Journal of Design for Sustainable and Environment, Vol. 1 No. 2 (2019) p.

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JDSE Journal of Design for Sustainable and Environment

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Design and Finite Element Analysis (FEA) of Palm Oil Mill

Thresher Drum Spider Arm
Mohd Hezri Mokhtar1,2,a*, Ashikin Ibrahim2, Huda A Majid1,b, Mimi Suliza Muhamad1,c

1Advanced Technology Centre, Faculty of Engineering Technology,

Universiti Tun Hussein Onn Malaysia, Pagoh Education Hub, 84600 Pagoh, Muar, Johor, MALAYSIA
2
Department of Mechanical Engineering Technology, Faculty of Engineering Technology,
Universiti Tun Hussein Onn Malaysia, Pagoh Education Hub, 84600 Pagoh, Muar, Johor, MALAYSIA

*Corresponding Author

Email: ahezri@uthm.edu.my, bmhuda@uthm.edu.my, cmsuliza@uthm.edu.my

Received 03 August 2019;
Accepted 15 October 2019;
Available online 31 October
2019
Abstract: This study aims to prevent cracks and failure of spider arm caused by the impact of the
load. It was designed based on observation to improve the existing design of spider arm for thresher
drum that is used in Palm Oil Mill Industry. Spider arm is one of the part in thresher drum. There
are three plates of spider arm welded inside the thresher drum located at the center and each end of
the horizontal cage. A thresher drum cage is supported by these spider arms which is linked to the
shaft that was driven by a motor. This drum type thresher is the common machine used to separate
the fruits from sterilized fresh fruit bunches (FFBs). Based on the observation, the spider arm had
several problems where the plate of the spider arm usually cracks and has high potential of failure
which increase the maintenance cost. Therefore, three new designs of spider arm were constructed
using Computer-Aided Design (CAD) software and analyzed by Finite Element Analysis (FEA) in
SolidWorks simulation. Then, the analysis of the three new designs were compared by decision
matrix in order to get the final result, which is the best design of spider arms. The final design can
withstand the fatigue problem which lead to prolong lifespan of the spider arm.

Keywords: Spider arm, Thresher drum, Palm oil mill, Cracks, Finite element analysis

1. Introduction avoiding Free Fatty Acid (FFA) content in oil further increase
The oil palm is originally from Africa but Malaysia is the [3]. Then, FFBs are transfer to a thresher drum which is used to
first country to embark on a large-scale planting and processing separate the palm fruit from the FFB. Thereafter the palm fruits
[1]. Nowadays, palm oil is an important source of food and a are conveyed to a digester, while the Empty Fruit Bunches
major source of lipid. High increase in the world population (EFBs) are returned to the plantation for bio-compost.
increases the demand for palm oil as an important source of
edible oils and fats.
The commercial value of this crop lies mainly in the oil
that can be obtained from mesocarp of the fruit palm oil and the
kernel of the nut-palm kernel oil. As shown in Fig. 1, the
individual fruit is made up of an outer skin (exocarp), a pulp
(mesocarp) containing the palm oil in a fibrous matrix. A
central nut consisting of a shell (endocarp) and the kernel (seed)
which itself contains an oil, quite different from palm oil and
resembling coconut oil [2].
Palm oil mill processes start with collecting the FFBs,
follows by weighing on the weigh bridge before being filled
Fig. 1 - Anatomy of oil palm fruit
into the cages and transfer to a sterilizer. The sterilization of the
FFBs is necessary to prevent enzymes from broken down and

*Corresponding author: hezri@uthm.edu.my

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 Mokhtar, M. H.et al., Journal of Design for Sustainable and Environment, Vol. 1 No. 2 (2019) p. 1-6
In the digester, the palm fruits are pounded and turned into
a mash which consists of mesocarp, fibers and nuts which
contain kernels. This mash is transferred to the screw press
where oil is pressed out. The remaining fibers and nuts are
recovered and dried. The press liquor is flowing to a
continuously settling tank, where oil and sludge are separated.
The clarified oil on the top phase of settling tank is
pumped into a centrifuge for final clarification before being
dried in a vacuum dryer. Then, the Crude Palm Oil (CPO) is
ready to be stored in the tank. The bottom phase of settling tank
is the sludge which goes into the decanter. There, the remaining
oil is recovered, while Palm Oil Mill Effluent (POME) and
solid waste are separated. The latter can be used as organic
fertilizer in the plantation [4].
The whole process in palm oil mill shows the development of
machinery and the establishment of plantations will provide the
opportunity of fully mechanized processing, from harvested
FFBs to a high yield of a quality product. Therefore, it is
important to make a machinery that can acquire high durability
and efficiency systemically.
In palm oil mill industry, the spider arm of thresher drum
always has same problems of cracks and fracture as shown in
Fig. 2. This problem affects the whole process which can make
the palm oil mill process breakdown. The target product will
not be achieved and a lot of time will be wasted to repair the
broken part. This will affect the cost and energy used to do the
maintenance.
Fig. 2 - The cracked of spider arm
Based on the problems, the design of spider arm need to
be improved. The design must be able to prevent cracks and
failure caused by the impact of load. The design also must
withstand the fatigue problem which helps to prolong the life
of spider arm. Thus, the objectives of this project are to remodel
the spider arm in Computer-Aided Design (CAD software
using SolidWorks. Next, to analyze and compare the model
with the existing spider arm. Finally, to propose the best design
of spider arm.
In order to explore the viability of using existing spider
arm in palm oil mill industry, it is essential to establish
fundamental data. The tasks to be accomplished to achieve the
objectives of this study includes the research on the thresher
drum in palm oil mill industry (Sindora Palm Oil Mill). Next,
the modification on the design of spider arm constructed by
using CAD software of SolidWorks and analyzing the
performance design of spider arm using FEA of the SolidWorks
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simulation. Lastly, the selection of design by decision matrix
between new designs and existing design of spider arm.
2. Literature Review
The function of thresher drum is to separate the sterilized
FFBs that come from the sterilizer [5]. The need for good
threshing machine is even more important at palm oil mill
industry such as a high throughput as target. In such
circumstances reliance must be placed on maintaining a very
low percentage of hard and incompletely stripped bunches are
being EFBs throughout to ensure that the threshing machine is
satisfactory [6].
In principle, the rotary drum thresher known as thresher
drum is quite simple. The machine consists of a long horizontal
cylindrical drum which is rotating continuously. The sterilized
bunches are fed in continuously at one end and EFBs pass out
continuously at the other end.
The cylindrical inner surface of the drum is made up of
spider arm. Thresher drum are often built with a central shaft
which support itself at bearings to be linked with the spider arm.
Spider arm also gives an impact to the stalks which cause the
fruit to detach from the bunch. The surface of the drum was also
made up of tee-bars, arranged at equal distances around the
outer circumference of the drum. The clearance between the
bars was sufficient to allow the released fruit to drop through
these gaps, whilst the empty bunch stalks remain inside the
drum and were transported to the end of the drum.
Spider arm is one of the thresher drum parts as shown in
Fig. 3. There were three plates of spider arm welded inside the
thresher drum located at the center and each end of the
horizontal cage. A thresher drum cage supported by these
spider arms which link it to the shaft. The shaft then was driven
by the motor.
Fig. 3 - Spider arm of thresher drum
The most commonly used thresher machine is the rotary
drum type, which depending on its physical size. It can have a
capacity about 45 ton FFBs/hour. The sterilized bunches were
fed into the thresher drum, which rotated at a fixed speed, 24
rpm. The specifications are as shown in Table 1. A compromise
has to be reached to obtain the most efficient threshing process
and the stripping effect.
Table 1 - Specification of thresher drum
Specifications
Capacity 45 tons FFB/Hour
Speed 24 Rpm
Drive 30 Hp
 Journal of Design for Sustainable and Environment, Vol. 1 No. 2 (2019) p. 1-6

Thresher drums are mostly used in the palm oil mill

industry because of its simplicity and low cost. The radially
arranged arms known as spider arms were mounted on the
shaft. These were made of mild steel flat welded or bolted to
the inner surface of the cage. Mild steel is a type of steel
containing a small percentage of carbon, strong and tough but
not readily tempered, also known as plain-carbon steel, is now
the most common form of steel because its price is relatively
low while it provides material properties that are acceptable for
many applications. The material specification of mild steel as
shown in Table 2. The new designs of spider arm used the same
material of mild steel as an existing spider arm. effect.

Table 2 - Material specification of mild steel

Material specifications
Density 7.85 g/cm3
Tensile Strength, Ultimate 400 -550 MPa
Tensile Strength, Yield 250 MPa
Modulus of Elasticity 200 GPa
Bulk Modulus 140 GPa
Shear Modulus 79.3 GPa
Elongation at Break 20.0 %
Poissons Ratio 0.260

The performance designs of spider arm were analyzed

using Finite Element Analysis (FEA) of the SolidWorks
simulation. FEA is a computer based method of simulating and
analyzing the behavior of engineering structures and
components under a variety of conditions. It is an advanced
engineering tool that is used in design and to augment or
replace experimental testing. FEA provides engineering
information of stress-strain about a structure which cannot be
obtained by using traditional analysis methods [7].
This study employed the solidworks simulation for FEA.
Solidworks simulation uses the displacement formulation of the
FEM to calculate component displacements, strains, stress and
factor of safety under internal and external loads [8]. The
analysis helps in evaluating the feasibility of the new design as Fig. 4 – Methodology flowchart
Based on the observation in Sindora Palm Oil Mill, the
well as finding solutions without the need to prototype and
dimensions had been taken. Besides the material, the outer
waste time or cost.
diameter which is welded to the cage, 2240mm with width of
200mm and inner diameter which is link to the shaft, 160mm
3. Methodology
will be fixed. Table 3 shows the detailed existing design of
The FEA using SolidWorks simulation will be tested on spider arm.
the designs of spider arm. The material of mild steel will be The ideal failure model in FEA will represent the existing
fixed and the design of spider arm will be changed for design of spider arm. For completion, three new designs of
improvement. Fig. 3 shows the methodology flowchart of the spider arm will be constructed as an improvement of the
project. This test was conducted to prove that the best design of existing design. The designs will be improved by increasing the
spider arm can avoid the fatigue problem and have prolonged thickness and the width of the center spider arm. The analysis
life. of the designs will be compared by using decision matrix in
order to get the best design. Table 4 shows the details of Design
A, Table 5 shows the details of Design B and lastly Table 6
shows the details of Design C.
Table 3 - Dimensions of existing design
Parts Dimensions (mm)
Thickness of plate 180
Width of center1 400
Thickness of center1 5
Width of center2 350
Thickness of center2 20

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 Mokhtar, M. H.et al., Journal of Design for Sustainable and Environment, Vol. 1 No. 2 (2019) p. 1-6

Table 4 - Dimensions of Design A

4. Result and Discussions
Parts Dimensions (mm)
All the simulations were conducted in the same test, run
Thickness of plate 190
by the SolidWorks simulation which used the static analysis.
Width of center1 400 The results for existing design and new designs of spider arm
Thickness of center1 20 were shown in a table and discussed. The analysis data was
ranked in decision matrix form to select the best design. Fig. 4
Width of center2 350 shows the simulation results of Existing Design, Fig. 5 shows
Thickness of center2 20 the simulation results of Design A, Fig. 6 shows the simulation
results of Design B and Fig. 7 shows the simulation results of
Design C.
Table 5 - Dimensions of Design B
Parts Dimensions (mm)
Thickness of plate 200
Width of center1 600
Thickness of center1 20
Width of center2 350
Thickness of center2 20

Table 6 - Dimensions of Design C

Parts Dimensions (mm)
Thickness of plate 210
Width of center1 700
Thickness of center1 20
Width of center2 500
Thickness of center2 20

In analyzation process, FEA method is comprised of three

stages. The technique is based on the premise that an
approximate solution to any complex engineering problem. Fig. 5 - Simulation results of existing design
First stage, the pre-processing involves the preparation of data,
such as nodal coordinates, connectivity, boundary conditions
and loading and material information. Second stage, the
analysis involves stiffness generation, stiffness modification,
and solution of equations, resulting in the evaluation of nodal
variables. Third stage, the post-processing stage deals with the
representation of results. Typically, the deformed
configuration, mode shapes, and stress distribution are
computed and displayed at this stage [9].
Finally, the simulation data of designs will be evaluated
by decision matrix which is based on concept evaluation.
Concept evaluation is the evaluation of design concept implies
and involves both comparison and decision making [10].
Evaluation technique requires a comparison between the
concepts evolved and the requirements must be filled along
with conclusions affecting how well they fit those
requirements. For this project, decision matrix is chosen as a
technique for evaluating the concept design.
The different decision criteria of new designs are listed as
the rows and the relevant factors affecting the decisions are
listed as the columns [11]. Then, establish a ratings scale to
assess the value of each design or factor combination. Each
combination was given a weighted ranking to determine how
important that factor in the final decision. Next, multiplying Fig. 6 - Simulation results of Design A
original ratings by the weighted rankings to get a score. All of
the factors under each option should then be added up. These
scores are for determining which design is most advantageous
to be the best design of spider arm.
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 Journal of Design for Sustainable and Environment, Vol. 1 No. 2 (2019) p. 1-6
Fig. 7 - Simulation results of Design B
Fig. 8 - Simulation results of Design C
From the static analysis simulation, there are four
categories; stress, displacement, strain and factor of safety.
These data are important to determine which new designs that
can endure the fatigue from occurring, better than existing
design. Fig. 8 below shows the result analysis of the designs.
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Fig. 9 - Result analysis of the designs
First criteria in the result analysis is stress which is the
point where the design is safe or fail. The lower the stress, the
safer the design, since the stress needs to be lower than yield
strength to get the safe design. Second criterion is the
displacement. Displacement in the design was determined by
the amount of force and needs to be optimized to work within
the given requirements. The lower the displacement, the better
the design.
Third criterion is strain which is a measure of geometric
response and the change in shape due to the applied forces.
Strain and stress are linked together by ratio of Elastic Modulus
or Young’s Modulus, which change by material. The lower the
strain, the safer the design. The last criteria, which is the factor
of safety, is the ratio of the maximum stress that spider arm can
withstand to the maximum stress it will be subjected to in
operation. The higher the minimum factor of safety, the better
the design.
From the result analysis, it can be concluded that Design
C is the only one that fulfills all the requirements. To prove it,
decision matrix will be used. It is an important selection that
was made by the evaluation rating in each criterion. Table 7
below shows the evaluation rating that was used to calculate the
matrix and Table 8 shows the rating for each criterion that will
be analyzed.
Table 7 – Evaluation rating
Rate Description
5 points Excellent
4 points Very good
3 points Good
2 points Poor
1 point Very poor
 Mokhtar, M. H.et al., Journal of Design for Sustainable and Environment, Vol. 1 No. 2 (2019) p. 1-6

Table 8 – Rating for each criterion number H457) and Short-Term Grant (STG – Vote number
U381).

References
[1] Malaysia Palm Oil Council (2012), “Malaysian Palm Oil
Industry”, Retrieved from
http://www.mpoc.org.my/Malaysian_Palm_Oil_Industr
y.aspx.
[2] Oi-Ming Lai, Chin Ping Tan, Casimir C. Akoh (2015).
“Palm Oil: Production, Processing, Characterization and
Table 9 – The value of displacement, stress, strain and Uses”. Elsevier, pp. 471.
factor of safety for each new design
[3] Cheng Hai Teoh, (2012), “The Palm Oil Industry in
Rate Design A Design B Design C Malaysia”, Retrieved from
Displacement http://www.wwf.ch/default.cfm.
0.0104331 0.00858243 0.00735391 [4] Rafidah Abd. Razak (2016), “The Introduction and
(mm)
Process in Sindora Palm Oil Mill, Sindora Palm Oil
Stress (N/m2) 1666506.3 1568519.8 1473646.8 Mill”, Kluang, Johor.
Strain ( x10-6) 5.95 5.41 5.11 [5] Food and Agriculture Organization, (2004), “Small Scale
Factor of Safety 210.96 224.14 238.57 Palm Oil Processing in Africa, Food and Agriculture
Organisation of United Nations”, Rome Italy, Science
Bulletin, pp. 148.
[6] Ojomo, A.O. Ologunagba, F.O. and Alagba, S.A. (2010),
Table 10 – Decision matrix for new designs “Performance Evaluation of a Palm Fruit Bunch
Rating Stripper”, Journal of Engineering and Applied Sciences,
Criteria
Design A Design B Design C volume 5, pp. 29-33.
[7] Randy Shih, (2011), “Introduction to Finite Element
Displacement 3 4 5
Analysis Using SolidWorks Simulation”, Schroff
Stress 3 4 5 Development Corporation, pp. 13-29.
Strain 3 5 5 [8] Paul Kurowski, (2011), “Engineering Analysis with
SolidWorks Simulation”, Schroff Development
Factor of Safety 2 4 5 Corporation, pp. 4-11.
Total 11 17 20 [9] T. Chandrupatla, (2004), “Finite Element Analysis For
Engineering & Technology”, Universities Press (India)
Table 9 shows the value of displacement, stress, strain and Private Limited, pp. 220.
factor of safety for each new design which was obtained from [10] Filippo A. Salustri, (2002), “Concept Evaluation and
the simulation result. Meanwhile, Table 10 shows the decision Decision Matrix”, Retrieved from
matrix for new designs. From the total points of rating in http://deseng.ryerson.ca/~fil/t/oldT/concept/evaluation1.
decision matrix shows that Design C has the highest point, 20. html
This result of decision matrix proved the previous result [11] P. Van Staaden , (2006), “A Case Study on the Selection
analysis that stated the Design C is safer and better than existing and Evaluation of Software for an Internet Organisation”,
design of spider arm. Faculty of Informatics, Cape Peninsula University of
Technology, Cape Town, South Africa, pp.
5. Conclusions
This study proposes the best design of spider arm. The
designs were improved based on the existing design of spider
arm and analyzed by the SolidWorks simulation of static
analysis. Design C fulfills all the requirements; stress,
displacement, strain and factor of safety, better than the existing
design of spider arm. The result of decision matrix proved that
Design C has the highest point of rating.
Apart from improving the design of spider arm, it is also
important to consider on the cost of manufacturing. Although
the design was improved, the cost of manufacturing maybe
higher than the existing design. Besides that, the design of
spider arm can be analyzed in more detail by using SolidWorks
simulation of fatigue analysis that can show the cyclic limit and
prolong the lifespan of spider arm

Acknowledgement
The authors would like to acknowledge the support of this
work by Universiti Tun Hussein Onn Malaysia on research
grant TIER-1 (TIER 1-Vote number H189), (GPPS-Vote

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