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One of The World's Largest Palm Oil Exporter Malaysia currently accounts for 39 % of world palm oil production and 44% of world exports. Being one of the biggest producers and exporters of palm oil and palm oil products. Malaysia has an important role to play in fulfilling the growing global need for oils and fats sustainably.
Oil
palm (Elaeis guineensis) was first introduced to Malaysia as an ornamental plant in 1870. Now become the cornerstone of the countrys agricultural sector, with a planted area of 3.3 million hectares (1999), which has grown every year. In Malaysia, the oil palm planted is mainly the hybrid tenera which yields about 4.0 tonnes of palm oil per hectare and 0.6 tonne palm kernel meal (PKM).
Harvesting of oil palm bunches commences 30 months after planting reaches maturity in three years and has an economic life of about 25 years.
The
fruit is about the size of a small plum and grows in large bunches weighing 10kg-20kg. A bunch can have up to 2000 individual fruits.
THE PALM
The material bred from these palms is referred to as Dura Deli . It is very stable and uniform in Oil and kernel content. An average content of the fresh fruit bunch (FFB) is 25% oil, 5.5% kernel, 6% shell, 9% fibre, 25% empty bunch (EB) and the balance is moisture. In recent years another parent has been introduced to produce the material referred to as Tenera.
THE PALM
The same Dura Dali palm is used to produce the Tenera palm seed but it is pollinated with pollen from a selected Pisifera palm (the selected Pisifera when self pollinated produce fruit with a small kernel and little shell).
The resultant Tenera material produces fruit with more oil than Dura material, the same kernels as Dura but less shell than Dura.
Each fruit consists of a hard kernel (seed) inside a shell (endocarp) which surrounded by a fleshy mesocarp.
The mesocarp contains about 49% palm oil and the kernel about 50% palm kernel oil.
1. Unripe Bunches 2. Ripe Bunches 3. Over Ripe Bunches 4. Empty Bunches 5. Dura Bunches 6. Long Stalk Bunche 7. Old Bunches 8. Dirty Bunches 9. Damage Bunches 10.Abnormal Bunches 11.Small Bunches
The
Bunch which has purplish color fruits and without detached fruit let
The
bunch which has reddish orange color fruits and has less than 10 detached fruitlets.
The
bunch which is reddish orange with at least 10 detached fruit lets and more than 50 % of the fruit still attached to the bunch
The
bunch which is darkish red with more than 50 % of detached fruitlets but at least 10% of the fruits still attached to the bunch
The
bunch which has more than 90% of its fruits have detached from it
The
Shell Thickness
Shell Fruit Ratio Mesocarp Fruit Ratio Kernel Fruit Ratio
2 8 mm
25 - 50 % 20 60 % 4 20 %
The
bunch has stalk longer than 5 cm in length measured from the lowest level of the bunch stalk
The
bunch which has been harvested and left at the field more than 48 hours. It is normally dry and blackish in color
The
bunch which more than half of its surface covered with mud, sand, other dirty particles and mixed with stone or other foreign materials.
The
bunch which has more than 30% of its fruits damaged by pest, such as rats etc
The
bunch which has more than 50% parthenocarpic fruits and has abnormal size and density.
The
bunch which has small fruits and weight less than 2,3 Kg.
HARVESTING
Harvesting is normally a 6 to 8 day cycle. It is important that the fruit must not be harvested before it is ripe, that is until the process of photosynthesis, which converts the carbohydrates into fat, is well in advance. The oil content of unripe mesocarp may be in the order of 35% whereas the oil content of ripe mesocarp is usually between 50% and 55%. The harvesting of under ripe fruit can cause losses in the order of 8% of the possible yield.
Stages of Processing
Sterilisation
This is the first operation in the processing line of palm oil. This involves the steaming of the harvested fresh fruit bunch (FFB) to loosing the fruit from the bunch and burst open the oil cell.
Stripping
This is the next stage after sterilisation and it involves the removal of the fruit from the bunches using a stripper.
Digestion
This process is the next stage after stripping and this involves the pounding of the fruits which have been removed from the bunch.
Clarification
Final stage in the processing of palm oil. Dirt, moisture and other impurities is removed from the crude palm oil by this process.
The FFB bunches loaded on trucks, cages or trailer are weighed on arrival at the mill and on departure when empty by weighbridge of 50 ton capacity and automatically recorded, that is computerised.
After weighing-in process of the truck, cage or trailer, the PFB are dumped into the inclined hopper at the ramp that will hold 900 mt PFB ( 2 lines of 15 bays x 30 mt PFB ).
Modern mills in Malaysia are equipped with the following in the reception area of the mill: A. Load cell (pitless) 50 tons weigh bridge of 3.3m W x 15m L and computerised. B. Larger loading ramp with double door hoppers of 30mt capacity per bay. C. FFB Cage and bogie with capacities of 5, 7 and 10 mt of wheel spanned of 800mm gauge. D. FFB loading into cages by conveyor system E. Straight line railway system with Cage transfer carriage located at both ends of the railtrack system to facilitate easier operation of the 2-door sterilizer and shunting of the cages can be handled easily with the capstan and Bollard.
On opening the hopper door ( 2 doors to a bay ) the bunches drop into the 7mt cages with bogies placed beneath it.
The loaded PFB cages are then conveyed by the transfer carriage on the rail track and pushed into the sterilizer, by a winch and ballard system for sterilization.
Reception Station
The sterilizer process is done in 5, 7 and today 10 tons capacity FFB cages which are pushed into long cylindrical steel vessel with special doors and subjected to steam at approximately 3 BAR. One of the effects of sterilisation is to inactivate the fruit enzyme. Once this enzyme has been inactivated the rise of the FFA is virtually stopped.
The objective after harvesting is to sterilize the fruit as quickly as possible with the minimum of handling and damage.
In addition to arresting the development of the FFA content, the sterilizing of the fruit also facilitates:
a.
The purification of the palm oil by coagulating nitrogenous and mucilaginous matter and thus preventing the formation of emulsions during verification of the crude oil. The extraction of the crude palm oil by freeing the fruits from the bunch stalks and by breaking the oil cells in the mesocarp.
b.
Majority of mills today has programmable automatic control systems to cater for proper sterilization of 90-minute cycle. Sterilisation is a simple process but it is essential, for the proper operation of the mill so that it is done correctly. This operation is the largest user of steam in the mill.
Sterilisation Station
Storage of CPO
Kernel Storage
The
two oils have very DIFFERENT composition. Palm oil contains mainly palmitic (C16:0) and oleic acids (C18:1), the two most common fatty acids in nature, and is about 50% saturated. While palm kernel oil contains mainly lauric acid (C12:0) and is more than 80% saturated. This point is important because the two oils are often confused by nutritionists.
The major fatty acids in palm kernel oil are C12 (lauric acid) about 48%, C14 (myristic acid) about 16% and C18:1 (oleic acid) about 15%.
Percentage of Fatty Acid Composition in Palm Kernel, Coconut & Palm Oil
Sharp melting fats leave a clean, cool, non-greasy sensation on the palate, impossible to match by any of the common non-lauric oils. This figure shows the melting behavior in terms of solid fat content (SFC) values of palm kernel oil (PKO), palm kernel stearin (PKS) and hydrogenated palm kernel stearin of melting point 35C (HPKS 35), together with cocoa butter (CB) and palm oil (PO) for comparison.
Shell amounting to 6%, out of which about 30% is dry enough to be used as boiler fuel, or 1 ton/h and Fibre amounting to 14% or 8.4 ton/h