1.       PENDAHULUAN
Kelapa sawit merupakan komoditasperkebunan yang telah di usahakan di Indonesia secara komersial sejak 1911, komoditas kelapa sawit mempunyai peran yang cukup besar terhadap perekonomoian nasional maupun daerah terutama dalam hal perolehan devisa  penyediaan lapangan kerja dan peninkatan pendapatan . Pada awal perkembangannya, perkebunan sawit hanya di usahakan  oleh perkebunan besar swasta dan milik Negara , tetapi sejak awal 80an mulai di kembangkan  perkebunan kelapa sawit rakyat (PIR). Saat ini komposisi ke pemilikan perkebunan kelapa sawit di Indonesia adalah 17% perkebunan besar milik Negara, 50% perkebunan besar swasta dan 33% perkebunan rakyat swadaya.
                Pengusahaan perkebunan kelapa sawit sebetulnya cukup menguntungkan dibandingkan dengan komoditas lainya. Namun, keadaan perkelapa sawitan Indonesia sering tidak menentu terutama karena harga crude palm oil (CPO) di pasar internasional yang berfluktuasi tajam. Selain itu pada saat produksi puncak, banyak tandan buah segar (TBS) yang tidak dapat di olah karena kapasitas pabrik yang terbatas. Sitasi ini dapat menyebabkan petani kelapa sawit, terutama petani rakyat suwadana dan perkebunan besar sekala kecil dan menengah mengalami kerugian sehingga dapat mengganggu pengembangan perkebunan kelapa sawit secara keseluruhan. Oleh karena itu perlu di cari upaya untuk menaikan nilai tambah kelapa sawit melalui suatu proses yang sederhana, murah serta berwawasan lingkungan sehingga pendapatan petani dapat meningkat.

2.  MASALAH  PEMASARAN TBS
                Dalam agro industri kelapa sawit, buah harus di panen apabila sudah masak dengan toleransi +/-5 hari dari masak optimum dan harus di olah selambat-lambatnya 24 jam setelah panen. Apabila sarat ini tidak di terpenuhi maka kualitas dan kuantitas minyak yang dihasilkan akan turun sehingga  perkebunan sangat tergantung  pada PKS.
                Masalah utama yang dihadapi produsen TBS adalah volume yang dapat di terima oleh PKS tidak konstan sebagai akibat dari fluktuasi produksi TBS dari kebun milik PKS sendiri atau pihak yang mempunyai ikatan kerja dengan PKS. Secara teknis ukuran PKS di tetapkan berdasarkan produksi bulanan maksimum  dari konsensi  areal baik berupa kebun sendiri maupun kebun lain yang mempunyai ikatan pengolahan dengan PKS. Ukuran PKS yang umum di gunakan adalah kapasitas  20, 30, 60, 90 dan 120 ton TBS/jam. Berdasarkan distribusi produksi bulanan, pada September, Oktober  dan Desember , PKS di Sumatra utara misalnya praktis tidak dapat menerima buah di luar konsensi karena produksi buah dari kebun sendiri  yang melimpah. Sebaliknya pada bulan Januari – April, PKS sangat membutuhkan buah dari luar konsensi karena buah dari dalamkonsensi hanya mampu memasok kurang dari 70% kapasitas. Pada Mei-Juli, PKS juga memerlukan buah dari luar konsensi meskipun tidak mendesak seperti pada Januari-April.
                Perkebunan Rakyat eks-proyek PIR, mempunyai ikatan dengan PKS sebagai inti sedangkan perkebunan rakyat swadana, UPBSK (Usaha Perkebunan Besar Sekala Kecil) dan UPBSM (Usaha Perkebunan Besar Sekala Menengah) umumnya tidak, sehingga tidak ada kewajiban PKS untuk menampung produksi mereka. Oleh sebab itu posisi tawar menawar (bargaining position) dari petani swadana, UPBSK dan UPBSM menjadi sangat lemah pada bulan Agustus-Desember. Dalam bulan bulan tersebut, mereka akan sulit dan bahkan  mungkin tidak dapat menjual TBS nya. Dalam keadaan demikian harga TBS di pasar akan lebih rendah dari semestinya.

3.  PABRIK KELAPA SAWIT MINI
                Berbagai permasalahan diatas telah mendorong  digunakanya teknologi tepat guna yang terpadu yang khusus dirancang untuk petani kelapa sawit atau kelompok tani dengan total luas area kebun 200-300ha. Teknologi terpadu yang di kembangkan  mempunyai cirri:

    Sederhana
    Murah
    Bernilai tambah
    Berwawasan lingkungan

Dengan memperhtikan keadaan tersebut, perlu di upayakan peningkatan pendapatan petani kelapa sawit, UPBSK dan UPBSM. Salah satu alternatifnya adalah dengan melakukan pengolahan TBS sendiri. Dengan Cara demikian petani kecil swadana, UPBSK dan UPBSM tidak terlalu bergantung pada PKS besar Sehingga nilai tambahnya dapat di nikmati.
PKS mini hanya memerlukn tenaga kerja 6 orng/shift termasuk pengawas dan tenaga teknik, memanfaatkan cangkang, seratmesokarp dan tandan kosong sebagai bahan baker, sangat mudah di oprasikan dan hanya memerlukan lahan seluas +/-2.500 m2 dengan bangunan sederhana seluas 250 m2 . Rancangan PKS mini cukup sederhana sehingga pemeliharaanya mudah dan dapat di lakukan oleh teknisi dengan kualifikasi STM.
a.       Deskripsi PKS mini
PKS mini terdiri dari 19 unit peralatan pengolahan yaitu:

    Satu unit boiler kapasitas 600 kg uap/jam.
    satu unit sterilizer kapasitas 1 ton tandan buah segar (TBS) per jam.
    Satu unit mesin penebah /threser.
    Satu unit Fruit elevator.
    Satu unit digester.
    satu unit screw press mini kapasitas 1 ton TBS/jam.
    Satu unit sand trap.
    Satu unit Vibrating Screen.
    Satu unit crude oil tank c/w pump.
    Satu unit tangki klarifikasi.
    Satu unit tangki penampung minyak kapasitas 25 ton CPO.
    Satu unit cake breaker confeyor.
    Satu unit fiber separator.
    Satu unit nut confeyor  c/w nut bin.
    Satu unit ripple mill kapasitas 500 kg biji/jam
    Satu unit genset 80 KVA
    Satu paket instalasi listrik.
    Satu paket piping dan valves.
    Satu paket pemasangan, uji coba dan training.

b.      Mutu CPO
Minyak sawit yang di hasilkan mempunyai mutu sesuai standar perdagangan Indonesia, yaitu asam lemak bebas (ALB) < 2,5 %, kadar air dan kotorn < 0,4 %, serta rendemen 20 %.

4. HAL-HAL YANG PERLU DI PERHATIKAN
a. Kualitas bahan baku.
                Pada kajian financial di asumsikan bahwa rendemen minyak yang akan di peroleh adalah 20%. Rendemen sebesar 20% atau lebih hanya dapat di capai apabila kualitas buah sawit yang di olah adalah cukup baik  dan berasal dari industri kelapa sawit Indonesia  mempunyai peluang yang sangat baik dan berasal dari buah tenera (DxP). Pada beberapa perkebunan sawit rakyat, kadang-kadang terjadi kontaminasi dengan buah jenis Dura atau Pisifera kibat dari penanaman dengan benih yang di ragukan keaslianya. Konsekuensinya, rendemen minyak tidak akan dapat mencapai 20% sehingga secara financial tidak akan layak. Berbeda dengan PKS konvensional, pengaruh buah non Tenera pada PKS mini sangat besar terhadap rendemen karena buah yang diolah hanya 20 ton/hari.
b. Lokasi PKS mini
                PKS mini dirancang untuk daerah “remote”, yaitu daerh yang jauh dari PKS konvensional sehingga ongkos angkut TBS ke PKS konvensional bias di pangkas. Untuk kebun rakyat yang lokasinya dekat PKS konvensional serta tidak ada masalah dengan pemasaran  TBS, pendirian PKS mini tidak di sarankan. Demikian juga untuk Kebun PIR yang masih mempunyai ikatan kontrak dengan kebun inti.
c. Aspek perijinan
                Ijin Untuk pendirian kebun dan PKS telah di atur dalam SK Menteri  pertanian No 357  tahun 2002. Pada SK tersebut disebutkan bahwa semua usaha perkebunan  harus menjalin mitra dengan rakyat dalam berbagai bentuk kemitraan  yang saling menguntungkan. Untuk PKS mini, SK tersebut juga berlaku sehingga diharapkan tidak akan terjadi hal-hal yang tidak diinginkan dengan keberadaan PKS mini.
d. Pemeliharaan PKS
                PKS mini dirancang dengan konsep kesederhanaan dalam pemeliharaanya sehingga diharapkan pemeliharaan PKS dapat dilakukan oleh tenaga dengan kualifikasi setingkat dengan STM. Keberadaan PKS mini juga diharapkan dapat merangsang perkembangan bengkel lokal untuk pemeliharaan PKS.
e. Aspek pemasaran CPO
                Pemasaran CPO serta produk-produk olahanya adalah kunci dari kesuksesan PKS mini. Pengelolaan PKS mini harus menjalin kerjasama dengan pembeli atau pemakai langsung sehingga pemasaran CPO hasil produksi PKS mini terjamin. Hal ini sangat penting karena PKS mini hanya memiliki tangki CPO yang dapat menampung produksi untuk 5 hari, sehingga jadwal pengiriman CPO harus terencana dengan matang.

5. KESIMPULAN
                Industri kelapa sawit Indonesia mempunyai peluang yang sangat baik untuk berkembang. Tehnologi industri kelapa sawit mini  yang ramah lingkungan, sederhana dan mudah di oprasikan, merupakan jawaban dalam upaya meningkatkan kesejahtraan petani.

Introduction

This is what to and a how to article for palm oil mill existing and aspiring palm oil mill management staff. This is a brief article and in future there will be other articles on specific topics for mill management.

This article is written because many managing staff have not been taught management and have been promoted to management positions due to experience.

This article is also for Palm oil mill owners and company senior management staff so that they understand what can be expected of a palm oil mill.

For detail explanation of the technical aspects the readers should refer to other sources of information or other articles.

A major characteristic of a palm oil mill is the very high rate of wear and tear of mill machinery. This is due to the nature of the fruits processed. The fruit fibres contain silicone and these causes wear. The fruits that arrive in the mill for processing also contain sand and dirt and these also contribute to the high wear rate.

What is a well operated mill?

A mill that can process fresh fruit bunches at the rated capacity and achieves a high extraction efficiency, with a below average industry production cost.

To achieve this following are required

    A trained and experienced mill manager

    

    Trained workers, workers who can take immediate actions if some machine is not performing as designed and adjust machines if the product loss is high.

    A well designed mill

    A system to monitor product loss and product quality

    A system to communicate information to all in the mill, with regards to quality and efficiency

    A system to maintenance the mill machinery

    Production procedures.

    Production records

The manager responsible for the operations of the palm oil mill must first understand his major objectives. This will enable him to make his decisions and manage his time for the maximum profitability of the mill.

Suggested Objectives are

To process the crop at the rated capacity of the mill.

 To achieve a high processing effiency ( More than 90%)

This is not always easy. Most of the mills are unable to process at the design capacity because of design defects. For example 60 tons per hour mill cannot process at 60 tons per hours for 20 hours per day if the maximun capacity of the mill is 60 tons/hr. The equipment wears out and the efficiency is not at its peak for all its operation life.

Every day when the mill starts in the morning it cannot immediately operate at its rated capacity. It normally takes about 30 minutes to 60 minutes for the mill to achieve its rated capacity. When the mill is shut down this process is reversed and all the conveyors, elevators and other equipment have to be emptied before all equipment is stopped.

The average throughput for the day will be less than 60 tons per hour and normally is about 90 % of the rated capacity i.e. 54 tons per hour. Therefore 60 tons per hour mill should be able to process 54x 20 = 1080 tons per day or 27,000 tons per month, assume 25 operation days per month. A well organised and maintained 60 ton/hr mill should be able to process 300,000 tons of FFB per year.

Many owners demand more that this from a mill. This will result in a mill to be run for longer hours and also on Sundays. This normally results in the mill breaking down more often and the end result is a less efficient mill. The above capacities are based on the mill stopping for a period of two weeks every year for major maintenance work, like the internal cleaning and inspection of the boilers and inspection of the steam turbines.

In normal off peak month operations the mill also stops one day a week for maintenance and cleaning.

The palm oil mill process consists of a series of machines processing the palm fruit components. There are more than 25 machines in series. If each machine is 99 % efficient the total process efficiency will be 99  To Power of  25.

  The total line efficiency will be 77 percent.

Example: 0.99 x 0.99 x0.99 x 0.99 …= 0.0.77.

To achieve the design throughput the individual machines in the mill should be designed to have a throughput of 120 % of the desired throughput. Many mills are not designed to do achieve this capacity.

As an example the steriliser station must have a capacity of 120%, so that the last machine can achieve a capacity of 100 %.

How to achieve throughput?

To achieve throughput if the mill is design correctly, the mill management can take a few actions. These include the following

Maintenance.

The mill equipment has to be looked after well so that it does not break down. The machines must be cleaned on a regular basis and any parts that have worn to limits of their use must be replaced. It is advised to have a planned schedule to carry out work. Most mills stop one day a week to carry out maintenance. Failure to do this will result in an unreliable mill.

Processing Procedures.

Procedures to start up and shut down the mill need to be documented and workers trained to carry these out.

The best way to operate the mill correctly is to employ experienced mill management staff who can guide the workers to take the correct actions when a problem arises.

Train staff in their jobs.

The mill supervisors cannot be every where in the mill at all times. To achieve the best through it is advisable to train the workers to work efficiently. This should be a continuous process and carried out by the mill manager or outside staff if required.



To Achieve High efficiency

By this we mean to extract the maximum amount of oil and kernel from the fruits delivered to the mill. The mill cannot increase the quantity of oil and kernel that is in the fruits, this is the job of the plantation.

Oil Extraction

The mill can reduce the oil loss in the process. The major oil loss in the palm oil process occurs in the Fibre, Sludge and Steriliser condensate. ((90 % of all oil losses)

Oil Loss in press fibre.

This is minimised by operating the screw press at the correct pressure with the screws in good condition. The fruits must also be pre-treated well in the digesters. The pre-treating or mashing of fruits in the digester depends on how well the fruits are sterilised.

Therefore oil loss in the press fibre depends on, correct sterilisation, correct digestion and correct pressing. All these processes must be monitored to achieve a low oil loss in the press fibre.

Oil Loss in Sludge.

Oil loss is the result of poor separation process in the clarification station. To achieve a good separation the clarification tank must be operated correctly.

This is achieved by setting the skimmer in the clarification at the correct height (100mm to 150 mm) and by maintaining an oil water ratio of 30 % to 38 %. The dilution should be monitored at the crude oil tank by the use of a hand centrifuge on an hourly basis by the operators themselves.

Experienced workers can adjust the water by monitoring the number of turns of the water valve to achieve correct dilution, depending on the number of presses in operation.

 The correct number of sludge centrifuges must be in operation. The nozzles must not be worn above the allowed limits. To achieve a good efficiency the sludge centrifuges must be maintained well.

The most common way to loose oil in sludge is to discharge un treated sludge into the drain. This normally happens when there is insufficient sludge centrifuge capacity.

The oil loss occurs due to a longer than necessary steriliser cycle or due to over ripe fruit. When the fruit is over ripe, the mill should shorten the steriliser cycle.

Kernel Loss occurs in the pneumatic kernel separators and the hydro cyclone. And press fibre.

For a mill to have low kernel loss the following must be attended to

Low nut breakage in the press; - Do not press at a very high pressure

Kernel loss in press fibre- Due kernel breakage in the screw press because of too high a press pressure.

A high cracking efficiency ensures lower kernel loss as there are less un-cracked nuts.

Monitoring of mill efficiency.

The function of process control is to help management to achieve a high efficiency.

This is achieved by taking the required samples and analysing them and reporting the results to management for action.

The following samples should be taken and analysed

    FFB Ripeness

    Un-stripped bunches

    Oil loss in condensate

    Oil loss in press-cake

    Oil loss in sludge

    Oil loss in final effluent

    Oil Loss in steriliser condensate.

    Percentage cracked nuts in press-cake fibre

    Cracking efficiency

    Kernel loss in press fibre

    Kernel loss in pneumatic separators

    Kernel Loss in Hydro cyclone

    Proper separation of oil in sludge  the sludge centrifuges.

To monitor oil quality, the following samples are required.

    Free Fatty acid content of production oil

    Dirt content in production oil

    Moisture content in production oil

    To monitor kernel quality, the following samples are required.

    Moisture content of production kernel

    Dirt content of production kernel.



Staff Requirements for a palm oil mill

Mill Manager

 Asst Manger

 Process Assistant

 Maintenance assistant

Mechanical Foreman

Electrical Charge man

Accountant

Administration staff

Laboratory Assistant

Store Keeper

Chief Security

Mechanical Fitters

Electricians

Process workers

The total number of workers in a modern 60 tons per hour palm oil mill should be about 130 workers for three shift operations.

The end of this brief article

By the POMILL team

 http://www.palmoilmill.co.nz/index.php?option=com_content&view=article&id=57:management-of-a-palm-oil-mill&catid=62:mill-mangement&Itemid=71

Edible Oil Processing - Production

PALM OIL MILLING PROCESS

Introduction

Sterilisation

Stripping

Digestion and Pressing

Clarification

Decanters

Oil Losses during Processing

Kernel Production

Biomass

Treatment of Raw Palm Oil Mill Effluent (POME)

References

• Khairiah, B and Khairul, A.M.A. Bio composites from oil palm resources. Journal of Oil Palm Research, April, 103-113 (2006).
• Loh, T.K. Tilting sterilizer. In: Palm Oil Engineering Bulletin, No 94, pp. 29-42 (2010). MONGANA Report, Volume 1 and 2 Coopérative des Producteurs et exportateurs de l’huile de palme du Congo Belge. (1955).
• Sivasothy, K., Shafil, A.F. and Lim, N.B.H. Analysis of the steam consumption during sterilization., Workshop on recent developments in palm oil milling technology and pollution control, Kuala Lumpur, p. 19, Malaysian Palm Oil Board, Kuala Lumpur )(1986).
• Sivasothy, K. Advances in Oil Palm Research, Vol 1, 747, Y. Basiron, B.S. Jalani, and K.W. Chan (eds) , Malaysian Palm Oil Board, Kuala Lumpur) (2000).
• Sivasothy, K. Continuous sterilization: the new paradigm for modernizing palm oil milling. Journal of Oil Palm Research, April, 144-152 (2006).
• Sulong, M. and Tan, R.C.W. Filtration system for crude palm oil clarification and purification. In: Proc. Of the 1996 PORIM International Palm Oil Congress, Kuala Lumpur, pp. 410-424. (B. Muhamd, A.N. Ma, M.S. Affandi, Y.M. Choo, A. Kuntom, C.L. Chong, A.G.M. Top, K. Yaakob, S. Ahmad, J. Thambirajah, Z.A.A. Hassan and R. Masri (eds), Malaysian Palm Oil Board, Kuala Lumpur)(1996).
• Yap, A.K.C. Palm waste as alternative fuel for cement plant. Palm Oil Engineering Bulletin No 91, 13-21 (2010).

Palm Oil Mill Operation, processing and process , production quality control, effluent disposals and maintenance course

OBJECTIVES

    To acquire overall broad knowledge of fundamentals and practices of palm oil FFB grading and analysis, mill productions, operations, managements and process quality control.
    To enhance, develop and provide a suitable platform to increase work productivity
    To learn overall process quality control in order to achieve high oil and kernel extractions for production cost reduction.
    To appreciate the significance of process planning to achieve smooth running of mill and to ensure the maximum/optimum productivity and with minimum breakdowns.
    To educate qualified professionals to solve problem encountered during processing of palm oil.

"KNOWLEDGE is POWER, MONEY, CONFIDENCE, SECURITY"


Palm Oil Mill Operation and Processing - Module 1
Target : Introduction to facts and informations for better understanding of Mill operations ,palm oil processing and quality control to increase OER and KER.

    Origin of oil palm tree.
    Oil palm nursery
    Anatomy of oil palm tree.
    Anatomy of palm fruits
    History of palm tree
    Fresh Fruit Bunch composition
    Type of fruits-Tenera,Dura,pisifera
    Fruitlets to bunch Ratio
    FFB and Fruitlets Quality Report
    Harvesting,Transportation and handling of FFB.
    Health and Nutritional facts of palm oil for consumption
    Field practices and Management for FFB
    Plantation practices to boost yield, OER and KER.
    Workforce and manpower –attitude,dedication,work quality,Trained etc..
    Uses of palm oil
    Video on oil palm tree.
    Video on environmental and oil palm matters.(PORIM-AOCS)
    Palm Products and General Discussions


Palm Oil Mill Operation and Processing - Module 2
Target : Advantages & disadvantages of conventional sterilization with continous sterilization

    Introduction to modern palm oil Mill (Video)
    Model Of Mills
    System Of Processing –Conventional Methods -Ilustrations
    Mill Process Stations,Flow Diagrams,Process Charts
    Administrative Office Functions,Duties and Responsibility
    Weighbridge -Computerised / Manual ,Purpose,Calibration,Yearly Inspections

           -Upkeep,Lightning Protection,Operation,Procedures
           -Issues on malpractice and control.etc..Rain/Flood and Load Cells.

    Bunch Reception –FFB grading station,FFB categorization and                               Analysis ,Hiping up and long storage of FFB.
    Loading Ramp- Design,Operation, Functions and capacity etc
    Filling of FFB into cages– FIFO system,Level of FFB..etc
    Total number of cages is essential to avoid delay in processing and to achieve mill throughput.
    Transportation of FFB cages to sterilizers– Use of Captains,Tractors,Bob Cat.
    Sterilization Plant—Sterilizer Vessels- Design,Operations,Functions .
    Sterilization Techniques-Single,Double,Treble peak systems Automatic or Manual operation.
    Sterilization Charts,Time Records, charging and discharging of steam and cages records.
    Blowdown and blowoff Chambers, Fat Pit — Operations and Functions.
    Safe operating procedures and awareness. (Safety)
    Importants of educated trained workers to avoid any major accidents.
    Weight loss during sterilization — Moisture Loss – Results and Reports
    Improper sterilization causes High Oil Loss — Profit Loss...
    Continuous sterilization—Video illustration with comparison between conventional methods of sterilization . Advantages and disadvantages between the two methods.
    Marshalling Yard –Captains,Crane or Tippler operations — Purpose etc..


Palm Oil Mill Operation and Processing - Module 3
Target : Coverage of operation & processing

    Water Source— River,ponds,canals,streams etc..
    Water treatment plant — Design,Operation,Functions,Machineries,Equipments,Chemicals.
    Boiler Station — Design,Operation,Functions,Machineries,Types,Softeners, Deaerator,Feed Water Tank and Pumps.etc
    Softners — Care and regeneration—Purpose.
    Power House — Design,Operation,Functions,B.P.Vessel,Diesel Engines, Electrical Control and Distribution Panels and Turbine.
    B.P.Vessel — Control Of Steam flow, Distribution and Pressure Levels.
    Turbine — Boiler steam pressure fluctuations — Process Delay,Temperature Loss, Low Throughput.
    Electrical Distribution Panel — Supply of Electricity and syncronisation.
    Turbine — Video on Turbine Care.
    General Discussions on main problems on co-ordination,breakdowns, uneven supply of steam and steam management.
    Threshing Station — Design,Operation, Functions,Double Threshing, Disposal of Empty Bunches-Incinerater,Mulching etc.
    Digestors — Design,Operation,Functions,Care,Stirring Arms, Temperatures and steam injection-Homogenisation etc.
    Presses — Design,Operation,Functions,Care,Types,Temperature and Amps Control, Automatic or Manual operation etc.
    Cake Breaking Conveyor — Design,Operation,Functions,R.P.M set, Overload,Cover — Moisture and Dust etc.
    Deprecarper — Design,Operation,Functions,Size, Suction Fan air velocity adjustments.etc..
    Boiler Fuel Storage Flatform — Care for fire hazards etc.
    General Discussions ,comments ,upgrades,imporovements..etc..


Palm Oil Mill Operation and Processing - Module 4
Target : Coverage of operation & processing

    Clarification Station (Without Decanter) — Design,Operation,Functions, Purpose, Reports .

           A) Vibrating Screen
           B) Crude Oil Tank
           C) Sand Trap
           D) Vertical Clarifier or Continuous Settling Tanks
           E) Sludge Tanks
           F) Sludge Vibrator G)Boiling Tank
           H) Clean Oil Tanks
           I) Sludge Separators
           J) Purifiers
           K) Vacuum Drier.
           L) Storage and Despatch Tanks.

    Clarification Station (With Decanter System)— Design, Operation,Functions, Purpose, Reports. Additional — Decanter, Sludge Drier etc..
    System Of Operation — Crude Oil or Sludge as Feed to Decanter. Advantages and Disadvantages. Reports.
    Sludge Drier — Use Of Boiler Flue Gas for Drying –Production of Dried Palm Oil Mill Effluent (POME)— sold as solid Fetiliser.
    Others — Disposal of liquid waste water,Temperature controls,Water Dilution,Hot Water,Vacuum levels,care,Maintenance, Wear and Tear of machinery Parts and replacements.
    General Discussions and improvements with reference to Mill Audit.


Palm Oil Mill Operation and Processing - Module 5
Target : Coverage of operation & processing (kernel recovery plant)

    Kernel Recovery Plant — Design,Operations,Functions,Purpose.

            A) Nut Bins,
            B) Nut Vibrator/distributor
            C) Nut Crackers-Types
            D) Hydrocyclone
            E) Mud Bath
            F) Kernel Driers
            G) Kernel Storage Bunkers and Kernel Despatch Tanks

    Others — Mud Bath S.G control- Use Of Salt or Calcium,Nut Dryness, Cracking, Kernel Losses control, Kernel Overdrying. Adjustment and setting of vortex at Hydrocyclone. Water compartment leaks.Waste Water discharge etc.
    Kernel Despatches
    General Discussions and suggestions— Mill Audit Reference— Improvements and upgrades.
    Main Problem Areas and solutions..
    Video On Palm Oil Operation and Processing.


Palm Oil Mill Operation and Processing - Module 6
Target : Production report , mill visit, goal setting & course exam.

    Summary Of Daily, Monthly,Yearly Production Report Review.
    Action Plan,Assessments,improvements with reference to Mill audit Report..
    Video on Palm Oil Mill Operation and Processing.
    Goal Settings and implementations
    Mill Visit—Practical approach and general Mill Audit.
    Presentation of Test papers for participant assessment on Palm Oil Operation and processing.


Palm Oil Mill Process and Production Quality Control - Module 7
Target : Procedures and methods of quality control

    Introduction
    Function Of Quality Control
    Laboratory Operations.
    Role Of Mill Laboratory
    Quality Analysis for palm oil
    Mill Losses Control
    Essential Laboratory Equipments-purpose and uses.
    Record Books Maintained in Laboratory
    Quality control on Mill Products
    Methods and procedures of sampling,sampling points at mill,Frequency of sampling,Average sample volume for final testing at Laboratory.
    Mill sampling and the importance.
    Specific Sampling procedures for various stations at Mill
    Test Methods—Solvent Extraction,Titration, Fibre analysis, Oil and Kernel Losses analysis, Samples from various stations, etc...
    Sampling procedures for production oil,Despatch Oil and Palm Kernel Production and Despatches.
    Visit to Laboratory to do Practical and General Discussions.


Palm Oil Mill Process and Production Quality Control - Module 8
Target : Procedures and methods of quality control at various stations

    Water Treatment Plant — Sampling,Analysis,Results,Purpose,Actions -

          A) Raw / River Water,
          B) Cachment Ponds
          C) Pond Water
          D) Treated Tap Water
          E) Settling Tanks
          F) Sand Filter etc..

    Boilers — Sampling,Analysis,Results,Purpose, Actions.Reports.

          A) Treated Softner water
          B) Deaerated Water
          C) Boiler Feed Water
          D) Boiler Water etc..

    Sterilizers — Sampling,Analysis,Results,Purpose,Actions.

          A) Sterilizer Condensate
          B) Final Discharge to Effluent Ponds

    Presses — Sampling,Analysis,Results,Purpose,Actions

          A) Presscake — Fibre and Nuts
          B) Crude Oil below presses.

    Deprecarper — A) Cyclone Fibre collected at boiler platform
    Clarification Station — Sampling,Analysis,Results,Purpose,Actions (without Decanter)

              A) Verical Clarifier Under flow sludge and oil.
              B) Separator Recovered oil and waste water.
              C) Boilout Tank discharge.
              D) Before and After Purifier Oil.
              E) Vacuum Drier Oil.
              F) Storage Tank Oil.

    Clarification Station — A) Oil Phase B) Decanter Solid C) Drier Solid (With Decanter)
    Kernel Plant — Sampling,Analysis,Results,Purpose,Actions

             A) Whole Nuts from Nut Bins
             B) Cracked Mixture from Ripple Miller
             C) Winnower Dry Shells
             D) Wet Shells and Wet Kernels from Mud bath or Hydrocyclone
             E) Wet Kernels from Kernel Drier. Dried Kernels from Kernel Drier Prior to Despatch.

    General Discussions and Practical at Laboratory

NOTE : For all the above Reports slides will be shown with examples and explanations.

Palm Oil Mill Process and Production Quality Control - Module 9
Target : Procedures and methods of quality control at various stations

    Palm Oil Analysis,Tests and Procedures:

           A) Free Fatty Acid (FFA) Test
           B) Moisture Test
           C) Dirt Test
           D) Peroxide Value Test etc..
           E) Other Tests

    DOBI (Deterioration Of Bleachbility Index) Test:

          A) Methods
          B) Test Procedures
          C) DOBI Index
          D) Categorization Of DOBI Value

    Field and Mill factors that causes for low DOBI Value.
    Causes for the variations in DOBI Value between Mill and Refinery
    Production and Despatch Kernel Analysis and Tabulations
    Histogram Of Nuts — Size Variations and the relationship to KER.
    Laboratory Chemicals and their health Hazards.
    FFB Analysis Methods and Reports.
    Summary Of Assesment and action Plan :

         A) Quality Control
         B) Process Control
         C) Fresh Fruit Bunches
         D) Pollution Control

    Effluent Analysis and Control.(Reports)
    Review Of All analysis in Full Detail.
    Latest all analysis by fast and quick method with spectrophotometer will be introduced.


Palm Oil Mill Process and Production Quality Control - Module 10
Target : Detailed analysis and calculations to determine mill efficiency, etc

    Production Process Reports :

           A) Prodution Oil Quality
           B) Kernel Production Quality
           C) Production Control - Oil Losses and Kernel Losses
           D) Quality Control on CPO at Press.
           E) Quality Control on Presscake
           F) Nut Breakage at Presses.
           G) Process Control Ripple Mills and Cracked Mixture.
           H) Process Control Nuts and Kernels
            I) Unstripped Bunches Count
           J) Stripped Bunches Catagarisation. (Tabulation)

    Mill Oil Losses to FFB.
    Mill Kernel Losses to FFB
    Moisture Loss in FFB during Sterilization
    Fruitlets to Bunch
    Oil Extraction Efficiency
    Kernel Extraction Efficiency.
    Oil and Kernel Losses Calculations to FFB.
    Ripeness influence :

           A) Oil to Mesocarp
           B) Oil to Bunch (FFB) ( Calculations)
           C) Kernel to Nut
           D) Kernel to Bunch(FFB)

    Main Factors that influence and contribute to oil and kernel Extractions
    In Palm Oil Mill— Rainfall, Soil Conditions,Sunshine,Fertiliser etc…….
    General Discussions and comments.
    Examination on Quality Control in Palm Oil Mill .


Palm Oil Mill Effluent Treatment- Module 11
Target : Effluent treatment analysis & various types of treatments

    Introduction
    Source of Palm Oil Effluent produce.
    Types of Palm Oil Mill Effluent Treatments— Malaysian Choice — Ponding System— Recommended and accepted by DOE and PORIM
    Mill capacity and Quantity produce — Calculation of Pond Capacity – Number of ponds– High retention time– Low BOD.
    Water course discharge or Land Appliation or Both DOE sandards.
    List of waste parameters.(Reports & Tabulations)
    Characteristics of Palm Oil Mill Effluents.(POME)
    Collection and removal of oil prior to discharge to ponds at Long settling ponds or at settling tanks and Fat Pit and temperature controls.
    Biological Digestion
    Anaerobic Digestion
    POME –Biological treatment system monitoring and testing.
    DOE standards and parameters.
    Direct discharge of POME into water course and the damage to Environment.
    Sketch of standard ponding system with various ponds.(Drawing)
    BOD reduction at various stages at pond. (Tabulation)
    Effluent Ponds at Hillside — By Gravity flow etc.(Slide)


Solid Waste Disposal in palm oil mill - Module 12
Target : Methods of disposal and visit to mill and effluent treatment plant

    Solid Waste in Palm Oil Mill: a) Empty Bunches b) Decanter Solids
    Disposal Of Solid Wastes:

           A) Empty Bunches send to field for Mulching
           B) Some used as Boiler Fuel
           C) Burnt in Incinerators

    Government rules and regulations for Effluent discharge to water course,Solid discharge to land and chimney smoke to atmosphere for palm oil mills in Malaysia.
    Mill and Laboratory Visit : Practical Study.
    General Discussions Goal Setting.
    Motivating slide shows— Philosopy, YOU are the WINNER.
    Finally Test and question Papers for evaluation.


Maintenance in palm oil mill - Module 13 (additional)
Target : Palm Oil Mill Machineries and Maintenance Auditing, Assessment, and Improvement Activity

    Types of maintenance
    Computerised maintenance, operation and systems
    Station/Machinery/Equipment
    Checklist - Mill Audit
    Problem Identification
    Corrective Actions
    Case Studies


END OF TRAINNING
THANKS FOR LEARNING ,
YOUR ATTENTION,
TIME SPENT AND
TO YOUR MANAGEMENT

* 9-month high rapeseed prices cause pain for oilmills

* Some may cut rapeseed crushing

* Germany buys from UK after poor crop

By Michael Hogan

HAMBURG, March 8 (Reuters) - The surge in rapeseed prices to new nine-month highs this week is putting intense cost pressure on European Union oil mills and some may be compelled to cut rapeseed crushings due to poor profit margins, traders and crushers said on Thursday.

"Some mills might have to reduce production as rapeoil price rises are being resisted by retailers and food processors," one German oilmill spokesperson said. "You can quote higher rapeoil prices but customers are not buying."

European rapeseed futures continued to climb Thursday following a rally in soybeans and crude oil coupled with bullish forecasts for palm oil prices.

Europe's benchmark rapeseed, the Paris May contract, touched 469.50 euros a tonne in morning trade on Thursday to notch up a new nine-month high.

U.S. soybeans are trading close to five-month highs after drought in South American exporters Brazil and Argentina, while crude oil remains in an upward trend despite losses earlier this week on macro-economic worries.

Analysts in Malaysia this week gave a bullish outlook for prices, helping to support rapeseed prices.

One major German rapeseed mill is on short-time working because of uncompetitive rapeoil prices and others may follow, traders said.

Rapeoil for May/July delivery was quoted in the Rotterdam/Hamburg market at 973 euros a tonne on Thursday, well above palm olein which was offered at 855 euros a tonne.

"Crushing mills have little option but to sit and hope for lower rapeseed prices," a German trader said. "It looks like rapeseed crushings will be cut as it is not possible to pass on the higher cost of rapeseed to supermarket customers, especially in Germany."

The rapeseed market is awaiting Friday's world crop estimates from the U.S. Department of Agriculture (USDA) for a fresh indication of drought damage to South American soybean crops. An optimistic forecast of Brazilian and Argentine soybean crops could weaken global oilseed prices.

"Nearby crush margins have been poor," a British trader said. "There have been signs of one or two crushers selling seed back onto the market"

Sluggish demand for rapeseed oil for biodiesel production was a factor which could put downward pressure on rapeseed prices, dealers said.

"Demand for rapeseed oil for biodiesel in Europe does not appear to have been strong since the start of the year, with competition from Argentine biodiesel and imported soy-oil and palm-oil esters (feedstocks)," French consultancy Offre & Demande Agricole said in a note.

Traders played down tightness in rapeseed supply in Europe, saying crop damage in Ukraine, a leading exporter to the EU, would be offset by good exports from Australia and Canada.

"There isn't a problem in terms of supply of the oilseed, the problem we have is competition from biodiesel imports," the French trader said.

GERMANS BUY BRITISH RAPESEED

Germany's 2011 rapeseed crop collapsed by a dramatic 31 percent after bad weather, creating a sustained import requirement and British farmers continue to benefit.

British dealers said the pace of UK rapeseed exports remains strong, with shipments so far in the 2011/12 season (July/June) totalling around 500,000 tonnes, already exceeding the 435,311 tonnes shipped in the entire 2010/11 season. Germany is the most important market for UK rapeseed exports.

"Exports are still running well," a British trader said. "We didn't have the logistical jams they had in the Black Sea so that probably helped some of the east coast UK ports top off some of the German demand."

But the outlook for the 2012 German crop is good.

Germany's 2012 winter rapeseed crop will to rise 25 percent to 4.8 million tonnes from 3.8 million tonnes in 2011, farm cooperatives cooperatives forecast on Thursday. (Reporting by Michael Hogan in Hamburg, Gus Trompiz in Paris and Nigel Hunt in London; editing by Keiron Henderson)