu,

Sabah2. National Seminar on Renewable Energy (SREP) 11 March Promenade

Hotel, Kota Kinabalu, Sabah

3. Programme Advisory Committee (PAC) Seminars 1 April MPOB, HQ4. Seminar & Workshop on Technology for Tertiary

Treatment of Palm Oil Mill Effluent (POMET)5-6 July Promenade

Hotel, Kota Kinabalu, Sabah

5. MPOB Transfer of Technology (TOT) Seminar 2010 17 June MPOB, HQ6. GSAS Seminar 18 June MPOB, HQ7. Palm Oil Familiarization Programme (POFP) 10-20 July Kuala Lumpur8. Persidangan Kebangsaan Pekebun Kecil Sawit 3-4 Ogos Miri, Sarawak9. 2010 National Seminar on Palm Oil Milling, Technology,

Quality & Environment (POMREQ)27-28 Sept. Kota Kinabalu,

Sabah10. Seminar Mekanisasi Ladang 27-29 Sept. PLASMA, Lahad

Datu, Sabah

Forthcoming Events

All information are correct as at press time.


Feature Article

COP 15Ma Ah Ngan*

T

* Malaysian Palm Oil Board, P. O. Box 10620, 50720 Kuala Lumpur,

Malaysia.

owards the end of 2009, when there were talks about global warming, climate change and sus-

tainability, we heard a lot about COP 15 and the much anticipated conference on climate change to be held in Copenhagen in Decem-ber 2009. Many seminars were organized with the theme Road to Copenhagen trying to crystallize some firm proposals to be dis-cussed at the conference.

But what exactly does COP 15 means. COP stands for Conference of Parties. This is dated back to 1992 when the United Na-tions organized the first Earth Summit meet-ing in Rio de Janeiro, Brazil and the United Nations Framework Convention on Climate Change (UNFCCC) was opened for signa-ture. With more than 50 countries ratifying the convention, it came into force in 1994. Since then, the Conference of Parties was held annually to address the issues concern-ing the climate change and global warming, and in 1997, the Kyoto Protocol was estab-lished to legally bind the developed coun-tries to reduce their greenhouse gas emis-sions. This was the 15th meeting held for the same purpose, so it is called COP 15.

The main objective of COP 15 was to es-tablish a much talked about and anticipated

climate change agreement for the period from 2012 when the first commitment peri-od under Kyoto Protocol expires. The world is looking to COP 15 to come out with a glo-bal agreement on significant reductions on greenhouse gas emissions.

The COP 15 was held from 7 to 18 Decem-ber 2009 in Copenhagen. It was attended by 194 of its member states and a few hundred climate-change-concerned non-government organizations to deliberate on the pressing issues and come out with a legal agreement to reduce the CO2 emissions. Unfortunately, the outcome was very disappointing. The delegates, especially those from the Third World and developing countries were infu-riated and frustrated. No legal agreement was put forward for debate and discussions. Though everybody at the conference agreed that the climate change or global warming is no longer a myth, there was, instead be the argument that a serious effort to limit the global warming would destroy the econo-my. This was mainly claimed by the devel-oped nations.

In order to control global warm-ing, every nation has a role to play. The developed nations which had built their high carbon economies over the centuries, should honour their promises under the Kyoto Protocol to cut down their emissions and provide adequate funds and appropri-


Feature Article

ate technologies to help the developing na-tions to achieve the common goals. We need a holistic approach to save everyone from this ailing earth. Of course saving the plan-et does not come free. But it does not cost much either. Looking around we are actu-ally wasting a lot of energy to maintain our

current standard of living. For example, we need not drive big air-con cars to go places, the temperature of our offices, conference rooms, shopping malls etc. are too cold for comfort. In other words, we should con-serve energy wherever possible.

2010 NATIONAL SEMINAR PALM OIL MILLING, REFINING, ENVIRONMENT AND QUALITY (POMREQ)

27-28 SEPTEMBER 2010 Magellan Sutera Harbour Resort, Kota Kinabalu, Sabah

PLEASE REGISTER EARLY For further information, please surf MPOB website at www.mpob.gov.my

or contact the following for further details:

Seminar RegistrationMs Ruba’ah Masri/Ms Solehah Abdul Bab.

Tel: 03-87694567/8769 4867 Fax: 03-8922 1743/ 8925 7549E-mail: [email protected] or [email protected]

Technical EnquiryMs Rosnah Mat Soom/Ms Fatah Yah Abd Manaf

Tel: 03-8769 4753/8769 4465 Fax: 03-8926 2971/ 03-8926 3827E-mail: [email protected] or [email protected]

Exhibition/Golf TournamentMs Lim Soo Chin/Ms Asiah Md Nor/Ms Siti Nur Shahirah Mohd Mahudi

Tel: 03-8769 4676/8769 4652/87694434 Fax: 03-8926 2971/03-8926 3827E-mail: [email protected] or [email protected] or [email protected]


Feature Article

Challenges Facing the Palm Oil IndustryMa Ah Ngan*

I


Malaysia.

t has been said many times that there will hardly be any drastic change in palm oil milling technology if mills

INTRODUCTION

continue to receive and process the FFB in its present form. The experience of past 50 years or so can testify this. However, it is justified to put on record here that there were many incremental improvement and changes in various unit operations, but these were hardly revolutionary in nature. The palm oil mills still rely on the massive heavy and huge steel vessels like sterilizers, cages and threshers to handle the fresh fruit bunch (FFB). Large quantities of steam and water are required to sterilize the FFB, either in full set or crushed form, and to dilute the crude oil slurry for oil recovery in the clari-fication process. The recent trend to reduce the water usage in the process has not been very encouraging. Most of the water used in the milling process, except the steam blow-off and exhaust-steam, ended up as palm oil mill effluent (POME) which has to be treat-ed to comply with the Department of Envi-ronment (DOE) discharge standards.

Till today, the palm oil mill’s key per-formance indicator is still the oil extraction rate (OER). It is a ratio of the crude palm

oil (CPO) produced to the FFB processed by the palm oil mill. It is taken for granted that the higher the OER the more efficient is the mill. In many instances, the OER has been misused to penalize palm oil mills as being operated inefficiently, thus, resulting in low OER. It must be remembered that the oil is made in the field, not in the mill. If for whatever reasons the FFB contains less oil than expected, there is nothing the mill can do except getting lower OER. Of course if a mill is not run efficiently, more oil will be lost. This will also result in low OER. This can be easily checked by conducting oil loss analysis on the waste streams of the mill. It is also true that, a mill suffers from high oil loss will also produce high OER. This is be-cause the FFB has high oil content.

The dilemma faced by the palm oil mill is that the palm oil mill does not know how much oil is received. The oil is contained in the FFB or fruits. The palm oil mill only knows the weight of the FFB received with the oil in it. Many attempts have been made to measure the oil contained in the FFB, but so far it has not been successful. There is no direct method to gauge the efficiency of the mill. Unlike the refinery where every kilo-gram of the oil can be accounted for, what a palm oil mill can do is to strive to reduce the oil losses as much as possible. As a good process control indicator, an oil loss of 1.5% to 2.0% to FFB is considered as good.


Feature Article

There are many factors contributing to oil content in FFB. It is beyond the scope of this article to deliberate on it. However, there is no question that ripe FFB or ripe fruits contain maximum oil and ripe fruits will detach from the bunch by themselves. No outside force is needed to detach fruits from the bunch. Unfortunately not all the fruits ripen at the same time. The ripe fruits at the lower part of the bunch (nearer to the ground), when detached from the bunch will drop to the ground. The fruits at the upper part of the bunch are retained by the bunch (or more precisely, the spikelets) until the bunch is cut, then the bunch will drop and fruits will scatter on the ground.

As regards when to cut the FFB depends on the ripeness standard of individual com-pany. Obviously, the oil content in the FFB follows the ripeness standards. The ripe FFB contains more oil. Thus, a palm oil mill re-ceives high percentage of ripe FFB will yield more oil and subsequently higher OER pro-vided the oil loss is under control, i.e. under 2% to FFB. This is the department that har-bours the endless arguments between the estates and the mill when the OER is low. The estates claim to have harvested the ripe FFB for the mill and it is the mill that is not operated efficiently, thus, getting low OER. Similarly, the mill claims otherwise. No-body can have the right answer. The prob-lem is that no one knows how much oil is in the FFB. Worst still the degree of ripeness is different for each FFB. Every consignment of FFB to the mill invariably contains differ-ent categories of FFB including over-ripe, ripe, under-ripe, unripe, rotten and long stalk, etc. Generally, ripe and under-ripe categories form the majority (>80%) of the FFB consignments.

It is clear that under-ripe fruit will not yield maximum oil, thus, oil is lost if under-ripe FFB with under-ripe and unripe fruits is harvested. The full potential of oil yield from the estates can never be realized with the current practice of harvesting by the es-tates. No one has ever estimated the amount

of financial loss in harvesting and process-ing the under-ripe and unripe fruitlets in the FFB. It amounts to billions of ringgit. At the current scenario, a 0.5% loss in OER (assuming the palm oil mills process 90 mil-lion tonnes FFB per annum) means a loss of 0.45 million tonnes of CPO. This amounts to RM 1125 billions assuming a price of RM 2500 t-1 of CPO.

As mentioned earlier, only ripe fruits yield maximum oil. Ripe fruits will detach and fall to the ground. Thus, if the estates can only harvest the ripe fruits for process-ing, then the full potential of oil yield from estates and the whole industry can be real-ized.

It is proposed here that the estates should not cut the FFB until all fruits on the lower part of the FFB have detached and dropped to the ground. The remaining fruits retained by the now half-empty FFB can be collected when it is cut as usual. But it must be men-tioned here that lose fruits should be collect-ed daily and sent to the mill for immediate processing.

Obviously this is easier said than done, because breaking out of old mindset is very difficult (painful). It is the bottle-neck of the palm oil industry. Collecting loose fruits is a very tedious job and nobody wants to do it. The problem is compounded by an acute shortage of labour. As a result, estates, in or-der to reduce the number of loose fruits un-collected, tend to harvest more under-ripe FFB so that no fruits will detach from the bunch. This will result in more oil lost. This trend will continue if the labour problem is not solved.

Notwithstanding that the industry should look seriously into this problem. The present R&D effort on loose fruits collection should be intensified. The loose fruit col-lection device should be made more user-friendly to entice more people to do the job. This should be done with utmost urgency


Feature Article

because the sustainability and profitability of the palm oil industry to a large extend de-pend on the success of this endeavour.

There are many tangible advantages if the palm oil mills only receive and process loose fruits:

• the transport vehicles can be more pro-ductive by transporting fruits only with-out the non-oil bearing bunch stalks;

• the throughput and productivity of the mill will be enhanced. This is because the mill needs only to process the ripe fruits with maximum oil and not togeth-er with the unproductive bunch stalk. The bunch not only carries no oil, it will also absorb oil during sterilization and threshing of the cooked FFB thus result-ed in more oil loss;

• the raw empty bunch stalks are left in the field. The mill will no longer be burdened to dispose of the empty fruit bunch (EFB);

• for the same oil output, a mill requires a smaller loading ramp to store the fruits and smaller number of sterilizer cages to transfer the fruits for sterilization;

• no thresher is required;

• the subjective FFB grading is no longer required; and

• most important of all, the full potential oil yield from estates can be realized as only the ripe fruits contain maximum oil.

These are just a few obvious advantages that can be easily realized at no cost to the palm oil mill. The most dramatic change to the palm oil industry will be the potential

evolution of a green and sustainable palm oil milling technology as discussed below.

Over the last decade the palm oil mill has been beset by an array of environmental ad-versities like air, water, noise and odour pol-lutions. Lately the LCA study (Vijaya et al., 2008) has demonstrated that palm oil mill is one of the chief contributors to global warm-ing. This is due to the emission of biogas during the anaerobic digestion of POME. Biogas consists of about 65% methane and 35% carbon dioxide, both are greenhouse gases; methane is 21 times more potent than carbon dioxide in terms of global warming.

Large amount of water is required in the palm oil milling process. Most of the water used, except the steam exhaust from the sterilizer during FFB sterilization, ended up as POME which requires rigorous treat-ment to comply with the DOE’s stringent discharge standards. This is the main cause of water pollution.

Environmental impact is the key factor determining the sustainability of palm oil production in future. A holistic and effective approach is required to address the environ-mental issues caused by the palm oil indus-try. In this context, a new and green palm oil milling process has to be developed. The new process should aim primarily to reduce energy consumption (i.e. more energy effi-cient), reduce black smoke emission and to reduce drastically water consumption thus eliminating the production of POME and biogas.

Vigorous response to a crisis often re-quires a profound shift in thinking. A dra-matic change in the current milling process is urgently required as the palm oil industry is under tremendous environmental pres-sure to survive. Never before did the in-dustry face such a prolonged assault by the


critics except the anti-palm oil campaign in the 1980s. It was on the health and nutrition issues. It lasted only a couple of years.

To develop a green technology for the in-

dustry is a formidable task. When the palm oil industry is in a comfort zone, many po-tentially green technologies have been re-jected before they were fully evaluated.

The main objectives of sterilization are

to supply heat to (1) detach the fruits from the FFB stalks, (2) stop the enzyme reaction that causes the free fatty acids (FFA) in the oil to rise and (3) condition the nuts for sub-sequent cracking. Currently large quantity of steam is used to do the job and prolonged steaming is necessary to allow sufficient heating of the inner layers of the bulky FFB. To complete a sterilization cycle 70 to 90 min are required. Almost half of the steam used is exhausted during the sterilization cycle, the remainder steam ends up as sterilizer condensate and it forms part of the POME.

It has been demonstrated by Chow and Ma (2009) that microwave heating is able to achieve the objectives of the conventional sterilization. A very short time (3 min to 5 min) is required. However, it works only for the outer layer of fruits on the FFB or spike-lets of fruits. The microwave is not able to penetrate into the inner layers of the FFB to achieve the objectives and prolonged heat-ing will severely damage the fruits and ker-nels.

Microwave heating can certainly be ap-

plied to treat individual palm fruits. A sin-gle layer of fruits can be conveyed through a microwave tunnel for efficient heating to stop the enzyme reaction. At the same time, the fruits are sufficiently dried to fur-ther protect the oil from enzyme attack. The heating time can be optimized to condition the nuts for subsequent cracking. This is a dry process. No effluent is generated.

The dried fruits now are in perfect con-dition for solvent extraction. Solvent extrac-tion is employed to extract oil from oilseeds like soyabean, sunflower, rapeseed, corn, etc. It was also used to extract palm kernel oil. It was phased out as it was found less costly to press out the palm kernel oil using screw press.

In view of the pressing environmental concern on greenhouse gas emission and the much talked about global warming, the palm oil industry has no choice but to com-promise for a clean technology, i.e. the sol-vent extraction technology whereby palm oil is extracted using a food grade solvent or supercritical fluid like supercritical car-bon dioxide. CPO (or a branded palm oil) is recovered by evaporating the solvent. The solvent is recovered for reuse. As the sol-vent extracted oil does not contain any fruit debris or sludge, no clarification is neces-sary and therefore no water is needed as in the conventional clarification process. This also makes the whole range of machinery in the clarification room redundant. There will be no more separator sludge and POME will be totally eliminated. Thus, there will be no POME to be treated, no biogas gener-ated and no global warming to worry about. The green image of palm oil industry will be greatly enhanced.

The main concern of this new technology is the quality of the CPO thus produced. This has to be thoroughly investigated be-fore the palm oil industry would consider adopting the solvent extraction technology. The solvent extracted CPO must be at least comparable if no better than the convention-al CPO in terms of all quality parameters as well as its refinability.

Palm fruit is also known to contain an array of valuable vitamins other than caro-tenes and vitamin E. Some are water soluble and some are not. Since no water is used in the solvent extraction process, all these mi-nor components should remain in the oil if

Feature Article


they are solvent extractable. This will add value to the oil or they can be extracted from the oil like carotenes and vitamin E.

The palm oil industry should seriously consider this proposal. This will overhaul the whole palm oil business, from A to Z of the industry. The extra revenue earned will be tremendous. It can easily increase the OER by 3.5%, i.e. 1.5% from the process loss and easily 2% from the oil yield from ripe fruits. From the similar calculation above, this amounts to an increase of 3.15 million tonnes of CPO per annum or a hefty RM 7.875 billion per annum which is much more than the total research cess collected by MPOB over the last 30 years. This can

pay for all the investments needed for R&D. The success of the endeavour will ensure a profitable and sustainable palm oil industry.

REFERENCES

CHOW, M C and MA A N (2009). Process-ing of palm fruits using microwave. Patent granted No: MY-139951-A.

VIJAYA, S; MA, A N; CHOO, Y M and NIK MARIAM NIK SULAIMAN (2008). Envi-ronmental performance of the milling proc-ess of Malaysian palm oil using the life cycle assessment approach. Amer. J. Environ. Sci., 4(4): 310-315.

Feature Article


Feature Article

I

REACH and the Malaysian Palm Oil IndustryTang Thin Sue*


Malaysia.

n 2001, the European Union released a white paper proposing the es-tablishment of a regulation on the

registration, evaluation and authorization of chemicals (REACH). The key objective of the regulation is to increase the protection of the consumers; health and the environment from the exposure to hazardous substances. The regulation was adopted in September 2003 by the European Union (EU) Parlia-ment and eventually, enforced on 1 June 2007. Affected parties have been advised to carry out pre-registration of phase-in substances in the period June to November 2008. Many Malaysian oleochemical manu-facturers, the most affected sector in the palm oil industry, have already pre-register their products.

The important implications of reach are:• only registered existing and new sub-

stances (except those exempted) may be manufactured, imported or used;

• not only the substances, but also the whole supply chain has to be registered, evaluated and authorized;

• manufacturers and downstream users are equally responsible for the safe han-dling and use of these substances; and

INTRODUCTION • there will be a tremendous increase in the cost of doing business involving af-fected substances because of the various requirements for the registration.

EXEMPTION FROM REGISTRATION

There are some substances that are ex-empted from REACH registration. This includes substances used in food, feeding stuff, medicinal products, cosmetics, vet-erinary products, etc. that are regulated by other EU legislations, as well as those listed in Annexes IV and V of the REACH Regu-lations. Substances exempted under Annex IV are specifically named products while Annex V contain a list of natural occurring substances, and those that have not under-gone any chemical modification processes, and include amongst others, mineral mate-rials, petroleum products, by-products, etc. As oils and fats are also used in non-food products, they may require registration un-der REACH.

Under the initial provisions of Annex IV, several oils and fats and their fatty ac-ids were exempted from registration, but palm oil, palm kernel oil and their fatty ac-ids were glaringly excluded from the list for unknown reasons. The Malaysian Oleo-chemicals Manufacturing Group (MOMG) established a technical working group com-prising members of MOMG, representa-tives from MPOB and SIRIM to work closely with ASEAN Oleochemicals Manufactur-


Feature Article

ing Group (AOMG) and relevant European trade associations such as the European Chemical Industry Council (CEFIC) and the EU Oil and Protein Meal Industry (FEDIOL) as well as MPOB, Ministry of Plantation In-dustries and Commodities (MPIC), and the Ministry of International Trade and Indus-try (MITI) in seeking for amendments in the REACH exemption list. Several petitions, with technical justifications, have been sent from 2007 to 2009 to the EC through the channel of MITI and MPIC to request for a review and clarification of the lists of ex-emption under Annexes IV and V.

Finally on 8 October 2008, a Direc-tive, Commission Regulations (EC) No. 987/2008 amending the Regulation (EC) No. 1907/2006 of the European Parliament and of the Council on the Registration, Eval-uation, Authorization and Restriction of Chemicals (REACH), as regards Annexes IV and V was released by the European Com-mission. This new document reviewed the former Annexes IV and V, and spelt out the revised lists of substances exempted from REACH Registration under the new An-nexes IV and V.

Revised Annex IV

Substances are exempted under this An-nex because sufficient information is known about them that they are considered to cause minimal risk because of their intrinsic properties as far as the oils and fats industry is concerned. The revised Annex IV includes substances in Table 1 (EC, 2008).

Revised Annex V

This Annex stipulates a more general list of criteria for exemptions from REACH reg-istration. The substances listed are generic in nature. In the case of oils and fats and their products, para 9 of the Annex V (or the new Annex II), states that (EC, 2008):

‘The following substances obtained from natural sources, if they are not chemically

modified, unless they meet the criteria for classification as dangerous according to di-rective 67/548/EEC with the exception of those only classified as flammable [R10], as a skin irritant [R38] or as an eye irritant [R36] or unless they are persistent , bioacu-mulative and toxic or very persistent and very bioacumulative in accordance with the criteria set out in Annex III or unless they were identified in accordance with Article 59(1) at least two years previously as sub-stances given rise to an equivalent level of concern as set out in Article 57(f)’. The sub-stances are vegetable fats, vegetable oils, vegetable waxes, animal fats, animal oils, animal waxes, fatty acids from C6 - C24 and their potassium, sodium, calcium and mag-nesium salts; glycerol.

As Annex IV provides specific names of substances that are exempted (thus there is no ambiguity), it is not the same in Annex V, where the substances listed are mostly generic. Thus, there could be different in-terpretations of the various clauses in An-nex V. As a tool to help registrants, ECHA has come up with Guidelines for Annex V [http://guidance.echa.europa.eu/guid-ance4_en.htm].

With this revision, common oils and fats products, their fractions and basic fatty ac-ids, whether as single component or in mix-tures (unless those which are skin and eye irritants) and natural glycerol are exempted. However, the following matters are still un-resolved:

• methyl esters of fatty acids derived from oils and fats are not listed in An-nex V, and in Annex IV, only coco me-thyl esters is listed. This means that methyl esters from other oils and fats are not exempted;

• as substances derived from hydrogen-ation are not considered natural, and thus will not be exempted under this Annex. As a result, the status of fatty acids derived by hydrogenation of un-saturated acids (e.g. stearic acid from


Feature Article

TABLE 1.

EINECS No. Name of substance CAS No.232-307-2 Lecithin 8002-43-5232-442-7 Tallow, hydrogenated 8030-12-4262-998-1 Fatty acids, coco, methyl esters 61788-59-8266-948-4 Glycerides, C16-18 and C18 - unsaturated 67701-30-8269-658-6 Glycerides, tallow mono, di and tri, hydrogenated 68308-54-3270-312-1 Glycerides, C16-18 and C18 – unsaturated, mono and di- 68424-61-3288-123-8 Glycerides, C10-18 85665-33-4

hydrogenation of oleic acid) as well as hydrogenated vegetable oils are still not clear; and

• it is not certain if glycerol obtained from transesterification of oils and fats (as in the production of biodiesel) is ex-empted under the provision of Annex V.

Thus, there are inconsistencies in the ex-emption of certain substances – e.g. hydro-genated tallow and coco methyl esters are specifically listed in the exemption under Annex IV. The Technical Working Group is still pursuing these items and hopefully a fair and non-discriminatory outcome can be found. If these issues are not resolved, then there will be a need to segregate (natural) stearic acid from fractional distillation of

TABLE 2.

Item Cost factors Amount (€)1 Registration fee (joint submission) 23 2502 Registration dossier, including technical data 1 582 6163 Cost of consortia/administration fees/miscellaneous 60 000

Total 1 665 866

tion is done by a consultant who acted as the ‘Only Representatives’ for the company or through the company’s branch office (which must be a legal entity) in the EU. Joint sub-mission by several companies through a consortium can bring down the cost tre-mendously. An estimated breakdown cost of registration for a single high production volume product has been worked out to as in Table 2. (Surina, 2009).

CONCLUSION

REACH is a complicated regulation and Malaysian exporters to the EU countries have no other alternative but to register the phase-in products unless they are willing to forego that market. It is rather strange that despite several petitions by the Malaysian palm oil industry through the appropriate

vegetable fatty acids from splitting that are derived from hydrogenation, and the same for glycerol from different routes!

COST IMPLICATIONS

Registration of phase-in substances under REACH Regulation can be a costly affair. The cost may vary from one manufacturer to another depending whether the registra-

channel, the inconsistencies in the exemp-tion of palm oil products and oleochemicals, as listed in Annexes IV and V still could not be rectified. Nevertheless, the Malaysian palm oil industry, especially the oleochemi-cal industries together with the relevant agencies are preparing themselves in a very cooperative manner to face the challenges post by complying with the REACH Regu-lations.


Feature Article

B

Tilting SterilizerLoh Thim Thak*

* Besteel Berhad, Lot 9683 Kawasan Perindustrian Desa Aman, Batu 11, Desa Aman, 47000 Sungai Buloh, Selangor, Malaysia.

est Steel Berhad is redefining the future of palm oil milling processes by introducing latest technology in

ABSTRACT

sterilization known as the Tilting Sterilizer®, a patented design by Best Steel. Its operation and performance have been successfully proven with a fresh fruit bunch (FFB) filling capacity of 15 to 30 t per charge and a throughput of 10 to 21 t hr-1.

The Tilting Sterilizer® eliminates the use of substantial amount of equipment in a conven-tional palm oil mill, leading to a saving in the construction cost of a palm oil mill by 9% to 16%. The design is simple and uses convention-al technologies, thus, making it easy to operate and maintain it. With simple training the op-erators and engineers can operate the system ef-fectively with minimum downtime maximizing throughput. With fully automated features only two to three operators are required to operate the complete sterilization station.

Its compact design provides great flexibility in the planning of both new mills and retrofit-ting old ones. It can be easily incorporated into the existing mill by replacing the horizontal sterilizer. For retrofitting projects there is only minimal impact on the existing production op-eration.

The Tilting Sterilizer® offers many advan-tages over other sterilizer systems. It carries out the sterilization process similar to that of the conventional sterilizer, but has the advantage in term of faster cycle time, lower oil loss, less steam consumption, lower heat losses and less production of waste water. Filling and unload-ing at a tilted position minimizes damage to the FFB ensuring fast discharge. Even distribution of fruit bunches in the vessel and a well designed steam distribution and venting systems ensure efficient cooking is carried out at the shortest time. Pre-treatment of FFB is not necessary.

INTRODUCTION

The high palm oil price has fueled the in-vestment in more efficient palm oil process-ing technology to reduce labour dependence through automation. The biggest challenges facing oil palm mills are the efficiency of oil and kernel extraction, product quality and environmental issues.

The patented Tilting Sterilizer® is the latest technology that can offer many ad-vantages in modern mill construction, im-proved milling efficiency, reduce the invest-ment, labour and maintenance costs of palm oil mills.

The Tilting Sterilizer® offers a steriliza-tion process very similar to that of the con-ventional horizontal sterilizer but carry out in a much more efficient and economic manner. This is now a proven and accepted


technology. It has installations in Malaysia, Indonesia and Thailand.

TILTING STERILIZER®

The Tilting Sterilizer® uses pressurized steam for cooking ensuring that the sterili-zation process is performed adequately in the shortest time.

The working of the Tilting Sterilizer® is il-lustrated in Figures 1 and 2. The sterilization process is carried out in the same way as the conventional sterilizer with the vessel in a horizontal position. Once the steaming proc-ess and venting are completed, the sterilizer is tilted in an inclined position allowing the sterilized fruit bunches (SFB) be discharged out under gravity through the bottom out-let into a collection hopper. While still in its

inclined position, new fresh fruit bunches (FFB) are fed into it from the top inlet. When filling is completed the sterilizer is low-ered to its horizontal position ready for the de-aeration and steaming processes. After steaming is completed the steam valve clos-es, the exhaust and condensate valves open to depressurize the sterilizer. The doors then open, and the process is repeated. Tilting ac-tion, door locking/opening and closing are carried out by hydraulics.

The steaming cycle starts only with the

vessel in the horizontal position, This elimi-nates the possibility of sterilization taking place while in a vertical/tilted position in which case the fruit bunches lying at the bottom segment are subject to compaction due to weight of the bunches lying above, and thus have less accessibility to the pres-surized steam. Such phenomena will give rise to uneven cooking of the fruit bunch-es concerned. In the horizontal position, it also avoids the situation of the treated fruit bunches lying further down along the length getting congested at the outlet (if sterilized in a vertical/tilted position) that results in a blockage, a situation generally referred to as bridging effect.

Filling of the FFB carried out at the tilted position allows bunches to roll down from the inlet to the bottom of the vessel, less-ening impact damages that would occur if bunches are loaded with the vessel in a vertical position. Damaging of the fruit ker-nels and delicate contents causes the release of certain enzymes which have the effect to deteriorate the oil quality of the fruits. Feed-ing the sterilizer is via a hydraulic operated telescopic chute which extends into the in-let opening ensuring minimum spillage. A hydraulic operated gate controls the flow of FFB into the sterilizer. A position sensor signals the operation of the gate and is in-terlocked with the inlet door position. Steri-lized FFB bunches are discharged into an auto feed hopper in a single tilt operation,

Figure 1. Operation of Tilting Sterilizer®.

Figure 2. Tilting sterilization station arrangement.

Feature Article

see page 35


TABLE 1. TILTING STERILIZER® SPECIFICATIONS

Description Size 15 t Size 20 t Size 30 tHolding capacity (t) 15 20 30Throughput capacity (t hr-1) 12.00 16.00 21.00Shell length (mm) 6 000 6 300 7 200Diameter (mm) 2 800 2 900 3 200Estimated holding FFB (t) 20 23 32Vessel volume (m3) 40 46 64Inlet/outlet door (mm) 1 200/1 500 1 500/1 500 1 500/1 500Plate Thickness (mm) 12 12 12Material standard (vessel) JIS SS 400 JIS SS 400 JIS SS 400Design pressure (kg cm-2) 3.5 3.5 3.5Design temperature (°C) 150 150 150Insulation (50 mm the rockwool c/w 0.7 mm Al cladding)

Yes Yes Yes

Vessel design approval to Malaysia regulation (DOSH)

Yes Yes Yes

Outlet door lining Optional Optional Optional Vessel body lining Optional Optional OptionalDischarge mechanism Tilting Tilting TiltingHydraulics for tilting and doors Yes Yes YesCycle time (min cycle-1) 70 to 75 70 to 75 70 to 80Feeding time (min) 10 to 15 10 to 15 10 to 15Steaming time (min) 45 45 45Discharge time (min) <5 <5 5Oil loss in EFB (%) <2 <2 <2Unstripped fruit bunch (%) <1 <1 <1Oil loss in condensate (OLWB) (%) 0.69 0.69 0.69Oil in condensate (%) <0.4 <0.4 <0.4Steam consumption (t t-1 FFB) 0.2 0.2 0.2DOBI >2.73 >2.73 >2.73

or if required by the operator, with multi-ple discharge operation using manual op-eration. The design comes in three standard sizes with holding capacities ranging from 15 to 30 t of FFB. Specifications for the Tilt-ing Sterilizers® are shown in Table 1.

DESIGN FEATURES

Construction

The vessel is designed to ASME pres-sure vessel code and satisfies the statutory requirements of Malaysia (DOSH). For cor-rosion and erosion protection, a liner plate

Feature Article

from page 30


at the lower section of the shell and at the discharge end door is provided either in stainless or carbon steel, depending on the requirement of the customer.

Steam supply and condensate removal is through a proven design, using reliable steam joint. The design ensures that the thermal expansion load is not transmitted to the seal, and allows unrestricted differential movement between the fixed steam main and the tilting action of the sterilizer.

Three saddles ensure minimum stress at the supports. The mid saddle forms the fixed point with the two end saddles free to take the thermal movement during opera-tion.

Inlet and outlet door openings are orien-tated in a position to ensure efficient filling and discharge of fruit bunches. The off-cen-tre discharge opening and a bottom sloping plate ensure smooth discharge of the steri-lized FFB. The sloping bottom liner which is also a part of the condensate drain cham-ber wall is perforated with elongated slots which allow the flow of condensate to the drain nozzles located at the bottom of the shell. The tilted position during filling en-sures minimum impact damage to bunches, and also allows filling to be done up to its maximum capacity. The design maximum tilting angle is 55° which is more than suffi-cient to allow easy discharge of the sterilized FFB. Steam supply, condensate discharge, steam exhaust points are adequately pro-vided, and with flow distributors to ensure efficient, fast and even cooking, and fast dis-charge of condensate and exhaust steam to minimize cycle time.

Hydraulics

Each hydraulic system consists of one power pack for operation of the tilting, doors as well as FFB feeding chute func-tions. To ensure operation reliability and safety, and low maintenance requirements,

the following main features are provided:• standard size heavy duty cylinders with

bolted ends;• self-aligned bearing at rod end;• variable piston pump;• counter-balancing valve;• suction and return lines filters;• stainless hydraulic tubing and steel

braided flexible hose to cylinders;• parts can be dismantled easily for main-

tenance;• installation dimensions meet the re-

quirements of ISO 6022; and • hydraulic operation pressure < 180 bar.

Steam and Condensate Systems

Steaming is carried out with steam in-jection from the top and sides with the ves-sel in a horizontal position. Steam distribu-tion spreader at all inlet nozzles to ensure even steam distribution, ease of air removal, avoid over-cooking of bunches immediately beneath the inlet nozzle, and causing un-due erosion locally due to high speed steam flow. To ensure effective and efficient cook-ing, a steam path of not more than 1.5 m is maintained. Deaeration is carried out in an efficient manner similar to that in conven-tional sterilizer with the vessel in a horizon-tal position, and steam directed from the top of the vessel. During this moment of first steam, the other steam inlets on the sides are closed and the condensate and by-pass valve opened. Provision is made in the con-trol system for the operator to make the nec-essary adjustments to optimize the de-aera-tion time. A relatively complete air removal will not only give a higher temperature but also improve the thermal conductivity since air is a very poor conductor of heat.

After de-aeration, the condensate dis-charge valve is closed but a by-pass valve is kept open. Steam then also starts to admit from the sides to quickly build up pressure in the sterilizer. The condensate together with a small quantity of steam mixed with air continues to escape through the by-pass

Feature Article


TABLE 2. STERILIZATION PROCESS CYCLE TIME (30 t capacity Tilting Sterilizer® with steam pressure 40 psig)

Sterilization process (two peaks cycles)

Time (min)

Sterilization process (three peaks cycles)

Time (min)

Deareation 1 Deareation 11st peak 5.5 1st peak 5.52nd peak 5 2nd peak 5.5Holding 34 3rd peak 5Exhaust/purging/drain 5 Holding 30Door open interlock delay 2 Exhaust/purging/drain 5Total steaming time 52.5 Door open interlock delay 2FFB filling 15 Total steaming time 54Discharge SFB 5 FFB filling 15Total cycle time 72.5 Discharge SFB 5

Total cycle time 74

valve. During cooking at maximum pressure more air is liberated from the fruit bunches, thus keeping the by-pass valve open is nec-essary to ensure efficient removal of air and condensate. Condensate is discharged at the bottom of the sterilizer through a number of drain nozzles. A condensate channel with a perforated cover is provided along the full length of the vessel allowing efficient con-densate flow but prevent blockage by the fruits.

Operation and Control

Each set of sterilizer is fitted with a highly reliable, easy to operate and maintain PLC control system. The control system together with limit switches and transmittals con-trol the operation of the steam/condensate, hydraulic, FFB feeding, tilting and doors systems. The modes of operation consist of auto, semi-auto, manual, remote and local. The system is capable of performing:

• single or multi-peaks sterilizing;• allows operator to key in different time/

pressure settings for operation;• selection of individual or sequential or

all sterilizers to operate together;• touch screen Human Machine Inter-

face; and

• monitor current status, and view opera-tion trends.

Tilting Sterilizer® offers the fastest and safest way in sterilization of FFB. The steaming time is from 40 min to 55 min. The feeding time is greatly dependent on the FFB conveyor capacity, and would take between 10 min to 20 min. The discharge is designed to unload the entire fill in less than 10 min into a SFB hopper. A few factors affect the cycle time of the sterilization proc-ess such as steam temperature, steam pres-sure, air present, FFB bunch size, ripeness, steam supply capacity, FFB filling and SFB discharge. Operation flexibilities are pro-grammed into the system controller which allows the cooking time to be adjusted to suit the operation philosophy of each mill.

A significant advantage of using Tilting Sterilizer® is that it renders the batch sterili-zation process into a semi or full automatic continuous operation process from start to finish, making it cost-effective to automate the complete FFB handling and sterilization systems with a significant reduction in la-bour requirement. Typical operation param-eters of the sterilization cycle process using tilting sterilizer of 30 t FB capacity are sum-marized in Table 2.

Feature Article


There is further potential in improving the cycle time through optimizing the fill-ing, discharge, steaming and venting opera-tions.

IMPLEMENTATION OF TILTING STERILIZER® PROJECTS

General Arrangement

The lesser space requirement of a Tilting Sterilizer® allows flexibilities in the plant arrangement in both new plant design and upgrading of existing mills with add-on sterilizers. There will be minimum impacts on the existing mill operation as the retro-fit/upgrading work can be carried out con-currently. Figures 3 and 4, show the different in the space requirement of two designs, a space saving of 70% of the sterilization sta-

tion area is achievable using the Tilting Ster-ilizer® concept. Figure 5 shows the concept of a much simpler modern mill as compared to a conventional plant.

THE ADVANTAGES OF TILTING STERILIZER®

Sterilization in palm oil milling is the most important unit process because of its crucial influence on oil palm fruits which will affect the efficiency and effectiveness of down-stream milling process and even to the refin-ing process in producing high grade palm oil. Improper processing would lead to high free fatty acids content resulting in increase cost of refining.

The patented Tilting Sterilizer® ensures high oil quality and offers many advan-tages over other systems currently in use in the industry for the sterilization of palm oil fruits. These are:

Lower Construction Cost

Can provide saving up to 16% of the to-tal construction cost due to lesser machinery and space requirements. There is no need for FFB cages, rail tracks, transfer carriag-es, capstans, bollards, winches, overhead-cranes, hoists, cage indexer system, canti-lever bridges, tipper, pushers and tractors.

High Throughput

Short steaming time (45 min - 55 min) and fast discharge of SFB in a single pour.

High Reliability and Availability

Full automation, reduced down-time due to lesser machinery and human factors. With Tilting Sterilizer® technology, there is no oil drips. The Tilting Sterilizer® system is tidy, safe, simple and easy to use guaran-teeing a cleaner and safer working environ-ment where operators will like to work in.

Figure 3. Mill arrangement using Tilting sterilizers®.

Figure 4. Mill arrangement using Horizontal Sterilizers®.

Feature Article


Figure 5. Comparing modern mill with conventional mill.

Low Oil Loss

The oil loss is relatively low compared to the conventional type. Condensates are col-lected for oil recovery, no oil drips from fruit cages, and oil loss in EFB is less than 0.2%.

Uniform Sterilization of Fruits Quality Oil Products

Sterilization is carried out with the vessel in a horizontal position allowing the fruit bunches to be more evenly spread out thus, ensuring even steam penetration for effi-cient and even cooking with minimum or no uncooked fruits.

Lower Power Consumption and Waste Wa-ter Discharge

Tilting Sterilizer® system uses less steam and produces lesser wastewater and oil losses, thus, is more energy efficient and causing less severe impact on the environ-ment.

Easy and Safe to Operate

With much lesser machinery, it is much easier to operate than conventional hori-zontal sterilizer. Automatic operation with safety interlocks, and cleaner working envi-ronment.

Lower Operation and Maintenance Costs

Fully automated operation starting at the loading ramp, needs only two to three op-erators to operate a multiple sterilizers sta-tion. Hydraulic systems are of proven de-sign and from reputable original equipment manufacturer (OEM). There is less machin-ery to maintain.

Smooth Handling of Fresh Fruit Bunch and Minimum Damage to Fruit Bunches

The tilting design allows smooth filling/loading and unloading of the fruit bunches by having the sterilizer placed at a slanting position allowing them to slide in and out

Feature Article


TABLE 3. PERFORMANCE OF TILTING AND HORIZONTAL STERILIZERS

Description Tilting Sterilizer® Horizontal Sterilizer®

No. of peak 3 3

Sterilization time (min) <55 90 – 110

Cycle time <80 min 100 to 120 min

Oil loss in EFB <2% <3.44%

Condensate oil loss OLWB % 0.69% <0.80%

Oil in condensate <4% <4%

Condensate oil loss (oil to NOS) %

10.46% <9.76%

Oil loss recovery Low, and oil in condensate is recovered separately

Low, oil drips onto floor

Throughput 20 t hr-1 (80 min) 11 t hr-1 (110 min)

Unstripped bunch <1% <2%

Operation flexibility 1 to 3 peaks 2 to 3 peaks

Steam consumption 0.2 t t-1 0.30 – 0.45 t t-1 FFB

Heat loss Minimal High (large vessel)

Number of equipment Less More

Number of operator 2 to 3 4 to 5

Cost of investment (new plant) 9%-16% lower than conventional mills

High

Maintenance requirement Only scheduled maintenance of hydraulics

Many plant items to be maintained

Cost of operation Low High

General operation and working environment

Simple to operate, sager and cleaner environment

Complex and many human dependent factors, oily working floor

Delays and downtime Minimal Transferring of cages

Waste water and recovery Minimum condensate More steam condensate

Upgrading plant Small space required provides many flexibilities in arrangement

Difficult to retrofit, need more space

Automation Fully automation from filling of FFB to unloading of SFB

Difficult to complete automation

Feature Article

via special designed openings. No need to fill water prior to FFB feeding. Less dam-aged fruit equates to lower oil loss and bet-ter oil quality.

Lesser Space Required

A saving of 70% in the sterilization station area is achievable with the use of Tilting Sterilizer®.

PERFORMANCE OF DIFFERENT TYPE OF STERILIZERS

A comparison of the performance between the tilting, vertical and horizontal sterilizers are given in Tables 3 and 4.

TILTING STERILIZER® PROJECTS

A 15 t hr-1 FFB Tilting Sterilizer® was initially installed in Tee Teh Palm Oil Mill at Keratong


TABLE 4. PERFORMANCE OF TILTING AND VERTICAL STERILIZERS

Description Tilting sterilizer Vertical sterilizer

Cycle time < 80 min Longer. SFB discharge by auger, need to operate cushioning water system (if used)

Unstripped bunch < 1% < 3%*

Oil loss in EFB < 2% < 6%*

Oil in condensate < 0.4% Higher, due to higher compaction pressure on fruits laying at the bottom

Maintenance requirement

Only scheduled maintenance of the hydraulics

Added maintenance of auger, and water system (if used)

Cost of operation Low Fair (some use water for cushioning)

General operation and working environment

Simple to operate Added tasks like water filling system and auger discharge

Note: *Based on technical specification issued by FELDA for Air Tawar POM, Kota Tinggi (Ref: Tender No. FPI-137/2009 [FH-376/09]).

TABLE 5. TILTING STERILIZER® PROJECT LIST

Location Client Unit x FFB capacity

Status Remarks

Pahang, Malaysia Tee Teh Palm oil Mill

3 x 30 t Operation since September 2009

Replacement of horizontal sterilizers

Pelambang, Indonesia

PPT Pinago Utama

2 x 20 t Operation since July 2009

Add-on to existing horizontal sterilizers

Sabah, Malaysia Berkat Sertia Sdn Bhd

2 x 30 t Installation Phase 1 replacement of horizontal sterilizers

Sabah, Malaysia Berkat Sertia Sdn Bhd

2 x 30 t Construction Phase 2 replacement of horizontal sterilizers

Chumporn, Thailand

CPI 4 x 30 t Operation since March 2010

Replacement of horizontal sterilizers

Perak, Malaysia FELCRA 3 x 20 t Construction Change from using vertical sterilizers

Chumporn, Thailand

Chumporn SP Palm Oil Ltd

4 x 30 t Engineering New mill

Feature Article

in 2007. It performed better than envisaged and subsequently the owner placed an order for 3 x 30 t units. In PT Pinago mill, 2 x 20 t units are installed as add-on to the existing horizontal sterilizers. They have

been in operation since July 2009. Other units ordered and are at various stages of construction are shown in Table 5. Among the big clients are FELCRA and Chomporn Palm Oil Industry Ltd of Thailand.


Feature Article

CONCLUSION

The Tilting Sterilizer® is a proven technol-ogy for the way forward in more efficient, lower investment cost and environmental-friendly palm oil milling process.

The brilliant design of the Tilting Steriliz-er® eliminates the use of substantial amount of equipment in a conventional palm oil mill, leading to an overall lowering in the construction cost of palm oil mill by 9% to 16%. The design is simple making it easy and cost less to operate and maintain. With fully automated features only two to three operators would be required to operate the complete sterilization station.

Its compact design provides great flex-ibilities in the arrangement design of both new mills and retrofitting. It can be easily

incorporated into the existing mill arrange-ment for horizontal sterilizer replacement and/or capacity expansion projects. For ret-rofitting projects, the on-going construction work would have minimal impact on the existing production operation of the mill.

Tilting Sterilizer® offers many advan-tages over other sterilizer systems. It has the advantage in term of faster cycle time, lower oil loss, oil loss in condensate is recoverable, consuming lesser steam, lower heat losses and producing lesser waste water. Filling and unloading at a tilted position minimiz-es impact damage to the FFB thus, ensure fast discharge. It allows even distribution of fruit bunches in the vessel. The well de-signed steam distribution and venting sys-tems ensure efficiency cooking is carried out at the shortest time. Pre-treatment of FFB is not necessary.


T

Feature Article

Mongana Basics: Part 20 – Processing of Nut**N Ravi Menon*

* Malaysian Palm Oil Board, P. O. Box 10620, 50720 Kuala Lumpur, Malaysia.

** Continued from p. 33 of Palm Oil Engineering Bulletin Issue No. 93.

GENERAL

The Cake

he extraction of oil, regardless of the process used, leaves a cake con-sisting of nuts and fibre. The latter

is, in fact, composed of fibrous filaments and cellular debris. The composition of the cake varies with the extraction process and the type of fruit from which it is derived.

It has been mentioned in Chapter 3 of Mongana Report (1953) that the cake compo-sition varies over very wide limits from a ratio of nuts to fibre of 5 to 1 for the Congo type dura fruit, 1 to 1 for tenera fruit.

In addition to variations in the composi-tion of the cake inherent in the fruit origin, important differences in the analysis and the morphology of the fibre are observed depending on the extraction process. More-over, the type of fruit affects the size distri-bution of nuts.

The analysis of the fibre shows that the oil content on dry basis can reach 30% or be as low as 3% to 4%, moisture content can range between 35% to 55% and that, in ad-dition, the size of the fibrous filaments and

the proportion of cellular debris in the fibre can vary widely.

For these reasons, a large number of vari-ables or parameters have to the considered in the study of the processing of nuts.

In this article, we shall examine the fol-lowing fundamental operations:

• separation of fibre and nuts;• nut cracking;• separation of kernels from the cracked

mixture; and• kernel drying.

Besides these fundamental operations, a number of auxiliary treatments are per-formed. Their objective is to make the op-eration easier or to improve upon it.

Before going into the study of this funda-mental operation, let us examine the effect on the cake composition of the extraction process and the type of fruit.

EFFECT OF THE EXTRACTION PROCESS

Wet Extraction Process

• The fibre does not contain large amount of cellular debris. The ratio of nuts to fibre is high.

• The fibre has high water content and relatively low oil content.


Feature Article

Centrifugal Extraction Process

• The fibre contains a high proportion of cellular debris.

• The ratio of nut to fibre is normal.• The fibrous filaments are long.

The Discontinuous Press Extraction Process

• The fibre contains less cellular debris than that derived from the centrifugal extraction process, more, however, than that resulting from wet extraction.

• The ratio of nuts to fibre is higher than that pertaining to centrifugal extraction.

• The fibre is drier than that of centrifug-es and the oil content is lower. The fibrous filaments are long.

Continuous Press Extraction Process

• The fibre has a low cellular debris con-tent.

• The fibre is dry and has a low oil con-tent.

• The ratio of nuts to fibre is higher than that of centrifugal extraction.

• The fibrous filaments are shredded.

EFFECT OF THE TYPE OF FRUIT

Dura (natural palm grove)

• High ratio of nuts to fibre.• Short fibrous strands generally with

high oil content.• Large size nuts with thick shell.• Numerous multi kernel nuts.

Tenera

• Low ratio of nuts to fibre.• Long fibrous strands generally with

lower oil content.• Small size nuts with thin shell and a tuft

at one end.• Multi kernel nuts seldom encountered.

• Loose fruit: very low impurities content, therefore high nuts to fibre ratio.

• Bunch: high proportion of trash and im-purities, therefore low ration of nuts to fibre.

It is of interest to provide data for some of the factors listed above.

The Average Length of Fibres

Tenera fruits have longer fibre. Figure 1 shows a size distribution curve for the two types of fruit.

The Fibrous Matter Content of the Fibre

In the laboratory, dry, oil extracted pulp is found to contain a proportion of fibrous matter raging from 24% to 30%. The accu-rate determination is rather difficult. After a number of unsuccessful attempts to use gravity separation and fractionated dis-solution (nitric acid, sodium hydroxide at Schweitzer reagent), a method of mechani-cal separation by screening under a flow of water was adopted.

In the course of industrial extraction of oil from the pulp, it may be observed that more cellular debris than fibrous matter pass over into the crude oil. Table 1 gives an indication of the proportion of fibrous strands in the extracted fibre and shows that the propor-tion is higher after extraction, particularly in the case of the wet process. For wet ex-traction, after repeated and thorough wash-ing, it is possible to reach as much as 90% of fibrous matter. Continuous pressing, when applied to fruit with a high proportion of tenera, also leads to high percentage of fi-brous matter (approximately 70%). To a cer-tain extent, the ability of the fibre to cake up depends on the ratio of fibrous matter to the fibre. Beyond 70% of fibrous material, that is less than 30% of cellular matters, the fibre no longer cakes up in the normal conditions of oil and moisture content.


Feature Article

Figure 1. Proportion of fibrous strands of various length in dura and tenera fruits.

TABLE 1. RATIO OF FIBRE TO TOTAL CELLULOSIC MATERIAL IN THE CAKE IN RELATION TO THE TYPE OF FRUIT AND TO THE EXTRACTION PROCESS

Fruit Wet process

Centrifugal Manual hydraulic press

Continuous press

P.G.TxTDxP

76--

495757

546166

516972

DURA

TENERA


Feature Article

Oil Content of Fibrous and Cellular Debris

The oil retention power of fibrous matter and cellular debris from a single sample of fibre is very different. The latter retains a significantly higher amount of oil. This oc-currence may be explained by difference in the ratio of surface to volume for the two constituents. The ratio is higher in the case of cellular debris (absorption).

A few results are given in Table 2. They are the averages of a series of tests with high variability. The fact that the oil content of cellular debris is higher than that of fibrous matter is clearly apparent from the compari-son between O/FM (oil on fibrous matter) and O/CD (oil on cellular debris).

Nut Grading

The grading of nuts is carried out on screens with round perforations. Tables 3, 4 and 5 give the following information in rela-tion to nut size as defined by the diameter.

• The number of nuts in each of the class-es.

• The ration of the number of nuts in each class the total number of nuts subjected to grading.

• The weight of nuts in each of the class-es.

• The ration of the weight of the nuts in each class to the total weight of nuts.

• The nut average weight in each class.

• The average thickness of the shell of the nuts in each class.

• The kernel average weight in each class.• The ratio of kernel to nut in each class. • The ratio of the weight of kernels in

each class to the total weight of kernels.

In these grading test, the kernels are con-sidered to be commercially dry (approxi-mately 7% moisture content).

The examination of the grading results shows clearly the difference between the three types of nuts. A few typical results are given in Table 6 (vide also Figure 2).

It is of interest to plot on a graph the thick-ness of shell against the diameter of nut for the three types of fruit under study (Figure 3).

For an identical diameter, the nuts of DxP bunches have a thinner shell than those of the dura nuts (palm grove) in the range of small diameters. The reverse is true for the area of large diameters. In other words, the increase in shell thickness follows more or less a linear relationship in the case of the P.G. nuts but the representative curve clear-ly presents on inflexion point in the case of DxP nuts. This inflexion point is situated approximately at 17 mm to 18 mm. The nuts of diameter comprised between 17 mm to 18 mm and 20 mm have an average shell thickness of 3.1 mm whereas those with a diameter slightly lower than 17 mm have an average shell thickness of 1.8 mm.

TABLE 2. EFFECT OF THE EXTRACTION PROCESS ON THE OIL CONTENT OF THE CONSTITUETNS OF FIBRE

Fruit

Wet process Centrifugation Manual hydraulic press

Continuous press

OF

OCD

OF

OCD

CF

OCD

OF

OCD

P.G.TxTDxP

14--

22-2

201531

332340

161518

212631

1665

252017

Note: F = fibre. CD = cellular debris.


Feature Article

TABLE 3. SIZE FREQUENCY DISTRIBUTION OF NUTS FROM PALM GROVE FRUITS

Diameter of nuts (mm)

Number of nuts

% of the total number

Weight of nuts

(g)

% of the total weight

Nut average weight

Shell thickness

(mm)

Kernel average weight

(g)

% of kernel to nut

% weight of kernel to total

weight

10111213141516171819202224262830323436

14

10173848

13513917024251154136826050301232

00.20.40.71.51.95.25.46.69.4

19.721.014.310.11.01.20.50.10.1

0.75

162580

105420505765

1 2003 1004 1803 4803 030

7104852256855

00.10.10.10.40.62.32.74.16.5

16.922.618.816.43.802.61.20.40.3

0.71.01.61.52.12.23.13.64.55.06.17.79.5

11.614.215.116.722.027.5

-1.21.31.61.71.41.92.32.42.93.53.94.14.64.64.74.5--

-0.340.470.520.530.640.710.780.900.921.001.141.24-

2.35----

-272935252923222018161513131313---

-0.040.170.310.711.103.404.005.457.70

17.7022.4016.114.003.202.251.040.320.25

Total or average

2 581 100 18 455 100 7.15 - - 15.2 100

TABLE 4. SIZE FREQUENCY DISTRIBUTION OF NUTS FROM TxT FRUITS


Number of nuts


Weight of nuts

(g)


Nut average weight

Shell thickness

(mm)

Kernel average

weight (g)

% of kernel to nut

% weight of kernel to total

weight

<10101112131415161718192022242628303234

141878

210212415331616552328440561383196111181631

0.30.41.74.74.79.27.3

13.712.37.39.7

12.38.54.42.50.40.30.10

81470

27032774072716.7

1 7551 2451 9953 1662 7001 754

11 2302502455927

0.050.10.41.51.84.14.08.89.66.8

11.017.414.89.76.81.41.30.30.1

0.70.80.91.31.51.82.22.63.23.84.55.67.09.0

11.014.016.319.627.0

0.80.80.91.00.91.11.21.31.82.02.23.13.43.84.44.55.55.55.5

0.230.290.400.510.580.630.660.750.740.840.871.101.001.081.171.351.321.341.34

-212333323234302222212117161514131414

-0.10.42.32.76.06.5

12.29.87.0

10.710.711.77.14.70.90.80.20.1

Total 4503 100 18 189 100 4.0 - - 20.6 100


Feature Article

TABLE 5. SIZE FREQUENCY DISTRIBUTION OF NUTS FROM DxP FRUITS


Number of nuts


Weight of nuts

(g)


Nut average weight

Shell thickness

(mm)

Kernel average

weight (g)

% of kernel to nut

% weight of kernel to total weight

< 1011 – 1212 – 1314 – 1516 – 1718 – 1920 – 2122 – 2324 – 2526 – 2728 – 29

30

2514269770948319111974301521

1.05.7

28.028.519.47.74.83.01.20.60.10.0

12206879

124112537616575323461712419

0.23.4

14.420.320.512.510.88.75.72.80.40.3

0.51.41.31.72.64.05.57.2

11.511.412.119.0

0.91.01.31.31.83.13.74.24.54.54.48.5

0.190.300.460.620.680.620.760.780.690.77--

36434039342428151113

--

0.24.8

19.023.09.99.94.22.11.00.10.0

Total 2 488 100.0 6 101 100.0 2.5 - - 31 100.0

TABLE 6. GRADING ANALYSIS OF THREE TYPES OF NUTS

Palm grove TxT DxP

Nut average weight (g)% ratio of kernel of nutPercentage of nuts with shell less than 2 mmThick: (% by weight) (% by number)

7.1515.2

3.69.9

4.0520.6

30.354.3

2.4531.0

58.882.6

TABLE 7. SIZE FREQUENCY DISTRIBUTION OF KERNELS FROM PALM GROVE NUTS

Nut diameter

(mm)

Number of kernels of the following diameter Total

7 8 9 10 11 12 13 14 15 16 17 18 19

111213141516171819202224262830323436

110301200100------

3046823507330-----

0844789542

102100100

-16

111749212519102818901420

-01

1011273133738958522426420

--00

11273133738958522426420

----0

102117498667483912722

-----164

2085

1271015413512

-----010

113372623446

1000

------002

153157654

13560

--------0

157

142608110

---------403

1305210

---------000112220

410153454

120120128215383428389282164945224

Total 9 44 65 221 265 412 351 421 233 198 72 28 8 2 318Kernels


Figure 3. Thickness of shell in relation to the nut diameter.

Figure 2. Size frequency diagram for DxP, TxT and P.G. nuts.

Feature Article

% n

uts p

assi

ng th

roug

h th

e pe

rfor

atio

ns


It should not be inferred however that an almost quantitative separation of dura and tenera nuts is possible by simple screening. The thicknesses given above are the average result of 20 to 50 measurements and the in-dividual variations are large.

For the P.G. and TxT nuts, the separa-tion into the two varieties is of no interest but in the case of DxP fruit, the separation has been investigated with a view to re-move the shell from the cracked mixture by a pneumatic process. It has been observed that screening of DxP nuts through 15 mm perforations allows more than 99% of the nuts to pass through. By comparing vari-ous shapes of perforations, it has been noted that the retention on a screen with circular perforations of 15 mm diameter is about the same as that recorded with 14 mm square perforations. In oil mills, the screens used for nut grading have oblong perforations. In that case, the results of grading are very different. This is due of the fact that 86% of the nuts are flat and they therefore pass through oblong perforations using the small dimension which is equal to the diameter of circular perforations which do not allow the passage.

TABLE 8. SIZE FREQUENCY DISTRIBUTION OF KERNELS FROM TxT NUTS

Nut diameter

(mm)

Number of kernels of the following diameterTotal

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

<101011121314151617181920222426283032

202001000000000000

453509452320400000

04

3363223218212

147

131353000

114

9550463067502212221668000

001

29101176759494686245301117240

--0 2

1310911817811673

13690483026410

---019

4922616863

124189983117513

----031

41695869

109843216121

-----011

16314878

1006013132

------1100

1730453813342

------00002

26174335431

----------0119

11542

-----------0011120

-------------00001

----------------1-

71043

19418738529763451733247960345626616026259

Total 5 46 250 430 809 944 984 486 354 152 131 33 5 0 1 4 630

Kernel Grading

In addition to the grading of nuts, the grading of kernels obtained from the cracked mixture was also carried out. The size frequency diagram is shown in Figure 4.

As for nuts, a Table 10 gives the percent-age ratio of kernels of various diameters to the total number of kernels. It is to be noted that out of the 10 000 kernels sub-jected to screening for the preparation of the four tables given (Tables 7, 8, 9 and 10), only one was found to be retained by a 20 mm perforation (circular). It has not been possible to carry out grading tests on nuts other than those originating from the Mon-gana area. If this were found to be a general features throughout the Congo, it would be worthy of interest and would be of practical usefulness since it would make it possible to sort out from kernels ready for packing the whole uncracked nut of diameter larger than 20 mm (case of small oil mills where the removal of uncracked nuts is often un-satisfactory).

Feature Article


Feature Article

TABLE 9. SIZE FREQUENCY DISTRIBUTION OF KERNELS FROM DxP NUTS

Nut diameter

(mm)

Number of kernels of the following diameterTotal

5 6 7 8 9 10 11 12 13 14 15 16 17 18

<10101112131415161718192022242628

4000000000000000

81250201461101000

446450

128

171754121000

321930

97 35206415111249320

01

1031297671975222512139620

-00

3112014086

11223182030101150

---0

197281

1333420213019921

----09

346830191632261120

-----00

1621989

11822

-----0-82

12625240

-------000120200

----------030100

-----------00010

------------0000

1980

1533433473312584971581991981279152203

Total 4 41 162 389 670 606 441 247 86 41 5 3 1 0 2 696

Figure 4. Size frequency diagram for kernel from D x P, T x T, and P.G. fruits.

TABLE 10. SIZE FREQUENCY DISTRIBUTION OF KERNELS COMPUTED AS PERCENTAGE OF THE TOTAL NUMBER OF KERNELS

Kernel diameter Total5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

P.G.TxTDxP

00

0.2

00.11.5

0.41.06.0

1.95.414.4

2.89.324.8

9.517.522.5

11.520.416.4

17.821.29.1

15.210.53.2

17.87.61.5

10.13.30.2

8.52.80.2

3.10.80.0

1.20.10

0.300

000

100100100


Datasheet

APPROVED OIL PALM-BASED RENEWABLE ENERGY PROJECTS IN MALAYSIA

Developer Location Grid Load

Biomass

Bumibiopower Pantai Remis 10 EFBTSH Bio-energy Tawau 10 EFBAlaf Ekspresi Tawau 10 EFBNaluri Ventures Pasir Gudang 9 EFBSeguntor Bioenergy Sandakan 10 EFBKina Biopower Sandakan 10 EFBMHES Asia Bhd Serting, Negeri Sembilan 10 EFBSunquest Sdn Bhd Port Dickson 5 EFBKalansa Energy Sandakan 5 EFBBell Eco Power Batu Pahat 1.7 BiogasEko Synthesis Kluang 10 EFBFELDA Serting Hilir, Jempol 0.5 BiogasAchi Jaya Segamat 1.25 BiogasCash Horse Sdn Bhd Sandakan 10 EFBBell Biopower Linggi 1.4 EFBBell Green Power Linggi 1.0 EFBBell Eco Power Batu Pahat 10 EFBFTJ Biopower Jengka 10 EFBMaju Intan Biomass Teluk Intan 10 EFBAgni Power Sdn Bhd Bera 10 EFBGarisan Rlika Kota Tinggi 10 EFBRapid Tech Systems Raub 10 EFBEco Biomass Power Lahad Datu 20 EFBBell RE Power Sdn Bhd Yong Peng 10 EFB


ADVERTISEMENTue to the increased cost of printing, the advertisement rate is RM 700 per issue for an A4 size page of black and white, whereas the cost for colour is RM 900. One year of complimentary Vendor’s List advertisement for every one page A4-size colour or black & white advertisement. Advertisers are required to submit to us either their own black and white artwork or colour separation films. Cheque should be made payable to the ‘Malaysian Palm Oil Board’. If you have any queries, please contact the following at MPOB.

Tel: 03-87694400 Fax: 03-89262971

Dr. Lim Weng Soon ext: 4406 • N. Ravi Menon ext: 4467 • Lim Soo Chin ext: 4676 E-mail: [email protected]

Advertising Schedule for MPOB Palm Oil Engineering Bulletin

Issue Quarter Deadline forRegistration

Deadline forSubmissionof Artwork

95 Apr - June 2010 30 Apr 2010 30 May 201096 July - Sept 2010 30 July 2010 30 Aug 201097 Oct - Dec 2010 31 Oct 2010 30 Nov 201098 Jan - Mar 2011 30 Jan 2011 30 Nov 2011

REPLY-SLIP

Dr. Lim Weng Soon/Ir. N. Ravi MenonEngineering and Processing Division Palm Oil Engineering BulletinMPOB6, Persiaran InstitusiBandar Baru Bangi43000 Kajang, Selangor

PALM OIL ENGINEERING BULLETIN ADVERTISEMENT – FULL PAGE ADVT.

1. We confirm our intention to advertise in the MPOB Palm Oil Engineering Bulletin.

Company:

Address:

E-mail: Tel. No.: Fax No.: Contact Person: Issue No.:

2. The artwork is attached/will be sent on for your further action.

3. Please find enclosed *crossed cheque No.: for RM ( ) being payment for the advertisement fee.

4. Thank you.

(Signature and Date) (Company chop)

D

MPO

B P

ALM

OIL

EN

GIN

EERI

NG

BU

LLET

IN -

FULL

PA

GE

# * Made payable to ‘MALAYSIAN PALM OIL BOARD’.


MPO

B PA

LM O

IL E

NG

INEE

RIN

G B

ULL

ETIN

- V

END

OR

’S L

IST

ollowing a decision by the Editorial Board to further increase the role of Palm Oil Engineering Bulletin to serve the industry better, a new addition called Palm Oil Mill Vendor’s List has been introduced similar to Telekom Yellow Pages to assist mill engineers to know where to source materials or services pertaining to the industry. In order to make this useful, we need the co-operation of the mill engineers/managers to persuade their vendors to advertise in the Vendor’s List for a nominal fee of RM 100/year (four issues). If you have any queries, please contact the following at MPOB.

Tel: 03-87694400 Fax: 03-89262971

Ir. Ravi Menon ext. 4467 or e-mail: [email protected] Ms. Lim Soo Chin ext. 4676 or e-mail: [email protected]

REPLY SLIP

Dr. Lim Weng Soon/Ir. N. Ravi MenonEngineering and Processing Division Palm Oil Engineering Bulletin AdvertisementMPOB, 6, Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia.

We wish to advertise in the MPOB Palm Oil Engineering Bulletin Vendor’s List

Company: Issue No.:

Contact Person: H/P:

Address:

E-mail: Tel: Fax:

Please find enclosed a crossed cheque No.: Bank:

for RM: (Ringgit Malaysia)

drawn in favour of MALAYSIAN PALM OIL BOARD

Please select the headings from the list given below (not more than five headings) under which you wish to advertise.

Air filters/dryersAir separatorsBearings/belts/bushesBiomass/bio-compost/productsBoiler spares/control/othersBoiler suppliers Bunch crushersCastingsCleaning - generalCivil engineeringCondition monitoringControl/automation/sparesConveyors/chains/elevatorsConsultancy services/certificationDiesel eng./services/sparesDynamic balancing Electric motors/systemsExpansion jointsFabrication works Fans

Signature:

Name:

Date: Company chop

ADVERTISEMENT

F

#

Filter press/materialsFluid control system/couplingsGaskets/packing materials/sealsGear boxesHardware Hydraulic systems/services/spares Laboratory analysisLaboratory equipmentLubricantsMill machinery/sparesMiscellaneousNut crackersOil recovery systemsPalm kernel oil crushing plantPollution control/safety systemsPressure vesselsPumps/services PurifiersRenewable energyScrew press/parts

ScrubbersSludge separators/decantersSteam turbines/generator/sparesSterilizer/partsStorage silosVacuum pumpsValves/seatsWaste water treatment Water treatmentWelding equipmentsWeighing machines/sparesWheel loaders/spares


From:

Address:

Question/Comment:

Signed: Date:

(We have enclosed this form to assist you in sending to us any questions or comments)

#


ChairmanThe Editorial BoardPalm Oil Engineering Bulletin Malaysian Palm Oil Board P. O. Box 1062050720 Kuala LumpurMalaysia

STAMP

Documents

LEMBAGA MINYAK SAWIT MALAYSIA MALAYSIAN PALM …palmoilis.mpob.gov.my/publications/POEB/poeb94.pdf · LEMBAGA MINYAK SAWIT MALAYSIA MALAYSIAN PALM OIL BOARD ... It has been a year