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INDUSTRIAL TRAINING REPORT
SIMEDARBY JOMALINA SDN. BHD
BATU 9, JALAN BANTING-KLANG
42500 TELOK PANGLIMA GARANG INDUSTRIAL ESTATE
SELANGOR DARUL EHSAN.
WAN SITI NOORHASHIMAH BT W.KAMARUZAMAN
KA 09135
IJAZAH SARJANA MUDA KEJURUTERAAN KIMIA
FAKULTI KEJURUTERAAN KIMIA DAN SUMBER ASLI
UNIVERSITI MALAYSIA PAHANG
JUNE- SEPTEMBER 2012
DECLARATION
“I hereby acknowledge that this Industrial Training Report has been verified and it does not contain any CONFIDENTIAL information to be released to the public”
Signature : …………………………………………………………………..
Official stamp :…………………….…………………………………………
Date :……………………………………………………………………….
ACKNOWLEDGEMENT
In preparing this report, I was in asking with many people especially in
Simedarby Jomalina Sdn. Bhd. They have contributed towards my understanding and
thoughts. In particular, I wish to express my sincere appreciation to my supervisor’s,
Mr.Varadaraj for encouragement, guidance, critics and friendship. I am also very
thankful to all executive, Mr. Masdar Beri, Mr. Suresh Onichandran, Ms. Nurdiyana, all
operators especially in refining plant, and all lab assistant in QC Department for their
guidance, advice and also motivation. I am also indebted to Faculty of Chemical
Engineering and Natural Resources (FKKSA) lectures for their support during my
practical in Simedarby Jomalina Sdn. Bhd.
My sincere appreciation also extends to my industrial supervisor’s from
Universiti Malaysia Pahang (UMP), Ms.Siti Hatijah bt Mortan, manager of Simedarby
Jomalina Sdn. Bhd., Dr.Razam bin Abdul Latif and other who have provided
assistance at various occasions. Their views and tips are useful indeed. Unfortunately,
it is not possible to list all of them in this limited space. I am grateful to all
communities of Simedarby Jomalina Sdn. Bhd and friends in the same batch with me
who also contribute to industrial training.
LIST OF ABBREVIATIONS
SHORT NAME FULL NAME
CPKO Crude Palm Kernel Oil
CPO Crude Palm Oil
COL Crude Olein
CPP Consumer Packing Plant
CST Crude Stearin
DNOL Deodorized Neutralized Olein
DNPO Deodorized Neutralized Palm Olein
FFA Free Fatty Acid
I.V Iodine Value
JGQRBDPO Jomalina Guaranteed Quality Refined Bleached Deodorized
Palm Oil
JGQRBDOL Jomalina Guaranteed Quality Refined Bleached Deodorized
Olein
M & I Moisture & Impurities
M.Pt. degrees Melting Point
MEOMA Malaysian Edible Oil Manufactures Association
MT Metric Tonne
NBDPO Neutralize Bleached Deodorized Palm Oil
PAO Palm Acid Oil
PKFAD Palm Kernel Fatty Acid Distillate
PFAD Palm Fatty Acid Distillate
PORAM Palm Oil Refiners Association Malaysia
RBD Refined Bleached Deodorized
RBDPKO Refined Bleached Deodorized Palm Kernel Oil
RBDPO Refined Bleached Deodorized Palm Oil
RBDOL Refined Bleached Deodorized Olein
RBDST Refined Bleached Deodorized Stearin
CHAPTER 1
INTRODUCTION
1.1 General Background
The overall development of the palm oil in Malaysia is described
as having been more colorful. Oil palm was first introduced to Malaysia
(then Malaya) in 1875. Early interest in oil palm was as an ornamental
plant, and from about 1917 onwards the palm oil sector began its
development into what it witnessed today as a multi-billion Ringgit
industry. Malaysia has one of the most ideal climatic conditions for
growing oil palm, and it is in Malaysia that the crop’s full potential has
been realized and exploited.
Malaysia is the largest producer of the palm oil in the world.
Simedarby Jomalina Sdn. Bhd is formerly known as Golden Jomalina
Food Industries Sdn. Bhd. It is commenced refining operation in 1977.
The area is 4 hectares of factory complex area. The company is
acquired by Golden Hope Plantation Berhad in 1984. The Merger of
Golden Hope Plantation Bhd., Kumpulan Guthrie and Sime Darby Group
to become the new Sime Darby Group in November 2007. They
changed to present name in 29 March 2010.
As part of the Sime Darby group, Sime Darby Jomalina is
distinct from other refiners by ways of securing continuous premium
quality crude palm oil supply from the plantations. Sime Darby Jomalina
is a leading sustainable solutions provider to the edible oils and fats
industry. Our company is certified to the strict requirements of HACCP,
ISO 9001, ISO 14001, OHSAS 18001 and others. We produced
customized premium quality products to meet customer’s requirements in
the business-to-business segment.
Our premier quality products are widely used in food industries
globally, with applications in dairy products manufacturing, food
preparation, as well as natural and healthy colorants for food ingredients.
The main brands marketed under our company are Golden JomaTM,
JomaTM, SAFaRTM and D’FaRTM.
We are committed to meeting and fulfilling our customer’s
stringent requirements. With our production expertise and professional
marketing team, we provide high quality products and excellent service
with timely delivery.
Sime Darby Jomalina Sdn. Bhd. produces a wide range of high
quality traceable refined palm oil and palm kernel oil products which
include industrial shortening, margarine, frying palm oil, dairy fat
replacer, animal fat replacer, dough fat, vegetable ghee and cooking oil.
Our products are exported to Far East, South East Asia, the Middle East,
Europe, Africa and United States of America. Locally, we well position
in the Malaysian market.
Sime Darby Jomalina Sdn. Bhd also manufactures tailor-made
products to meet consumer’s specific requirements as well. We are being
supported by highly trained and dedicated Innovation Centre Asia under
Sime Darby Research Sdn. Bhd which has well over 200 technocrafts,
scientist and technicians. They work very closely with our sales and
operations team tp serve customer better in providing solutions that meet
and extend customer’s need.
These specialty produced from our very own Premium Quality (PQ)
Crude Palm Oil includes:
1. Special Animal Fat Replacer (SAFaRTM ) – vegetable fats to replace
animal fats in frozen food products
2. Jomalina Guaranteed Quality (JGQTM) - products-products made from
Premium Quality CPO
3. Golden JomaTM Red Palm SuperOlein - red palm oil with very high
beta carotene content
4. Customised oil products with specific parameters for frying,
application in dairy products, colourants and as healty food ingredient
Head of Factory Operation
Head of Department, Production
Senior Executive, Planning
Executive, Production
Senior Operator
Operator
Process Control Technician
Attendant
Clerk, Production
Organization Chart
CHAPTER 2
TRAINING ACTIVIES
1.1 Scope
This chapter will cover all the information data related to Physical
Refining Plant (Plant 22) operations and control from feed raw material of
Crude Palm Oil (CPO) to the processing parameters and control in order to
get the desired quantity and quality of products that meet or exceed the
customers requirements. This plant has a capacity of 700MT/day. The main
product from this plant is Refined Bleached Deodorized Palm Oil (RBDPO)
and by products Palm Fatty Acid Distillate (PFAD).
CPO
Pumping to Bleacher Feed Tank
Degumming
Bleaching under vacuum
Niagara Filter
Aluvion & Pocket Filter
Bleached Palm Oil Holding in the tank
Pumping to deodoriser P22
Cartridge Filter
Daeration & Pre-heating
Deodorization
Phosphoric Acid
Bleaching Earth
Cooling Fatty Acid Scrubbing & Condensation
RBDPO storage PFAD storage
1.2 Refined Bleached Deodorized Palm Oil (RBDPO) Process Flow
1.3 Palm Fatty Acid Distillate (PFAD):
Palm Fatty Acid Distillate is by product obtained from condensation of
fatty acid and other volatile materials during the deodorization stage in the
physical refining of crude palm oil. The fatty acids produced from the
various fat splitting processes are purified and separated into fractions or
even individual fatty acids by distillation and fractionation. Fatty Acid
Distillation. of crude fatty acids removes both the low and high boiling
impurities as well as odor bodies. Fatty acids are extremely sensitive to
heat, oxidation, and corrosion effects. This is due to the reactive acid group
at the end of the long carbon chain. These factors are taken into
consideration in the design of the distillation unit and its operating
parameters.
Distillation is carried out under high vacuum and lower temperatures and
with the shortest residence time allowable. Technical design of most
distillation units features high vacuum with no allowance for air leakage,
effective heating to achieve short contact time, good circulation for effective
mass transfer between vapor and condensate, and steam economy. Internal
arrangements of the column vary among suppliers with the ultimate purpose
of achieving the design objectives. The basic steps in processing are about
the same.
Figure 1: Continuous Fatty Acid Distillation
Crude fatty acid is predried and degassed under vacuum and fed to the
distillation unit, which is operated at a vacuum of 1.2 kPa or less and a
temperature of approximately 200℃. Modern stills use thermal oil or high
pressure steam as the heat source. Stripping steam is provided to improve
circulation and reduce partial pressure, thus lowering the temperature and
reducing degradation losses. The steam facilitates the removal of low boiling
impurities as well as odor and color bodies from the vapor exiting the system
and from the light ends.
The distilled fatty acid has an almost water white color and is free of
the major impurities. The heavy ends consist of the higher boiling components,
usually of lower quality, which can either be withdrawn separately or recycled
directly for redistillation The bottoms or residue are charred viscous
polymerized material, which is disposed of by blending with heavy residual oil
and used as boiler fuel. It may also find use as an asphalt additive.
Master of Product Code and Customers.
Product Type Code Customers Brand
190kg Drum PFAD-45/48-
DR(JM)-01-001
Polymeric
Technology S/B
-
190kg Drum PFAD-45/48-
DR(JM)-01-002
Sun Rythym S/B -
Process and QC Limit
i) PFAD-45/48- DR(JM)-01-001
Packing
Clearance
Despatch
Control
Buyer Spec
Packaging 190kg Drum
FFA (Palmitic)
% min
70 70 70
M & I % max 0.5 1.0 1.0
Total Fatty
Matter % min
95 95 95
ii) PFAD-45/48- DR(JM)-01-002
Packing
Clearance
Despatch
Control
Buyer Spec
Packaging 190kg Drum
FFA (Palmitic)
% min
70 70 70
M & I % max 0.5 1.0 1.0
Total Fatty
Matter % min
95 (basic 97) 95 (basic 97) 95 (basic 97)
Determination of Free Fatty Acid (FFA)
1.1 Principle
The fat is dissolved in an appropriate solvent after which the solution is
titrated with Potassium Hydroxide (KOH) solution. The amount of KOH
solution consumed is a measure of the acidity of an oil or fat. Free
fatty acid (FFA) content is calculated as percentage by weight of fatty
acid of specified molecular weight, according to the type of oil or fat
under investigation. Noemally, Palmitic acid with a molecular weight of
256 is taken. In a number of cases an average molecukar weight, more
appropriate to the nature of the oil or fat is used. In each report, the
basis must be clearly stated.
1.2 Reagents
Solvent : ISO Propyl Alcohol (IPA). Neutralize shortly before use
with 0.1N KOH solution by drop wise addition using
phenolphthalein as indicator.
KOH solution : 0.1N aqueous solution accurately standardized
Phenolphthalein indicator: 1% in IPA. 5g Phenolphtalein powder
into 500g IPA.
1.3 Apparatus
Electric sources hot plate with stirrer
Magnetic stirrer bar
Beaker, 150ml
Digital burette, 25ml
Analytical balance, capable of weighing to the nearest 0.001g
1.4 Method
1. Dissolved the oil or fat in at least 50ml of the solvent, if necessary
by gentle heating.
2. Titrate while swirling (the magnetic stirrer) using Phenolphtalein as
indicator
Titration is carried out at room temperature
3. The end point is reached when a permanent pink colour is obtained.
This should persist for at least 30seconds
4. The weight of the oil and the normality of titrant are chosen as
follows:
Oil type Approx amount of
oil to be weighed
(g)
Accuracy of
weighing (mg)
Normality of alkali
(N)
Crude Oil 3 1 0.1
Refined oil,
neutralised oil
20 10 0.1
Acid oil, fatty acid
distillate
0.5 1 0.1
1.5 Calculation
Free Fatty Acid (FFA) % : VNM10W
Where,
W: Weight (g) of the sample
V: Volume (ml) of KOH solution
N: Normality of KOH
M: Molecular weight of fatty acid
Normally, assume a molecular weight (MW) of 256 for palm oil. The
following values are often used:
Type of acid Molecular weight
Lauric Acid 200
Palmitic Acid 256
Oleic Acid 282
In the analysis report, the value which is applied should be clearly
mentioned. Report results as follows:
FFA <5% to nearest 0.01%
FFA between 5-10% to nearest 0.05%
FFA>10% to nearest 0.1%
Determination of Lovibond Colour
1.1 Scope
The test specifies a method for the determination of the Lovibond
colour of palm oil and palm oil products.
1.2 Apparatus
Lovibond Tintometer Model E (Manual)
Lighting Cabinet
Glass cell 5.25’’ (1334.1mm) or 1’’ (25.4mm)
1.3 Method
Refined samples are first heated if cloudy, filtered to
remove impurities if any. (Refer SOP QC Section 8-
Heating Instruction for Quality)
Read colour in 5.25’’ or 1’’ cell depending on stages of
refining the oil has undergone
Colour is reported as Red (R) and Yellow (Y) Lovibond
units. Sometimes, Blue (B) and Neutral (N) filters are used
to improve the colour matching
1.4 Expression of Result
Expression the results in term of the following:
1. The numbers of red, yellow and blue or neutral standars
necessary to obtain the match
2. The optical path length of the cell used
Only standard cell sized shall be used. Colour measurement taken
in one cell sized shall not be used calculate colour values for
another cell sized.
Note: 1) Samples must be in liquid form
2) Tintometer shall NOT be set up facing a window
or in direct sunlight
3) Glass cell must be throughly clean and dry
before use
Determination of Slip Melting Point (SMP)
1.1 Definition
The slip melting point is the temperature at which the fat
softenes or becomes sufficiently fluid to slip or run
1.2 Apparatus
Capillary glass tubing, internal diameter 0.8-1.2mm, wall
0.2-0.3mm, and length approxiamately 7cm
Thermometer -20℃ to 60℃ (graduated 0.2℃
Glass beaker 500-600ml
Test tube, internal diameter about 10mm, 1mm thickness
length 7cm with cap
Heat sources or electric stirring hot plate with rheostat
magnetic stirrer
Thermostat water bath or incubator set 10 +/- 1℃ or
refrigerator freezer also can be used but care should be
exercise to avoid opening it frequently once the samples
being tempered in it.
1.3 Method
1) Melt the sample and filter through filter paper to remove any
impurities and the last traces of moisture. The sample must be
absolutely dry
2) Dip at least 3 clean capillary tubes into the completely liquid
sample so that the fat stands approxiamately 10mm high in
the tubes. Solidify the sample at once by holding the ends of
the tubes that contain the sample pressed against a piece of
ice untill the fat has solidified. Do not allow the open ends
of the tubes to touch the ice. Wipe the tubes against a piece
of tissues paper as quickly as possible.
3) Place the capillary tubes in a test tube with a tight cover into
a beaker and hold in a refrigerator at 4 to 10℃ (40 to 50℉)
over night (16 hours). Remove the tubes from the refrigerator
and attach with a rubber band or by any other suitable means
to the thermometer so that the lower ends of the tubes are
even with the bottom of the mercury bulb of the thermometer
4) Suspend the thermometer in a 600ml beaker of a clear
distilled water. The bottom of the thermometer is immersed in
a water to a depth of +/-30mm
5) Adjust the starting temperature of the bath to 8-10℃ below
the expected slip point of the sample. Agitate the water bath
by means of a magnetic stirrer and heat slowly so as to
increase the batch temperature at the rate of 1℃ per minute
slowing down to 0.5℃ per minute as the slip point is
approached.
6) Continue heating until the fat column rises in each tube.
Observe the temperature of the water at which each column
rises and calculate the average of all tubes. The diffrence
between the three values should not be more 0.3℃
1.4 Expression of Result
Record the average value of triplicate results as the slip melting
point, expressed in one decimal place.
Sources:
1. http://camtrip.biz/fatty_acid.html