The exact cost depends on many factors including palm fruits situation, level of automation, whether kernel and fibre separation system is needed, whether oil filling machine is included, your requirements on final crude oil and so on. Get in touch with us now and let us help you make the business plan on palm oi processing and calculate the cost of plant construction and production costs and profits.
A small palm oil processing plant necessarily does not mean less efficient with low production capacity. Even small-scale palm oil processing plants can handle a considerable amount of production. For existing palm oil mills, enhancing the capacity of a small palm oil mill plant from 2 tonnes per hour to 4 tonnes per hour can quadruple the production. This small palm oil processing plant that was upgraded in 2017, is a live example.
A production unit doesn’t require costly machines like steam boilers or any other pressure vessels like autoclave sterilizers to work efficiently. This helps to cut-down capital costs and machinery maintenance expenses.
Crude Palm Oil Processing Flow Design
View the content below to get a clear understanding of the palm oil mill process flow. Any questions about palm oil mill operation and processing, welcome to apply for our free counseling service!
Receiving Palm Fruit Bunches
The first step is to receive fresh fruit bunches (FFB) from the oil palm plantations. They are then weighed and threshed to remove stems from bunches by using palm fruits threshing machine, halved or quartered manually before putting inside the basket. The fruits are then loaded into stainless steel cooker baskets, each of which has a holding capacity of approximately 200kgs of FFB.
Cooking / Sterilization
After the cooker baskets are filled, they are moved to the gantry and lifted onto the cooker platform with an advanced technology of electric chain hoists. Next, they are loaded into the cooker for steaming which lasts for 90 minutes. Maintaining the right temperature between 85 to 100 degree Celsius, and adjusting when required is a simple process and can be done conveniently as required.
After the palm fruits are cooked for 90 minutes, the baskets are lifted from the cookers and moved to the self-tipping mechanism which is placed on top of the stripper platform. An operator controlling the movement of the machinery empties the baskets into the stripper.
The mechanism is designed in a way that it allows fruits to automatically dislodge from the bunch. Empty fruit bunches are then ejected from the drum and removed for drying. These when dried, make excellent fuel for the furnaces and also great compost for plantations.
After sterilization, the palm fruits go into a digester where boiling water is added to dilute to make digestion easier. During the digesting process, the cells of the fruits rupture, this accounts for the palm oil production.
Palm Oil Extraction
A screw type of palm oil processing machine (also known as palm oil expeller) compresses the digested fruits between the main screw and the traveling cones to extract oil. When the digested fruits are passed through the mechanical palm oil press, the oil, water, and other liquid impurities are forced into the crude oil tank whereas the dry fiber and nuts find their way out through the cones.
Crude Oil Clarifying and Water Treatment
When the oil extraction is over it is time to clarify the oil and make it usable. The palm oil clarification process is basically meant for separating impurities from the crude palm oil. The extract from the screw press consists of water, fibers, and impurities. The crude oil is pumped into the clarifiers and processed at temperatures between 86 and 95 degrees Celsius. The finished palm oil separates from the water and other solids when boiling water is added as a diluter. The effluent which comes out at the end is drained to either effluent ponds or used for killing weeds.
Palm Oil Storage and Packing
The palm oil is then stored in the oil tank. As and when required, oil is weighed and bottled.
In recent years, small and medium scale crude palm oil processing is becoming a hot project to invest in, especially in Malaysia, Indonesia, Nigeria and Thailand. Feel free to contact us now to get free guidance on open a palm oil processing company. Besides, we have built many project around the world including Nigeria and Thailand.