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MISGuidelines PalmOilIndustry PDF
MISGuidelines PalmOilIndustry PDF
For further information, please feel free to contact the Bureau of Water
Technology and Industrial Pollution Management of the Department of
Industrial Works, Ministry of Industry.
The palm oil industry has a high potential for biomass energy utilisation and
therefore is one of the industrial sectors, which can contribute substantially to
the supply of alternative sources of energy. To be more competitive and to
ensure supply of alternative sources of energy the palm oil mills therefore
have to introduce suitable measures for eco-efficiency improvement including
improved energy/environmental management.
Total area for Oil palm plantation in Thailand is currently (2005) about 1.93
million Rai, allowing the production of about 4 million tones of Crude-Palm-
Oil (CPO) in 2005, which is an 8% increase compared with the CPO
production in 2003.
The share of palm oil in Thailands vegetable oil industry is about 58%,
indicating the importance of palm oil for the countrys supply of edible oil.
Details of vegetable oil production distribution are shown in Figure 1.1a.
Sunflower 3%
Rice Bran 3%
Coconut 4%
Palm 58%
Soybean 21%
Details of oil palm plantation during 2002 2004 are provided in Table 1.1.a.
Currently there are a total of 38 palm oil factories using standard wet process
located in eight (8) provinces of Thailand. Total milling capacity is 1,610 ton-
FFB per hour. A list of the palm oil factories is provided in Table 1.1b below.
Source: Department of Alternative Energy Development and Efficiency (DEDE) & GTZ (2004)
Surat Thani province has a total of 12 palm oil mills, which is the highest number
of factories in a single province. Total production capacity of the mills in Surat
Thani province is 615 FFB per hour, followed by Krabi, Chumporn and Trang.
Locations of palm oil factories are close to the oil palm plantations, as shown in
Figure 1.1b.
Chonburi
Chumporn
Numbers of Factories in each Province
Ranong More than 10 factories
6 - 10 Factories
Surat Thani
1 5 Factories
Pang Nga
Krabi Nakhon Si Thammarat
Phuket Pattalung
Trang
Pattanee
Songkla
Satun
Yala
Naradhiwas
Source: Department of Alternative Energy Development and Efficiency (DEDE) & GTZ (2004)
The generated by-products are empty fruit bunch (EFB), fibre, shell, and
decanter sludge. In addition palm kernel are generated and subsequently used
for kernel oil production.
Losses in the production process can be avoided by, for example controlling
steam pressure and time during sterilisation to save energy, monitoring empty
fruit bunches to collect remaining palm fruits for re-sterilisation, controlling
the pressure during screw pressing to get maximum oil from fibre, etc.
Solid residues from palm oil mill include empty fruit bunch (EFB), fibre, shell
and decanter cake. Liquid residue is palm oil mill effluent. Utilisation of
these residues could reduce factorys waste disposal costs and reduce impacts
to the receiving environment simultaneously.
Almost all fibre generated by the mills is used internally as fuel in the boiler for
steam and electricity generation. The amount of fibre generated by the palm oil
mills is sufficient to satisfy all steam and electricity requirements for Crude
Palm Oil (CPO) production. If excess fibre is generated, it can also be sold as
biomass fuel to other industries (i.e. cement and power plants).
Since the amount of fibre is generally sufficient as energy source for an individual
the palm oil mill, the majority of shells generated is sold to other industries (i.e.
cement and power plants) as biomass fuel or for the production of activated
carbon.
Decanter cake from the oil separation process is either dumped as solid waste
or sold to farmers to be used as fertilisers or animal feed ingredient.
Wastewater generated from the palm oil mill has a high organic and nutrient
(Nitrogen) content and therefore can be used after suitable treatment for
irrigation in the oil palm plantation. Some mills are using the raw wastewater for
biogas generation, which is subsequently used for electricity production.
Utilisation of raw wastewater for biogas and electricity generation is discussed in
Section 2.1.9.
Information provided by the Thai-German E3Agro Project indicate that the total
installed production capacity of all existing palm oil mills is around 43% higher
than the existing supply of fresh fruit bunch (FFB) from the available oil palm
plantation area. Since the supply of FFB does not meet the demand of palm oil
mills shortages of raw material (FFB) and FFB price increases obstruct
competitiveness and further development of the palm oil industry in Thailand.
As a result, the profit margin of palm oil mills is comparatively small.
In recent years, a biogas system has been introduced to palm oil industry as its
application is proven to be economically viable. Process wastewater from the
palm oil production process is used as input to a system to generate biogases
mainly methane. Biogases are fed into gas engine to generate electricity, which
can be sold to the Provincial Electricity Authority (PEA). This is one of the
means that palm oil industry can generate additional revenue apart from crude
palm oil production. The application of biogas system can also reduce the
organic loading of the process wastewater and eventually minimise effect on
water pollution.
The palm oil industry has a high potential for biomass energy utilisation and
therefore is one of the industrial sectors, which can contribute substantially to the
supply of alternative sources of energy. Unused materials or by-products from
palm oil mills can be used as biomass fuel and sold to other industries, such as
shells, palm fibre and empty fruit bunch (EFB). Maximising the utilisation of
these by-products can contribute in improving business performance and provide
a competitive advantage to the palm oil industry.
In recent years, palm oil industry in Thailand has started to realise the
importance and benefits gained from eco-efficiency improvement. For
instance, palm oil mills have focused theirs efforts more on the management
of saleable by-products (i.e. shells and fibre), installation of biogas system, and
resource conservation activities.
The principle of palm oil production process is to extract the oil from palm
fruit using steam and pressing machine. The oil is then purified by the
application of gravity inducing oil separation. A schematic flow diagram of
the standard process of palm oil mills is shown in Figure 2.1a.
Empty Fruit
Threshing
Bunch (EFB)
Steam Digestion
Screw Pressing
Hot Water
Fiber-Nut
Vibrating Screen Fibre
Separation
Nuts
Shell-Kernel
Shells
Underflow Dryer Separation
Storage
Decanter-Separator
Sold
Water
Chemical Biogas
Wastewater Pre-treated
Treatment wastewater Biogas Stream
Steam Boiler
Electricity Plant Plant Generator Turbine
Diesel
Generator
2.1.2 Sterilisation
FFB are sterilised in order to inactivate the natural enzymatic activity and
loosen the fruit, as well as to soften the mesocarp, resulting in easier
extraction of oil. Sterilisation is carried out in autoclaves of 20 to 30 tons FFB
capacity, with the application of live steam, at temperature of 130 Celsius
and pressure of 3.1 bars, during 90 minutes.
2.1.3 Threshing
The sterilised FFB are sent to rotary drum threshers to separate the sterilised
fruits from the bunch stalks. The generated residues from this process
include empty fruit bunches (EFB) which contain moisture. EFB can be used
as organic fertiliser and soil conditioner as it maintains humidity of the soil.
It can be sold to local farmers for using as a substrate for mushroom cultivation.
Some mills introduce EFB pressing techniques to achieve lower moisture content
in the EFB, which can subsequently be used as biomass fuel in suitable boiler
systems for steam/electricity production.
2.1.4 Digestion
Screw pressing is a process to extract palm oil from mash. The extracted oil
phase is collected and discharged to the purification section while the solid
parts comprising fibre and nuts are separated by physical means.
This recovery process is further detailed in Section 2.1.8.
The process of oil purification is divided into four (4) sub-processes during
which the suspended matter is dissociated from the raw crude oil.
Screening of raw crude oil is carried out in order to separate large size of
solids such as dirt, fibres and fragments of the pericarps from the liquid phase.
Water is added to the raw oil and passed through a vibrating screen (Johnson-
Screen or Sweco-Screen) in order to improve the separation process. After
sieving, the oil still contains small size solids and water. Due to large surfaces
of contact of oil with air, the oil quality can be affected as an oxidation process
can occur.
The process is carried out to produce raw crude oil with expected composition
of 90%oil and 10% water.
The separated oil floating on top of the settling tank is then collected by
a funnel system and sent to the oil purification system. The settling tank
underflow is collected in the sludge tank and subsequently treated for
recovery of oil.
Purification
Raw crude oil from the settling tank (top oil) is combined with recovered oil
from the treatment of the settling tank underflow. This results in a total
crude-oil production of about 163 kg per ton of FFB being processed.
Centrifuges carry out this final oil purification step (solids removal).
For improved operation efficiency, these centrifuges are equipped with
an automatic cake discharge and cleaning system. As the suspended solids
content in raw crude oil is low, generated volumes of solid residues are
negligible leading to a lower impact on the environment.
Due to high content of water in the purified crude oil, a treatment process
referred as oil drying and cooling is required.
The purified crude oil goes into a vacuum evaporation system. Subsequently,
the dried crude oil is kept in storage tanks and sold to an oil refinery.
This crude oil drying process-step has a lower environmental impact.
The recovery process comprises two (2) sub-processes, which are carried out
in order to recover oil and to decrease the organic load of the liquid residue.
The bottom sludge from the oil separation tank is characterised by high oil
content (around 14%), high concentration of organic substances (both in the
dissolved form and suspended solids) and water-soluble substances.
In addition, the water phase contains fine fibres and sand.
Desanding
Decanting-Separating
Decanting process recovers the oil contained in bottom sludge from separation
tank. The oil is then returned to oil separation tank.
After the solids parts leave the screw press, fibre and nuts are separated by
physical means. The fibre is used as biomass fuel in boiler on-site, whereas
the nuts are sent to the nutcracker or ripple mill section for recovery of palm
kernel, which is another product of palm oil mill besides crude palm oil
(CPO). The shell is separated from the kernel and collected for sale as fuel to
other industries. Only a small portion of shells is used as boiler fuel at
the palm oil mill.
The main utility system in palm oil mill includes boiler, wastewater treatment
plant and biogas system (which is applicable to some of the palm oil mills).
Boiler
Wastewater Management
Generated wastewater from the palm oil mill typically goes to a biological
wastewater treatment process to ensure that effluent quality meets industrial
standard. However, in some palm oil mills, this generated wastewater with
high organic content (BOD 30,000 mg/l, and COD 90,000mg/l) undergoes
anaerobic digestion process as part of the biogas system for generating
electricity. Details are provided in the following section.
Environmental Management Guideline for Palm Oil Industry (1997) has provided
a review of suitable wastewater treatment technologies for palm oil industry,
including primary wastewater treatment, secondary wastewater treatment
and nitrogen removal.
Biogas System
Since palm oil wastewater has high organic load, it is suitable for producing
biogas by using an anaerobic treatment system. In the past, the most popular
wastewater treatment plant was pond treatment system, comprising anaerobic
pond, facultative pond, and polishing pond. Biogas generated from anaerobic
ponds was neither captured nor utilised. As energy price has significantly
increased in recent years, a biogas system has been introduced to palm oil
industry in order to reduce the cost of purchased energy.
Oil in FFB
Recovered Oil
CPO to sell
Oil loss in Wastewater
Decanter cake
Oil loss in
Thru CPO production since entering fresh fruit bunches (FFB) into production
process, losses of CPO occur in various sub-processes. Losses are via empty
fruit bunches (EFB), fibre, wastewater and decanter cake. According to
Environmental Management Guideline for Palm Oil Industry (1997), about 56% of
the oil loss is through solid residues i.e. EFB and fibre, while the other 44 % is
discharged along with the liquid residues (mainly oil-room effluent).
Hot water
Effluent
Fresh water is converted into steam by boiler operation. Steam is mainly used
for sterilisation, and is used for digestion of fruit bunches. The steam is
partially lost in the exhaust of the sterilisation stage. Vibrating screen and
settling tank in the oil room section also require water to aid the processes.
Process wastewater mainly comes from the oil room section prior to being
treated, and discharged as effluent from the wastewater treatment plant.
DRY PROCESS
OIL ROOM
WASTEWATER BIOGAS SYSTEM
UTILITY
Remark
Oil room section consumes the highest electricity, compared with the other sections.
*
All machinery and equipment in all sections of the palm oil production
process consume electricity. Electricity is mainly generated by the steam
turbine to sustain the production process, and in absence of plant operations
electricity is generated from the diesel generator. In some factories with
a biogas system electricity is produced mainly for selling and distributing to
Introduction to
MIS Application
3 MIS INTRODUCTION
3.1 BACKGROUND
Cost reduction;
Increasing quality of products and services;
Increasing innovations and employee motivation;
Responsibility to community;
Profitability;
Managing environmental risks and liability; and
Maintaining or increasing market share.
In this perspective, the introduction of MIS can provide valuable support for
successful decision-making at the management level in palm oil industry.
With such a tool, eco-efficiency improvement can be achieved while at
the same time, competitiveness can be enhanced.
3.4.1 People
The most important element in MIS is the people involved since all objectives
and benefits will be addressed by understanding personnel who will also
oversee MIS process, information and tools.
It should be noted that the amount of MIS personnel is based on plant owner
consideration. Typical roles and responsibilities in MIS implementation are
described as follows.
In general, there are three (3) levels of roles and responsibilities for personnel
involved in MIS implementation, comprising management role, supervision
role, and operation role.
Management Role
Supervision Role
Operation Role
Operation role can be assigned to any plant staff, who is involved in any
particular process that needs data collection. Typically, the plant personnel
taking the operational role come from different departments such as
production staff and laboratory staff. Understanding that data collection and
MIS procedure implementation are different tasks from regular operation
tasks, selecting personnel for this role requires those who understand and able
to perform MIS tasks with comprehension and care.
Nevertheless, this would depend on the plant owner insights, budget and
operations.
People, as described in the previous section (Section 3.4.1), will need to adopt
MIS processes and understand the information flow to implement MIS, and
successfully meet its objectives and benefits. A methodology for applying an
MIS needs to be selected for MIS implementation.
Every industry is different and so are their processes, information flow and
methodology. Conversely, the MIS processes could be applied to the palm oil
industry. This section describes typical MIS processes, information flow and
methodologies for applying an MIS.
Preparation Stage
At this stage, people roles need to be assigned, tools need to be selected and
acquired; processes will need to be set and communicated to relevant
personnel and departments. Training is often required for personnel of
related process. Management shall take on the role in identifying the needs
for MIS implementation, setting the strategy, objectives, and the foundation
and its cooperation between internal departments and management, which in
turn determines the achievement of MIS commencement.
After collection, data need to be consolidated and stored such as entering data
into software1 to be systematically structured for further analysis.
This process is sensitive and is regarded as the most human error process in
MIS. Entering incorrect data, into the system would lead to poor analysis.
To prevent human error, data verification process based on each plants MIS
policy may need to be implemented.
Personnel involved: MIS Supervisor and Assigned Operator
This process is optional depending on each plants MIS policy. This process
varies from industry to industry but is required for financial application
Data Processing
Processing of entered data will create sets of information that will allow
management to support decision-making. Each set of information will then be
compared and analysed to measure each production processes efficiency,
illustrated by key performance indicators (KPI), creating plant and industry
benchmarks. Data processing is generally carried out by software.
This process is viewed as the most vital process in MIS processes since data
processing will provide key information such as how efficient each process is,
how each data collected can help improve efficiencies, and how to initially
adjust each process for better throughput according to data analysis.
Decision-making
Information Flow
Methodologies
To capture and enter data through analyse and present information, all MIS
processes need to apply a methodology to centralise and store such data while
enable the information flow. Methodologies can be categorised as such:
Manual Method
This is the most labour intensive approach to carry out any process.
It requires involved personnel to utilise basic tools such as paper forms and a
calculator to perform process tasks. Filing of gathered or even analysed
information is at the heart of each method. The manual method requires
paper-based filing (storing) as actual working documents while act as back-up
copies at the same time.
This manual method requires the most resources when compare to the next
two methods but may present the most cost-effective approach due to low
investment in tools and low maintenance. However, this method presents
frequent human errors.
Management
Information
Data calculation reporting &
analysis
MIS Supervisor
Data storage
Data collection
& consolidation
Data
verification
MIS Operation
Decent GUI allows users to engage and interact with data whether entering,
formatting, calculating or so on with a low learning curve. However, good
GUI design also depends on the software functionality. If it serves simple and
straightforward functions such as data entry, it shall be designed to
accommodate the sequence of data to be entered for such industry specific
process.
No matter how well designed-software GUI is, error occurs at the interaction
of human and PC since human performs data input. In addition, data
auditing and process monitoring are viable options to assure better data
quality and lower human errors.
File-based is where MIS personnel create or adopt file associated to each MIS
processes and deploy them on role usage basis. For instance, data entry at
sterilisation process may have one PC with a file to enter data for such
particular processes involved. This approach, although widely practice,
presents problems of storage, analysis and reporting since data are scattered
in files on multiple PCs. To solve this problem, MIS can customise
productivity software such as Microsoft Excel and Access to service the
information flow. Such approach is an in-house software design, which
requires time, tools (network, cable wiring, database, server and so forth) and
resources and is not standard but highly customised to that particular
business. Consideration to take this approach depends on MIS know-how
and skill.
Automated Method
3.4.3 Tools
This section introduces MIS tools from paper-based to sophisticated tool, and
their attributes to consider its suitability to adopt.
Paper, pencil/pen and calculator are the most basic tools for any business
operation, and also the fundamental tools for MIS. No matter how
sophisticated MIS implementation can be, these tools would always be
required in business, as they are extremely familiar to any level of business
operation and are mostly adopted. Thus, application of these basic tools in
MIS process is straightforward. The advantage of these tools is that they
require almost no explanation in usage. The manual methodology requires
these sets of tools as mentioned previously for business continuity planning
and support.
For MIS, these tools can be applied specifically to data collection and
calculation processes. Unavoidably, as manual it is, prone to errors it
becomes. Repetition and verification of each process may be required to
guarantee its correctness.
In the late 1970s and early 1980s the personal computer (PC) has made its way
into every business. The reason is because it can support several tasks in one
machine lending a lot of equipment obsolete such as the typewriter.
However, it is the software inside the PC that makes all the difference.
Software are computer programs designed to serve specific tasks. The most
widely adopted next to operating system (programs to make PC function) is
productivity software such as Microsoft Office.
The common purpose of these two is storage of data; the difference is in its
form. A file cabinet files paper-based documents, but database files digital
information in a digitally structured file cabinet.
A database is crucial to store data for data input such as entering data for data
collection and data output such as displaying data consolidation to perform
calculation or even as a report. Database is an electronic centralised place for
data storage. Normally the access of data is from many PCs; therefore, a
database is usually placed in a server on a network of PCs to access.
Before or after storing data electronically, the actual paper is used for writing
down data collection from any production process to print outs of data forms
to perform calculation or reports. All need a physical location to store, which
is the file cabinet.
File cabinets act as a backup location for databases data printouts whether in
forms of raw data, data tables or reports. File cabinets are proven inadequate
to serve data input and output like databases. Hence, in business practice,
both coexist due to dependability. Procedures to guarantee the safety of
business data are also critically required; backup procedures are commonly
adopted.
A Local Area Network (LAN) comprises of multiple PCs, servers and network
equipment (i.e. hub, router, switch, etc.) to enable communication with other
PCs. The purpose of communication is to exchange information whether
being email, documents, data, and any forms of electronic information.
There are two (2) types of networks, which are wired/cable and wireless.
Wired/Cable Network
Wireless Network will use radio emission as media to carry the data over the
air between each PC. The advantage of wireless is the flexibility of location if
within radio emission reach, but it will sacrifice speed. When compare similar
size of networks, wireless networks are more expensive than wired.
MRP stands for Manufacturing Resource Planning; similarly ERP stands for
Enterprise Resource Planning. Both are software designed to connect
business processes and facilitate information flow using PCs, servers, and
network.
Each industry has its own specific MRP/ERP as processes are different.
For a given industry, MRP/ERP attempts to consolidate most processes by
using MIS. Currently, the average business that implements MRP/ERP can
bind 20% of the overall operation. This is due to the complexity of each
department and the interconnectivity to facilitate information flow.
Each department has its own sets of processes, which can create a complex
flow of information within the department. Implementing MRP/ERP requires
the management to to emphasize to all departments for cooperation. Over the
past two decades, Key Performance Indicator seems to be the driving force for
department cooperation.
Figure 3.4b illustrates different tools at each MIS process in accordance with
information flow.
It should be noted that tools are to facilitate people to carry MIS processes and
information flow; understanding the methodologies, nonetheless, is more
essential than selecting and acquiring tools. The reason being that with such
understanding, MIS can better select and apply suitable tools that support
process requirements.
Production Control
Process Modification
Decision making
Management
Data
verification
MIS Operation
MIS Methodologies
Process
Manual Software-enabled Automated
Pros/ Cons Most basic/ low-to- Widely adopted/ Currently best Highly effective/
no investment low investment practice/significant high investment
investment
Whether noting down data on a piece of paper then enter into a database form
or key-in collected data into a software on the plant floor and printout to store
in a file cabinet, a mixture of tools are often used based on each plants
operation, familiarity and budget. Therefore, a pre-defined set of tools is often
mistaken.
This section describes how an MIS process is applied to palm oil industry in
order to improve eco-efficiency. A production process model that facilitates
the MIS application for palm oil industry is hereby addressed. Also, the MIS
process for typical palm oil industry starting from data collection and
consolidation, data processing and to information reporting, is described.
In order to facilitate data collection as part of the MIS process for improving
eco-efficiency, a representative Production Process Model for a typical palm
oil mill has to be established. As a consequence, a typical production process
of palm oil mill (shown in Figure 2.1a) can be arranged or sub-divided into
five (5) sections comprising: Primary Production Process; Oil Room; Dry
Process; Wastewater & Biogas; and Utility.
Once raw crude palm oil comes out from screw pressing step, it enters the Oil
Room. The main task of Section 2 is to purify the raw crude palm oil and to
improve physical property of crude palm oil. This section comprises vibrating
screen, oil separation tank, de-sander, decanter-separator, purifier and dryer.
This section also produces a significant volume of wastewater and decanter
cake.
Dry process has a series of separation and drying activities of the fruit starting
from fibre-nut separation, nut drying and cracking, shell-kernel separation
and kernel drying. Kernel is one of the products from palm oil mills, which is
typically sold for further crude kernel palm oil production. During this
process, by-products are also generated such as fibre and shell. These by-
products can be used and sold as biomass fuels for other industries, such as
cement and power plants.
DRY PROCESS
OIL ROOM
Recovered Oil
WASTEWATER BIOGAS SYSTEM
UTILITY
In order to apply MIS, a set of data will continuously need to be acquired for
further usage. The first step as described in MIS principal process will be
the data collection and entry of each section in MIS production process model
(Figure 4.1a). After collecting data from each section, MIS will need to
consolidate all data into one centralised place whether on paper or in
a computerised format such as an excel file or a database. This is to help
facilitate the information flow for further processes.
Priority 1 Data that are directly related to palm oil productivity and the
use of main raw materials as well as the management of value-added
unused materials where economically viable to palm oil mills. In addition,
environmental data required to be reported to the government are also
included (Examples of data include the use of fresh fruit bunch, the use of
water, saleable shell and effluent quality); and
Priority 2 Data that are indirectly related to productivity of the palm oil
mills including pollution outputs from the production process, and also
those data that play a key role in the production process however are
hardly or costly measured at present (Examples of data include disposal of
decanter cake and boiler stack emissions).
Priority 1 data are the minimum data requirements for applying meaningful
MIS for increasing business competitiveness and enhancing eco-efficiency for
a typical palm oil mill. In addition, these data will be further processed into
information or performance indicators to allow the management to use and
make decisions based on the given information. A set of management
information is addressed in Table 4.4a of this Guideline.
Whereas, Priority 2 data are optional data requirements that are useful and
help business competitiveness and eco-efficiency however these data are
considered as the second priority for the palm oil mills (with less concern than
Priority 1 data). Thus, these data will not be transformed to the information
or performance indicators in this Guideline (but can be added on according to
the specific needs of individual palm oil mill).
In general, the collected data are first stored in a database and processed in
MIS software, and then key performance indicators (KPIs) are created and
these information are reported to management for decision-making.
Remark
* - Priority of data collection is classified into two levels: 1 as minimum data requirements and 2 as optional data requirements, based on the criteria mentioned earlier.
OIL ROOM
Recovered Oil
Remark
* - Priority of data collection is classified into two levels: 1 as minimum data requirements and 2 as optional data requirements, based on the criteria mentioned earlier.
Remark
* - Priority of data collection is classified into two levels 1 as minimum data requirements and 2 as optional data requirements, based on the criteria mentioned earlier.
Remark
* - Priority of data collection is classified into two levels: 1 as minimum data requirements and 2 as optional data requirements, based on the criteria mentioned earlier.
From Threshing
Water
Biomass
UTILITY
E7 Fuel
Steam
Steam Boiler
Turbine
E8 W13 W14
Electricity used or
sold to Grid Diesel Blowdown Emission
E10 Generator
To Sterilisation Digestion
Steam
Remark
* - Priority of data collection is classified into two levels: 1 as minimum data requirements and 2 as optional data requirements, based on the criteria mentioned earlier.
Remark
* - Priority of data collection is classified into two levels: 1 as minimum data requirements.
In order to enhance business advantage and eco-efficiency of the palm oil mill,
Priority 1 data listed in the previous section are required to be processed and
transformed into information or key performance indicators using MIS
software that can allow the management of native starch factories to use such
information for their own analysis and making decision.
Remarks
(1) - The amount of kernel and oil loss/gained depends on internal control value of individual palm oil mill factory.
Management personnel of the palm oil mills may require different information.
Typical reporting contents for each management personnel are addressed below
(It should be noted that the needs of information by these personnel have been
established base on the interviews with management representatives of selected
palm oil factories).
Owner
CPO Yield
Value of CPO Yield
CPO Production
Value Added From FFB to CPO
Unit Market Price of CPO
Amount of Sold CPO
Proceeds from Sold CPO
Amount of Sold CKPO
Proceeds from Sold CKPO
Production Operating Hour
Capacity Utilisation
Kernel Yield
Kernel Production
Value of Kernel Yield
Unit Market Price of Kernel
Amount of Sold Kernel
Proceeds from Sold Kernel
Value of Kernel Losses in Shell-Kernel Separation Processes
Use of FFB
Total Expense of FFB
FFB Quality Index
Average Unit Cost of Acquired FFB
Water Consumption
Shell Sold/ FFB Used
Share of Saleable By-Products (Fibre and EFB)
Factory Manager
CPO Yield
Value of CPO Yield
CPO Production
Value Added From FFB to CPO
Unit Market Price of CPO
Amount of Sold CPO
Proceeds from Sold CPO
Amount of Sold CKPO
Proceeds from Sold CKPO
Production Operating Hour
Capacity Utilisation
Kernel Yield
Kernel Production
Value of Kernel Yield
Unit Market Price of Kernel
Amount of Sold Kernel
Proceeds from Sold Kernel
Value of Kernel Losses in Shell-Kernel Separation Processes
Use of FFB
Total Expense of FFB
FFB Quality Index
Average Unit Cost of Acquired FFB
Shell Sold/ FFB Used
Share of Saleable By-Products (Fibre and EFB)
Value of Saleable By-Products (Shell, Fibre and EFB)
Oil Losses in the Process (Decanter Cake, Wastewater and Fibre)
Value of Oil Losses in Process (Decanter Cake, Wastewater and Fibre)
Generation of By-Products (EFB, Decanter Cake, Shell, Fibre, and Wastewater)
Production of Fibre
Generation of Biogas
Production Manager
CPO Yield
Value of CPO Yield
CPO Production
Value Added From FFB to CPO
Unit Market Price of CPO
Amount of Sold CPO
Proceeds from Sold CPO
Amount of Sold CKPO
Proceeds from Sold CKPO
Production Operating Hour
Capacity Utilisation
Kernel Yield
Kernel Production
Value of Kernel Yield
Unit Market Price of Kernel
Amount of Sold Kernel
Proceeds from Sold Kernel
Kernel Losses in Shell-Kernel Separation Processes
Value of Kernel Losses in Shell-Kernel Separation Processes
Shell Sold/ FFB Used
Share of Saleable By-Products (Fibre, and EFB)
Value of Saleable By-Products (Shell, Fibre, and EFB)
Oil Losses in the Process (Decanter Cake, Wastewater and Fibre)
Value of Oil Losses in Process (Decanter Cake, Wastewater and Fibre)
Use of FFB
Total Expense of FFB
FFB Quality Index
Average Unit Cost of Acquired FFB
Utility Manager
Use of FFB
Average Unit Cost of Acquired FFB
Production Operating Hour
Kernel Losses in Shell-Kernel Separation Processes
Oil Losses in the Wastewater
Water Consumption
Generation of Wastewater
Generation of Biogas
Generation of Electricity from Biogas System
Generation of Steam from Boiler Operation
Saleable Electricity from Biogas System
COD Removal by Biogas System
Wastewater Treatment Efficiency (BOD)
Wastewater Treatment Efficiency (COD)
Influent Wastewater Characteristics (BOD) prior to being sent to the treatment
system
Influent Wastewater Characteristics (COD) prior to being sent to the treatment
system
Organic Loading of Biogas System
Treated Wastewater Characteristics (BOD) at the final pond of the treatment
system
Treated Wastewater Characteristics (COD) at the final pond of the treatment
system
Chemical Usage for Wastewater Treatment
Electricity Consumption for Wastewater Treatment
Electricity Consumption from the Steam Turbine Generation, Provincial
Electricity Authority (PEA) and Diesel Generator
Total Electricity Consumption
Total Electricity Consumption Rate
Expenses on Purchased Electricity from the PEA
Average Cost of Purchased Electricity from the PEA
E4 Electricity Consumption for kWh/Day - - - Daily The amount of electricity consumption for wastewater treatment
Wastewater Treatment indicates the functioning of wastewater treatment system. This data
is one of the data being required for reporting to the Department of
Industrial Works.
W6 Influent Wastewater mg/l - - - Monthly Influent characteristics of wastewater provides information on
Characteristics (BOD) prior to influent quality and help the estimation of wastewater loading prior
being sent to the treatment to entering the treatment system, in order to allow the in-charge
system operator to properly control and maintain the treatment efficiency
W10 Influent Wastewater mg/l - - - Monthly Influent characteristics of wastewater provides information on
Characteristics (COD) prior to influent quality and help the estimation of wastewater loading prior
being sent to the treatment to entering the treatment system, in order to allow the in-charge
system operator to properly control and maintain the treatment efficiency
W7 Treated Wastewater mg/l Monthly Monthly Monthly Monthly Quality of treated wastewater at the last pond provides information
Characteristics (BOD) at the on compliance status of treated effluent.
final pond of the treatment
system
Remarks
(1) - The amount of oil loss/gained depends on internal control value of individual palm oil mill factory.
Cecelja, Franjo (2001) Manufacturing Information and Data Systems, First Edition :
Analysis, Design and Practice (Manufacturing Engineering Series)
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