DAFTAR ISI

KATA PENGANTAR ........................................................................................ i

INTISARI............................................................................................................ iii
DAFTAR ISI ....................................................................................................... iv
DAFTAR GAMBAR .......................................................................................... ix
DAFTAR TABEL ............................................................................................... x
DAFTAR LAMPIRAN ....................................................................................... x
BAB I PENDAHULUAN ............................................................................ I-1
1.1 Latar Belakang ........................................................................ I-1
1.2 Perumusan Masalah ................................................................ I-2
1.3 Tujuan pra Rancangan Pabrik ................................................. I-3
1.4 Manfaat perancangan ............................................................. I-3
BAB II TINJAUAN PUSTAKA ................................................................... II-1
2.1 alpukat .................................................................................... II-1
2.2 Minyak Biji Avokad ............................................................... II-2
2.3 Asam Linoleat (Omega 6) ...................................................... II-3
2.4 Manfaat Asam Linoleat (Omega 6) ........................................ II-4
2.5 Proses Pembuatan Asam Linoleat .......................................... II-5
2.5.1 Proses Twitchell dan Pressing ...................................... II-5
2.5.2 Proses Splitting ............................................................. II-5
2.5.3 Proses enzymatic ......................................................... II-6
2.5.4 Proses Hidrolisis ...........................................................
2.5.4.1 Proses Hidrolisis Minyak Biji Avokad ............ II-6
2.5.4.2 Proses Fraksinasi Asam Lemak ....................... II-7
2.6 Pemilihan Proses ..................................................................... II-7
2.7 Deskripsi Proses Pembuatan Asam Linoleat .......................... II-8
2.7.1 Penyimpanan Biji Avokad ............................................ II-9
2.7.2 Proses Pencucian ........................................................... II-9
2.7.3 Proses Pengelupasan ..................................................... II-10
2.7.4 Proses Penggilingan dan Pemanasan............................. II-10
2.7.5 Proses leaching .............................................................. II-11

i
 2.7.6 Proses pengepresan (pressing) ...................................... II-11
2.7.7 Proses Degumming ....................................................... II-11
2.7.8 Centrifuge .................................................................... II-15
2.7.9 Proses Hidrolisa ............................................................ II-14
2.7.10 Flash Tank ................................................................... II-15
2.7.11 Crystallizer .................................................................. II-15
2.8 Sifat Bahan Baku dan Produk ................................................. II-16
2.8.1 Bahan Baku ................................................................... II-16
2.8.2 Produk ........................................................................... II-17
BAB III NERACA MASSA........................................................................... III-1
3.1 Tangki Pencuci (WT-101) ...................................................... III-2
3.2 Dehuller (D-101) .................................................................... III-2
3.3 Filter Press (FP-101) .............................................................. III-2
3.4 Grinder (G-101)...................................................................... III-2
3.5 Leaching (LC-101) ................................................................. III-3
3.6 Filter Press (FP-102) .............................................................. III-3
3.7 Centrifuge (C-101).................................................................. III-3
3.8 Tangki Degumming (DT-101) ................................................ III-4
3.9 Centrifuge (C-102).................................................................. III-4
3.10 Tangki Hidrolisis (T-102) ...................................................... III-4
3.11 Flash Tank (FT-101) ............................................................... III-5
3.12 Crystallizer I (CR-101) ........................................................... III-5
3.13 Crystallizer II (CR-102) ......................................................... III-5
BAB IV NERACA ENERGI .......................................................................... IV-1
4.1 leaching (LC-101) .................................................................. IV-2
4.2 Filter Press (FP-102) .............................................................. IV-2
4.3 Centrifuge (C-101).................................................................. IV-2
4.4 Heat Exchanger (HE-101) ...................................................... IV-3
4.5 Tangki Degumming (DT-101) ................................................ IV-3
4.6 Centrifuge (C-102).................................................................. IV-3
4.7 Heater 02 (H-102) .................................................................. IV-4
4.8 Heater 01 (H-101) .................................................................. IV-4

ii
 4.9 Tangki Hidrolisis (T-102) ...................................................... IV-4
4.10 Flash Tank (FT-101) ............................................................... IV-5
4.11 Heat Exchanger 02 (HE-102) ................................................. IV-5
4.12 Kondensor (K-101) ................................................................. IV-5
4.13 Crystallizer I (CR-101) ........................................................... IV-6
4.14 Crystallizer II (CR-102) ........................................................ IV-6
4.15 Bak Penampung Dengan Koil Pemanas (TP-103).................. IV-6
4.16 Bak Penampung Dengan Koil Pemanas (TP-104).................. IV-7
BAB V SPESIFIKASI ALAT ....................................................................... V-1
5.1 Gudang Penyimpanan Biji Avokad (G -101) ......................... V-1
5.2 Tangki Penyimpanan Larutan Garam (T-101)........................ V-1
5.3 POMPA 1 (P-101) .................................................................. V-2
5.4 Bucket Elevator (E-101) ......................................................... V-2
5.5 Washing Tank (WT -101) ...................................................... V-3
5.6 Belt Conveyor (BC -101) ........................................................ V-3
5.7 Dehuller (D-101) .................................................................... V-3
5.8 Filter Press (FP-101) .............................................................. V-4
5.9 bak penyimpanan kulit ari (TP-101) ....................................... V-4
5.10 Blower (BL-101) .................................................................... V-4
5.11 Bucket Elevator (E-102) ......................................................... V-5
5.12 Grinder (GR-101) ................................................................... V-5
5.13 Screw Conveyor (SC-101) ..................................................... V-6
5.14 Bucket Elevator (E-103) ......................................................... V-6
5.15 Leaching Tank (LC-101) ........................................................ V-7
5.16 Screw Conveyor (SC-102) ..................................................... V-7
5.17 Filter Press (FP-101) .............................................................. V-7
5.18 Bak Penyimpanan Cake (TP-103) .......................................... V-8
5.19 Pompa 2 (P-103) .................................................................... V-8
5.20 Centrifuge (C-101).................................................................. V-8
5.21 Pompa (P-104) ........................................................................ V-9
5.22 Heater (H-101) ....................................................................... V-9
5.23 Pompa (P-105) ........................................................................ V-10

iii
 5.24 Degumming Tank (DT-101) ................................................... V-10
5.25 Pompa (P-106) ........................................................................ V-11
5.26 Centrifuge (C-102).................................................................. V-11
5.27 Pompa (P-107) ........................................................................ V-11
5.28 Pompa (P-108) ........................................................................ V-12
5.29 Heater (H-101) ....................................................................... V-12
5.30 Heater (H-102) ....................................................................... V-13
5.31 Pompa (P-109) ........................................................................ V-13
5.32 Tangki Hidrolisis (T-102) ....................................................... V-14
5.33 Pompa (P-110) ........................................................................ V-14
5.34 Flash Tank (FT-101) ............................................................... V-15
5.35 Pompa (P-111) ........................................................................ V-15
5.36 Heat Exchanger (HE-102) ...................................................... V-16
5.37 Kondensor (K-101) ................................................................. V-16
5.38 Pompa (P-114) ........................................................................ V-16
5.39 Crysatllizer I (CR-101) ........................................................... V-17
5.40 Pompa (P-112) ........................................................................ V-17
5.41 Crystallizer II (CR-102) ......................................................... V-18
5.42 Pompa (P-113) ........................................................................ V-18
5.43 Pompa (P-114) ........................................................................ V-19
5.44 Tangki Penyimpanan Gliserol (T-105) .................................. V-19
5.45 Tangki Penyimpanan Asam Lemak Jenuh (T-106) .............. V-20
5.46 Tangki Penyimpanan Asam Lemak Linoleat (T-104) ............ V-20
5.47 Tangki Penyimpanan Asam Lemak Linolneat (T-104) .......... V-21
5.48 Tangki Bak Penyimpanan Sementara (T-103) .................... V-21
5.49 Tangki Bak Penyimpanan Sementara (T-104) .................... V-22
BAB VI INSTRUMENTASI KESELAMATAN KERJA ............................. VI-1
6.1 Instrumentasi........................................................................... VI-1
6.2 Keselamatan Kerja pada Pabrik Gliserol ................................ VI-5
6.2.1 Pencegahan Terhadap Kebakaran dan Peledakan .......... VI-6
6.2.2 Peralatan Perlindungan Diri ........................................... VI-7
6.2.3 Keselamatan Kerja Terhadap Listrik ............................. VI-11

iv
 6.2.4 Pencegahan Terhadap Gangguan Kesehatan ................. VI-11
6.2.5 Pencegahan Terhadap Bahaya Mekanis ........................ VI-12
BAB VII UTILITAS ........................................................................................ VII-1
7.1 Kebutuhan Uap (Steam) ......................................................... VII-1
7.2 Kebutuhan Air ........................................................................ VII-2
7.2.1 Screening ....................................................................... VII-5
7.2.2 Sedimentasi .................................................................... VII-5
7.2.3 Klarifikasi ...................................................................... VII-5
7.2.4 Filtrasi ............................................................................ VII-6
7.2.5 Demineralisasi ............................................................... VII-7
7.2.6 Deaerator ....................................................................... VII-11
7.3 Kebutuhan Bahan Kimia......................................................... VII-11
7.4 Kebutuhan Listrik ................................................................... VII-12
7.5 Kebutuhan Bahan Bakar ......................................................... VII-14
7.6 Unit Pengolahan Limbah ........................................................ VII-15
7.7 Perhitungan Untuk Sistem Pengolahan Limbah .....................VIII-16
7.7.1 Bak Penampungan .........................................................VIII-16
7.7.2 Bak Pengendapan Awal .................................................VIII-17
7.7.3 Pengolahan Limbah Gum dengan Sistem Activated Sludge
(Lumpur Aktif) ............................................................VIII-18
7.7.4 Kolam Aerasi ...............................................................VIII-20
7.7.4 Bak Sedimentasi .........................................................VIII-20
7.8 Spesifikasi Peralatan Utilitas .................................................. VII-21
7.8.1 Pompa Sungai (P-101) .................................................. VII-21
7.8.2 Bak Pengendapan Air Sungai (E-11) ............................ VII-21
7.8.3 Bak Penampungan Air Sungai .......................................VII-22
7.8.4 Pompa Clarifier (P-103) ................................................ VII-22
7.8.5 Tangki Pelarutan Alum [Al2(SO4)3] (M-101) ................VII-23
7.8.6 Tangki Pelarutan Soda Abu [Na2CO3 ] (M-102) ........... VII-23
7.8.7 Clarifier (S-102) ............................................................ VII-23
7.8.8 Pompa Sand Filter (P-104) ............................................ VII-24
7.8.9 Sand Filter (S-103) ........................................................ VII-24

v
 7.8.10 Pompa Menara Air (P–105) ......................................... VII-24
7.8.11 Menara Air (D-102) ..................................................... VII-25
7.8.12 Pompa Menara Air (P–107) ......................................... VII-25
7.8.13 Penukar Kation / Cation Exchanger (E-101)............... VII-25
7.8.14 Pompa Penukar Kation / Cation Exchanger (P-108) ...VII-26
7.8.15 Penukar Anion / Anion Exchanger (E-102) ................. VII-26
7.8.16 Pompa Penukar Anion / Anion Exchanger (P-109) ..... VII-26
7.8.17 Pompa Cooling Tower (P-115) .................................... VII-27
7.8.18 Cooling Tower (CT-101) ............................................. VII-27
7.8.19 Pompa Cooling Tower (P-115) .................................... VII-27
7.8.20 Deaerator (S-104) ........................................................VII-27
7.8.21 Boiler (E-101) .............................................................. VII-28
7.8.22 Boiler (E-102) .............................................................. VII-28
7.8.23 Blower Steam (BL-102) .............................................. VII-29
7.8.24 Tangki Penyimpanan Etilen Glikol (M-105) ............... VII-29
7.8.25 Pompa Etilen Glikol (P-111) ....................................... VII-29
7.8.26 Refrigator (RF-101) ..................................................... VII-30
7.8.27 Pompa Refrigator (P-112) ........................................... VII-30
7.8.28 Tangki Pelarutan Kaporit [Ca(ClO)2] (M-104) ........... VII-30
7.8.29 Tangki Penampungan Air Domestik (M-103) ............. VII-31
7.8.30 Canopy Hood Ventilation (CH– 101) .......................... VII-31

BAB VIII LOKASI DAN TATA LETAK PABRIK ........................................ VIII-1

8.1 Gambaran Umum.................................................................... VIII-1
8.2 Pemilihan Lokasi Pabrik ......................................................... VIII-1
8.3 Lokasi Pabrik Pembuatan Asam Linoleat............................... VIII-2
8.4 Tata Letak Pabrik Pembuatan Asam Linoleat ........................ VIII-4
8.5 Perincian Luas Areal Pabrik Asam Linoleat .......................... VIII-5
BAB IX ORGANISASI DAN MANAJEMEN PERUSAHAAN .................. IX-1
9.1 Organisasi Perusahaan ............................................................ IX-1
9.1.1 Bentuk Organisasi Garis ................................................ IX-2

vi
 9.1.2 Bentuk Organisasi Fungsionil........................................ IX-2
9.1.3 Bentuk Organisasi Garis dan Staf .................................. IX-3
9.1.4 Bentuk Organisasi Fungsionil dan Staf ......................... IX-3
9.1.5 Bentuk Organisasi Pabrik Pembuatan Asam Linoleat ... IX-3
9.2 Manajemen Perusahaan .......................................................... IX-4
9.3 Bentuk Hukum Badan Usaha.................................................. IX-5
9.4 Uraian Tugas, Wewenang, dan Tanggung Jawab ................... IX-6
9.4.1 Rapat Umum Pemegang Saham (RUPS) ....................... IX-6
9.4.2 Dewan Komisaris........................................................... IX-7
9.4.3 Direktur .......................................................................... IX-7
9.4.4 Staf Ahli ......................................................................... IX-8
9.4.5 Sekretaris ....................................................................... IX-8
9.4.6 Manajer Produksi ........................................................... IX-8
9.4.7 Manajer Teknik .............................................................. IX-8
9.4.8 Manajer Umum dan Keuangan ...................................... IX-8
9.4.9 Manajer Pembelian dan Pemasaran ............................... IX-9
9.5 Sistem Kerja............................................................................ IX-9
9.6 Jumlah Karyawan dan Tingkat Pendidikan ............................ IX-10
9.7 Tata Tertib .............................................................................. IX-13
9.8 JAMSOSTEK dan Fasilitas Tenaga Kerja ............................. IX-14
BAB X ANALISA EKONOMI .................................................................... X-1
10.1 Modal Investasi ....................................................................... X-1
10.1.1 Modal Investasi Tetap / Fixed Capital Investment
(FCI)............................................................................. X-1
10.1.2 Modal Kerja / Working Capital (WC) ......................... X-3
10.1.3 Biaya Tetap (BT) / Fixed Cost (FC) ............................ X-4
10.1.4 Biaya Variabel (BV) / Variable Cost (VC) ................. X-5
10.2 Perkiraan Rugi / Laba Usaha .................................................. X-5
10.3 Analisa Aspek Ekonomi ......................................................... X-6
10.3.1 Profit Margin (PM)...................................................... X-6
10.3.2 Break Even Point (BEP) .............................................. X-6
10.3.3 Return on Investment (ROI)......................................... X-7

vii
 10.3.4 Pay Out Time (POT) .................................................... X-7
10.3.5 Return on Network (RON) ........................................... X-8
10.3.6 Internal Rate of Return (IRR) ...................................... X-8
BAB XI KESIMPULAN ................................................................................ XI-1
DAFTAR PUSTAKA ......................................................................................... DP-1

viii