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DEVELOPMENT OF A MECHANIZATION
SELECTION SYSTEM FOR OIL PALM
PLANTATIONS WITH ALTERNATIVE
PLANTING PATTERNS
HELENA ANUSIA JAMES JAYASELAN* and DESA AHMAD*
ABSTRACT
This article describes a study on the conceptual design and development of the most efficient mechanization
selection system for oil palm plantations with alternative planting patterns. The study was conducted by
extrapolating various planting patterns based on the existing triangular pattern and comparing these with
machine information based on a constant mechanization package made for a large and rather flat area. The
comparison of machines was conducted in earlier studies based on a combination of various plantation
operations like fertilizer application, weeding, harvesting, in-field collection and loose fruit collection. The
results obtained suggest that the most efficient planting pattern is the triangular planting pattern. The
findings from this study will help to determine the efficiency of each machine besides optimizing the cost of
implementing the package.
Date received: 3 May 2010; Sent for revision: 5 May 2010; Received in final form: 20 August 2010; Accepted: 6 January 2011.
990
DEVELOPMENT OF A MECHANIZATION SELECTION SYSTEM FOR OIL PALM PLANTATIONS WITH ALTERNATIVE PLANTING PATTERNS
carried out but no unified suggestions have throughout the life span of the palms, showed that
emerged. Hartley (1967) reviewed the problem a figure of 139 palms per hectare was most suitable
and concluded that “From the scanty information (Turner and Gillbanks, 1974). Results from the
available……a density of about 29-30 ft triangular Congo were similar, and it was concluded that a
was suitable in Africa…..”. In the Far East “…… range of 138-148 palms per hectare was the most
it would be unwise……to reduce the stand much suitable single-density planting. An experiment in
below 60 palms per acre” (Corley et al., 1973). Sumatra showed that by the 12th year, a reduction
Hartley’s recommendations were for maximum to 96 palms from its original 120 palms per hectare
cumulative yield over the life of the palms, but resulted in no yield loss. Thus, it seems that in the
optimal density can be defined in several ways long run, a lower density gives the highest overall
which include: the density giving the highest yield.
current yield in any given year; the density giving High-density planting can be carried out in the
the highest cumulative yield over a given period; initial few years, before the palms start to enter the
and the density giving the maximum cumulative stage of inter-palm competition. This indicates that
profit, with or without a discount on returns, the effect would be minimized at an intermediate
over a given period. Usually the second and third spacing where there is high maintenance. The time
definitions are preferred where the period used is of thinning is critical, because one of the effects of
the economic life span of the palms which is 25-30 competition at high densities is to induce a high
years (Corley et al., 1973). rate of male inflorescence formation; thus, delayed
The existing planting pattern is triangular in thinning leads to yield loss (Turner and Gillbanks,
which the palms planted in one row are positioned 1974).
opposite the mid-points of the inter-palm space in Should double intensity planting be envisaged,
adjacent rows. This gives a greater utilization of it would require a hexagonal planting design which
the land for crop nutrition and of available space would give a triangular pattern after thinning.
and light for crown development (Turner and A trial in Malaysia proved triangular planting to
Gillbanks, 1974). It has been proven in Africa that be superior over hexagonal planting. Some of the
a triangular planting pattern results in a higher advantages of high-density planting are increased
yield than from a square pattern. This is achieved productivity of the land from the time of bearing
because the distance between the rows will be less onwards, and earlier and fuller use of capital
than the planting distance between palms within a investment in a factory, while the disadvantages
row, and the inter-row distance can be calculated by of high-density planting are higher costs of
using the following formula: establishment, planting and harvesting, and so on.
For effective and efficient FFB transport, in-field
• row distance = palm spacing in a row ×
mechanization is used. These machines are used to
0.866.
transport the harvested FFB safely and with minimal
• the angle from one palm to the nearest in an
damage in order to produce high quality oil (Teo
adjacent row = 180 ÷ 3 = 60°.
et al., 1993). Some of the machines used in many
There are many factors influencing the growth of plantations in Malaysia are the mechanical Grabber,
the palm and its yield, which include the planting the compact transporter, the mechanical harvester,
density. During the young stage, there is less the motorcycle trailer, the general-purpose vehicle,
competition for nutrients and light between the the mechanical loose fruit collector; the air-assisted
palms but as they mature and develop canopies, loose fruit separator, the Crabbie mechanical loader,
the competition rises. The dense canopies result the half-track machine, the mechanical buffalo, the
in reduced dry matter production, leading to Rambo and the Taltrac (Helena et al., 2009).
a reduction in yield. Some factors affecting the From studies conducted earlier (Helena et al.,
young palms include initial vegetative conditions, 2009), Package A which was a combination of a
standard of maintenance and level of fertilizer spreader with a mini tractor (40 hp) for fertilizer
application, soil type, fertility, water availability, application, a tanker sprayer (600 litres) with a mini
rainfall distribution and the amount of sunshine tractor (40 hp) for weeding, a motorized cutter for
over the year as well as genetic differences (Turner harvesting, the Wakfoot; a single chassis-machine for
and Gillbanks, 1974). low ground pressure was used for in-field collection,
Plants planted at higher than their optimum and an air-assisted fruit separator for loose fruit
density show overcrowding symptoms such as collection was suitable for a rather flat large area,
reduced light intensity and less inter-row vegetation, especially in the big estates. Subsequently, Package
fronds from neighbouring palms interlock and B which is a combination of a spreader with a mini
overlap reducing photosynthesis and vegetative tractor (40 hp) and lower ground pressure (LGP)
matter production, as well as other factors. In Ivory tyres for fertilizer application, a tanker sprayer (600
Coast, an extensive trial to assess the optimum litres) with a mini tractor (40 hp) and LPG tyres for
density, where the same density was retained weeding, a motorized cutter for harvesting, a half-
991
Journal of Oil Palm Research 23 (APRIL 2011)
track machine for in-field collection, and an air- MATERIALS AND METHODS
assisted fruit separator for loose fruit collection was
found to be suitable for areas with soft soil to reduce A variety of planting patterns was studied to
further compaction and yet be able to maintain estimate a more efficient use of machinery to
high productivity. Package C, a combination of a obtain a better yield. Studies were carried out on
spreader with a mini tractor (40 hp) for fertilizer the different kinds of planting patterns, such as
application, a tanker sprayer (600 litres) with a mini the triangular, rectangular, square and even the
tractor (40 hp) for weeding, a motorized cutter for hexagonal shapes, to calculate the most efficient
harvesting, an iron horse with a capacity of 500 to use of space and to determine the effects of the
600 kg which is suitable to work at terraced area due soil texture as well as nutrient absorption in the
to its small structure was used for in-field collection, production of the best FFB yields.
and an air-assisted fruit separator for loose fruit Based on the existing triangular planting pattern,
collection, was suitable for hilly and terraced an extrapolation of the square, rectangular and
areas. Next, Package D which is a combination of hexagonal planting patterns was derived. Figures
a spreader with a mini tractor (40 hp) for fertilizer 1 to 4 show the projection of a minimum distance
application, a tanker sprayer (600 litres) with a of 8.2 m between palms. This was shown on an
mini tractor (40 hp) for weeding, a motorized area of 1 ac which is equivalent to 0.405 ha in the
cutter for harvesting, Rambo; a 4×4 skid steer driven dimensions of 90 m × 45 m. There were around 55
machine fitted with the a Scanmech Grabber model palms in the square pattern (Figure 1), 66 palms in
RS/FFB20 that has maximum reach of 2.7 m and the equilateral triangular pattern (Figure 2), around
lifting capacity of 100 kg with a slewing angle of 56 palms in the hexagonal pattern (Figure 3), and 50
360° was used for in-field collection, and an air- palms in the rectangular pattern (Figure 4).
assisted fruit separator for loose fruit collection was The alternative planting patterns discussed
recommended for flat coastal plantations. Lastly, were combined with the mechanization system
a combination of a spreader with a mini tractor for various terrains, and thus the machine cost,
(40 hp) for fertilizer application, a tanker sprayer operational cost and productivity were estimated
(600 litres) with a mini tractor (40 hp) for weeding, together with the coverage per acre of each machine.
a motorized cutter for harvesting, Wu-Chart with This was then produced in templates for the estate
a productivity of 14 t per day was used for in-field manager to use for achieving optimum yield.
collection, and an air-assisted fruit separator for Table 1 shows a proposed machine combination
loose fruit collection, or Package E, was a special for alternative planting patterns, where the
package that offered the lowest machine prices machines for carrying out the operations of fertilizer
(that were less that RM 10 000 for each operation) application, weed control and harvesting have
with high productivity. This package is best applied been made constant while machines for in-field
on flat land and in small plantations. transportation and loose fruit collection are varied
This article describes a study on the conceptual according to the different planting patterns as given
design and development of the most efficient in Tables 2 to 5.
mechanization selection system for the oil palm
plantation with alternative planting patterns, Calculation According to Planting Pattern
including a database designed for optimum yield.
The specific objective was to provide a combination Unit conversion. Unit conversion was done from
of mechanization systems that would be efficient the coverage area obtained by calculation as
with alternative planting patterns.
27 ft (8.23 m)
27 ft
(8.23 m)
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DEVELOPMENT OF A MECHANIZATION SELECTION SYSTEM FOR OIL PALM PLANTATIONS WITH ALTERNATIVE PLANTING PATTERNS
27 ft (8.23 m)
27 ft (8.23 m)
27 ft (8.23 m)
x x x x x
53 ft (16.15 m) 27 ft (8.23 m)
47.3 ft (14.42 m) x
x x x x x
x x x x
x x x x x
x x x x
x x x x x
Figure 3. Hexagonal planting pattern.
30 ft (9.14 m)
27 ft (8.23 m)
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Journal of Oil Palm Research 23 (APRIL 2011)
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DEVELOPMENT OF A MECHANIZATION SELECTION SYSTEM FOR OIL PALM PLANTATIONS WITH ALTERNATIVE PLANTING PATTERNS
tanker sprayer of 300-litre capacity; a motorized and varying topography. In addition to that, it has
cutter is used as the harvester; a Wakfoot for in-field an average productivity of 18 to 25 t per day with
collection; and finally an air-assisted loose fruit an operation cost of only RM 1 t-1. For loose fruit
separator is used for loose fruit collection. All these collection, the air-assisted loose fruit machine was
machines were kept constant when the alternative selected because it has the highest productivity
planting patterns were studied. compared to other machines, while the machine
These machines were selected because they cost is far cheaper than for the other machines with
have a larger coverage area compared to the lower productivity.
cheaper machines but are also more affordable This package is suitable for flat large areas of
than other machines with larger coverage areas. plantations. The total machine cost calculated
For harvesting activities, the motorized cutter, also for the package was RM 145 100 with a total
known as Cantas, was selected for its efficiency and productivity of 58.5 t per day. Thus, the package
high productivity – around 350% higher compared was made constant in this study for the extrapolated
to the manual method – and minimum energy is alternative planting patterns. For the triangular
required for handling it. planting pattern, the total operational cost was RM
Wakfoot was selected as in-field collection 3.30 ha-1 with a productivity (capacity) of 2.21 t ha-1
machine due to its ability to work in difficult areas and a coverage of 31.34 ha per day.
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Journal of Oil Palm Research 23 (APRIL 2011)
The combination of machines for the in-field collection and the air-assisted loose fruit
mechanization package for the square planting separator kept constant. The total machine cost
pattern is shown in Table 3 with the entire operations was RM 124 100, and the total operational cost was
kept constant as in the triangular planting pattern. RM 17.30 ha-1 with a productivity of 1.88 t ha-1 over
The total machine cost for this planting pattern 21.9 ha per day.
was RM 142 700, and the operational cost was The mechanization package for the hexagonal
RM 19.6 ha-1 with a productivity of 2.03 t ha-1 for a planting pattern is shown in Table 5 with the
coverage of 24.7 ha. machines for the operations of fertilizer application
For the rectangular planting pattern, the and weed control kept constant as in the triangular
combination of machines is shown in Table 4 with planting pattern. The total machine cost for this
the fertilizer application machine of the spreader planting pattern was RM 142 700, and the operational
plus a mini tractor (40 hp), weed control with the cost was RM 20.6 ha-1 with a productivity of 2.08 t
tractor-drawn tanker sprayer of 300-litre capacity, ha-1 for a coverage of 26 ha per day.
the motorized cutter for harvesting, the Wakfoot for
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DEVELOPMENT OF A MECHANIZATION SELECTION SYSTEM FOR OIL PALM PLANTATIONS WITH ALTERNATIVE PLANTING PATTERNS
997
Journal of Oil Palm Research 23 (APRIL 2011)
Appendix 1
1) Square planting pattern 2-row distance = 2 × 164.56 m = 329.12 m
Total number of palms per acre = 55 palms Additional row = 9 × 9.14 m = 82.26 m
Movement of machine: Inter-row distance = 2 × 8.23 m = 16.46 m
1-row distance = 21 × 8.23 m = 172.82 m Total distance a machine can move per acre
2-row distance = 2 × 172.82 m = 345.64 m = 428 m
Additional row = 10 × 8.23 m = 82.3 m
Inter-row distance = 2 × 8.23 m = 16.46 m The following conversion was based on triangle
Total distance a machine can move per acre planting pattern:
= 444.4 m
For 1 ac of the triangular planting pattern, the
machine moves 534.9 m,
To obtain the coverage per hectare from the
Thus,
available information of the triangular planting
pattern was used to extrapolate the conversions of 534.9 m = 1/2.471y ac per day
the following: 1m = 1/(2.471y)(534.9) ac per day
Coverage = y ha per day Coverage for the rectangular
1 ha = 1/y day planting pattern = 428/(2.471y)(534.9) ac per day
= y × (444.4/534.9) ha per day
But,
Productivity = coverage × (triangular
1 ha = 2.471 ac productivity/66 palms) × 50 palms
Then,
3) Hexagonal planting pattern
1 ha = 1/2.471y ac per day
Total number of palms per acre = 58 palms
For 1 ac of the triangular planting pattern, the Movement of machine:
machine moves 534.9 m,
1-row distance = 15 × 8.23 m = 123.45 m
Thus,
3-row distance = 3 × 123.45 m = 370.35 m
534.9 m = 1/2.471y ac per day Additional row = 9 × 8.23 m = 74.07 m
1m = 1/(2.471y)(534.9) ac per day Inter-row distance = 3 × 7.13 m = 21.4 m
Coverage for the square
Total distance a machine can move per acre
planting pattern = 444.4/(2.471y)(534.9) ac per
= 465.8 m
day
= y × (444.4/534.9) ha per day
The following was based on triangle planting
Productivity = coverage × (triangular
pattern:
productivity/66 palms) × 55 palms
Since 1 ac of triangle moves 534.9 m, thus
2) Rectangular planting pattern 534.9 m = 1/ 2.471y ac per day
Total number of palms per acre = 50 palms 1m = 1/ (2.471y)(534.9) ac per day
Movement of machine:
Coverage of square
1-row distance = (10 × 8.23 m) + (9 × 9.14 m) planting pattern = 465.8/(2.471y)(534.9) ac per day
= 164.56 m = y × (444.4 / 534.9) ha per day
Productivity = coverage × (triangle productivity/
66 trees) × 55 trees
998