SOY OIL

PROCESSING
INDUSTRY
PRESENTED BY:
MALAYSIA BOLEH
RESEARCH &
CONSULTANCY





MALAYSIA BOLEH
RESEARCH &
CONSULTANCY
1. MR. MOHD HILMI MOHD IDRIS
2. MS. ADLINA SNAWI
3. MR. MUHAMMAD SUFFIAN AHMAD
4. MR. ABDUL MAJID IBRAHIM
5. MR. SHAHRUDDIN KASSIM
6. MR. ZAKARIA ABU HASAN
7. MR. FAZIL MAT ZAIN
8. MS. ZURAIDAH KORNAIN
9. MS. ZAUYAH TARMIZZI
10. MR. MARZUKI ZAINAL ABIDIN
MALAYSIA BOLEH
RESEARCH & CONSULTANCY
PROCESS FLOW
DIAGRAM
Process Flow Diagram
Testing
Yard
Big Silos
Day Silo
screener
De-Stoner
Cracker
Cooker
Flakers
Dryer
Extractor
Economiser
Evaporator
Stripper Cum Dryer
Storage
Tanks
CRUDE OIL
DT-DC
Screener
Lump-crusher
Oversized lump
Mixing & Packing
Storage
Tanks
DOC
cyclone
WET DOC
PREPARATORY
SECTION
SEED UNLOADING &
CLEANING SECTION
SOLVENT EXTRACTION
PLANT
Testing
Yard
Big Silos
SEED UNLOADING &
CLEANING SECTION
Day Silo
screener
De-Stoner
Cracker
Cooker
Flakers
Dryer
PREPARATORY
SECTION
Extractor
Economiser
Evaporator
Stripper Cum
Dryer
Storage
Tanks
CRUDE OIL
DT-DC
Screener
Lump-crusher
Oversized
lump
Mixing &
Packing
Storage
Tanks
DOC
cyclone
WET
DOC
SOLVENT EXTRACTION PLANT
MATERIAL FLOW
DIAGRAM (Hexane)
Extractor
Economiser
Evaporator
Condenser
DT-DC
Cyclone
(Miscella+Hexane)
Stripper Cum Dryer
(Jet + Chiller)
Water-Solvent
Separator
Loss
Material Flow Diagram
DOC
MISCELLA
SOLVENT EXTRACTION
PLANT
MAJOR WASTE
STREAMS/AREAS OF
LOSSES
PROCESS PLACES/AREAS WASTE/LOSS
1
Transportation
Conveyor &
Bucket Elevator
Seed
Husk
Stone 2 Big Silo to Day Silo
3
Preparatory
Section
Day Silo to
Screener
Cracked Seed
Dust
Husk
4 De-Stoner
Mud Balls
Stone
5
Mechanical
Cracker
NIL
6
Condensed
the soy seed
Cooker
Steam
Water
7 Flaking Flakers Soy Seed
8 Drying Dryer NIL
MAJOR WASTE STREAMS/AREAS OF LOSSES
PROCESS PLACES/AREAS WASTE/LOSS
9
Solvent
Extraction
(Crude Oil
Production)
Rotary Type
Extractor (RTE)
Hexane
10 Distillation Hexane
11 Stripper Hexane
12 Condenser Hexane
13
Water/Solvent
Separator
Waste Water
Hexane
14
Desolvent

DT-DC
(De-Oiled Cake
Production)
Hexane
Moisture
Heat
15 Cooling
Moisture
Heat
16 Seaving NIL
17 Packaging NIL
MAJOR WASTE STREAMS/AREAS OF LOSSES
FISHBONE DIAGRAM
MAN
METHOD
MACHINE
ENVIRONMENT
FISHBONE DIAGRAM

Hexane
Loss
MATERIAL
High
humidity
Poor air
quality
Process control
not effective
Poor equipment
calibration
No standard
operating
procedure
Poor soy
seed quality
Poor hexane
quality
Poor steam
quality
Human
error
Lack of
training
Lack of
motivation
Inefficient
machine
DT-DC
RTE
Jetcon
RTE
Chiller
condenser
Economiser
Stripper
(Dryer)
Hexane/water
seperator
Evaporator
Hexane supply
system
Hexane
recovery
system
Leakage
PROPOSED
GP OPTIONS
GP OPTIONS
GP OPTION DESCRIPTION
1 NEW EQUIPMENT
Up to date & efficient machine
Upgrade
Total Preventive Maintenance
2
NEW MATERIAL/
CHEMICAL
Replace Hexane (hexane is
hazardous to health,
substitute
with more environmental
friendly chemical)
Better quality of soy seed
3
ALTERNATIVE
SUPPLIER
To supply better quality of soy
seed
4 METHODOLOGY
Develop Standard Operating
Procedures (SOP)
Implement EMS (ISO 14001)
Equipment calibration
GP OBJECTIVES
& TARGETS
GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAM
SOY BEAN OIL REFINING PROCESS

1 2 3 4 5 6
OBJECTIVE TARGET PROGRAM ACTION RESPONSIBLE
PERSONS
TIME
FRAME
1.1
Minimise
Hexane
Usage
2.1
Reduce
consumption
by 10%
within one (1)
year
3.1.1
Maintenance (Total
Productivity Maintenance
TPM)
Condition-based Maintenance
- CBM
4.1.1
Implement TPM &
CBM
5.1
5.1.1
Head of Dept
5.1.2
Maintenance Mgr
5.1.3
Maintenance
Technicians
5.1.4
Contractors
6.1.1
Start
Immediately
& monitor
within one (1)
year.
Annual
review.
3.1.2
Improve Calibration of
equipment
4.1.2
Scheduled
calibration
5.1.2
Approved Calibration
Agency or Company
6.1.2
Continuous-
based on
equipment
validity
3.1.3
Replace old and unreliable
equipment
4.1.3
Reliablity Trending
and Analysis
5.1.3
Maintenance Manager
6.1.3
Continuous-
based on
equipment
condition and
techno-
economics
3.1.4
Improve Hexane Quality from
Supplier
4.1.4
Testing of raw
material


5.1.4
Testing
engineer/technician
6.1.4
One (1) year.
Annual
review.

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAM
SOY BEAN OIL REFINING PROCESS
1 2 3 4 5 6
OBJECTI
VE
TARGET PROGRAM ACTION RESPONSIBLE
PERSONS
TIME
FRAME
1.2
Reduce
moisture
content
in seed
2.2
Reduce
moisture
to
minimum
acceptabl
e limits
3.2
Incoming
seed
testing

4.2.1
Enforce
Contract
Specifica
tions
4.2.2
Test for
moisture
at
Incoming
Goods
5.2
5.2.1
Head of Dept
5.2.2
Testing Mgr
5.2.3
Testing
engineer/technici
an
5.2.4
Contractors
6.2
Start
Immedia
tely &
monitor
within
one (1)
year.
Annual
review.
1.3
Reduce
husk
content
in seed
2.3
Reduce
husk to
minimum
acceptabl
e limits
3.3
Incoming
seed
testing

4.3.1
Enforce
Contract
Specifica
tions
4.3.2
Test for
husk at
Incoming
Goods
5.3
5.3.1
Head of Dept
Contract &
Operations Sect
5.3.2
Testing Mgr
5.3.3
Testing
engineer/technici
an
5.3.4
Contractors
6.3
Start
Immedia
tely &
monitor
within
one (1)
year.
Annual
review.
GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAM
SOY BEAN OIL REFINING PROCESS
1 2 3 4 5 6
OBJECTI
VE
TARGET PROGRAM ACTION RESPONSIBLE
PERSONS
TIME
FRAME
1.4
Optimise
flake
thicknes
s in
Flaker
2.4
Optimis
e flake
to
accepta
ble
limits
3.4
3.4.1
Implement
TPM & CBM
3.4.2
Measure
flake
thickness
3.4.3
Ensure
reliability
of
equipment

4.4.1
Use TPM
4.4.2
Testing
for flake
thicknes
s using
specialis
ed tools.
4.4.3
Use
good
quality
equipme
nt
5.4
5.4.1
Head of Dept
Contract &
Operations Sect
5.4.2
Testing Mgr
5.4.3
Testing
engineer/technicia
n
5.4.4
Contractors
6.4
Start
Immediat
ely &
monitor
within
one (1)
year.
Annual
review.
GP POLICY
GP : POLICY
We are committed to :

1. Answer the societal demands for
higher productivity in a sustainable
manner with preserving the
environment.
2. Ensure the natural environment on
which society depends is not
degraded and polluted.
3. Make a better and cost-effective
approach in implementing efficient and
innovative GP solution.
4. Assist other companies in gaining
their competitive advantages and cost-
effective reduction of waste and
emissions.