1.0 INTRODUCTION
Industrial Training is a scope which is a syllabus to the each student in IPTA level
weather for diploma or degree and UTeM also one of them. It is compulsory for an UTeM
student to pass the industrial training before being awarded the degree or diploma in their
course. Each student must complete the whole duration period i.e. 20 weeks for Degree course
and 10 weeks Diploma course and not permitted to end the training earlier than the specified.
5. To instil spirit of teamwork and good relationship between student and fellow
workers.
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2. To prove to lecturer that the student have complete the industrial training.
Industrial Training is one of the aspects which importance to the student to instil
higher sprit and confidence level in their self when joins in actual working environment soon.
Beside that, the student will make comparison what they learn at UTeM with the jobs while
industrial training. The will know whether what they studies is learn or not and it most benefit
responsibility, open minded, inquires and self-confidence will in their self it will make student
to done the works perfectly and smoothly. Relationship student and employee need to close.
The student can ask anything what they not understand easily. So the student can get more
To the students who were passed for industrial training they will feel difference in their
self. With the skill and experience which they learn during industrial training will make them
more confidence to join in what ever they do because the skill and experience very benefit to
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The era
of the
Figure 2.1 Aerial view of the Ulu Bernam Oil Palm Factory
discoveries brought the people of Western Europe face to face with the ancient cultures of the
old world. Perhaps it is a legacy of those events, strengthened by an inherent urge of much
greater antiquity that moved man of talent and initiative to seek the wonders of the East.
During the year 1885, the founder of United Plantations, Mr. Svend Aage Westenholz
left Denmark for the Kingdom of Siam upon graduation as a civil engineer. Mr. Westenholz,
who had served in the Danish Army as an Artillery Officer, joined the Siamese Forces
together with other Danes living in Bangkok when a French Navy Force tried to subdue the
The French Navy Group was forced to retreat due to the fierce resistance. As a
consequence, the Danes won much goodwill from H.R.H. the King of Siam and the Siamese
people. Mr Westenholz and others were given concessions to supply electricity to Bangkok by
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the creation of a company called Siam Electric. This in turn caused Bangkok to have a
tramway system before it was introduced in Copenhagen. The East Asiatic Company was
given the concession of the teak wood extraction and rice export from Siam. A Danish naval
officer, Commander Richelieu, was promoted to Commander in Chief of the Siamese Navy.
These were the early days of the great economic advance of the West. Around the turn
of the century, the rubber industry was in its infancy and interest in rubber planting in Malaya
was growing
In 1906, Mr. Westenholz found the opportunity to realize a plan close to his heart and
the Jenderata Rubber Estate of 809 hectares was established in Lower Perak, near Teluk
Anson. This initial plantation venture in Malaya, the Jenderata Rubber Company, was
followed some years later by the establishment of Corner, Raja Una and Westenholz Brothers
Coconut Estates on the Selangor Bank of the Bernam River, opposite to Hutan Melintang.
Finally during 1917, all were merged into United Plantations Limited.
Mr. Westenholz retired in 1911 and was succeeded in Bangkok by his younger cousin,
Commander William Leannart Grut, who likewise elected to spend his working life in the
In view of the successful planting of 8 hectares of oil palm at Sungei Bernam Estate
during 1918, Commander Grut was delighted to meet with a Dutchman, Mr. Blumendall when
he returned from leave in Europe. Mr. Blumendall managed to awaken Commander Grut’s
interest in oil palms, wherefore Mr. Blumendall was appointed Planting Advisor when
Commander Grut acquired 2,428 hectares situated 60 kilometres, up the Bernam River, which
in turn made Commander Grut the founder of Bernam Oil Palm, one of the pioneers of the
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Malaysian Palm oil Industry, which coincided with Guthrie’s and Socfin’s ventures into the
It was Tan Sri Dato’ Seri B. Bek-Nielsen’s privilege to the employed by Bernam oil
Palm Ltd. as an Assistant Engineer during 1951 – at the height of the Emergency. Tan Sri
Dato’ Seri B. Bek-Nielson was posted at the Ulu Bernam Oil Mill, which is 60 kilometres up
the Bernam River, totally surrounded by jungle. Security protection was then provided by
During 1966, United Plantation Ltd. and Bernam Oil Palm Ltd. were amalgamed into
United Plantations Berhad. United Plantations Berhad was sold to Kumpulan Fima under New
Economic Policy and Malaysianisation process. Danish shareholders kept 25% of the
company. Approx. 4,047 hectares of plantation land were acquired which resulted in United
The Danish group Aaehus Oliefabrik (now AarhuKarlshamn AB), a leader in the
global speciality fat complex, acquired Kumpulan Fima’s controlling stake in United
Enterprises (M) Bhd, 10,522 hectares of plantations, on 25th March 2003 resulting UP’s land
Socfin’s Lima Blas Estate was successfully acquired by United Plantations Berhad
which brought the Company’s total land bulk to 40,874 hectares and has thereby become one
of the key players in the Malaysian palm oil industry. On 25 th April 2006 UP announced
acquisition of 2 Indonesian plantation companies, namely: PT. Surya Sawit Sejati and PT.
Mirza Pratama Putra. Upon the acquisitions, the company will have access to approximately
30,000 hectares of land in Indonesian. The land will be developed over the next 6 to 7 years.
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On 27th April 2007 UP announced that it had entered into a new conditional Master
Agreement with the shareholders of PT Surya Sawit Sejati and the existing shareholders of PT
Sawit Seberang which will, upon completion, result in the Group having access to
The company’s principle business activity is in the cultivation and processing of palm
oil, coconut and other plantation crops in a sustainable manner. Its subsidiary companies are
engaged in several downstream activities such as; processing palm oil; and manufacturing;
packing/ distributing of end products in the form of cooking oils, edible oils, specialty fats and
soap products.
United plantations Berhad is one of the most efficiently managed, eco-friendly and
integrated plantation companies in Malaysia and is well known globally for its best
agricultural practices and high quality standards. In Malaysia UP’s total Land banks consist of
approximately 40,874 hectares. The main focus in cultivation of oil palm (90%) and coconuts
(10%). In Malaysia, United Plantations Berhad operates 6 Palm Oil Mill and the Unitata
refinery, a subsidiary that has been cooperating for a number of years, on a joint venture basic,
With the acquisition of two Indonesian plantation companies in 2006 the total hectare
the next 10 years. Development is progressing as planned. United Plantation Berhad possesses
considerable know-how in plant breeding, agronomy, and micro-propagation through its own
R&D facilities for the development of new and improved plan ting materials as well as
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This has resulted in United Plantations Berhad being recognized as one of the highest
Plantations Berhad’s connection with the AarhuKarlshamn group is seen as a vey important
business strategy in providing traceability and thereby the ability to control the raw material
from the agricultural source to final product-contrary to many other refineries, who have to
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• To produce quality palm oil, palm kernels, coconuts and their derived products to the
• To produce elite oil palm, coconut and banana planting materials with proven yield
potential.
• To value our human resources and to continuously strive to provide a conductive and
compatible.
plantations.
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We at United Plantations Berhad are committed to secure the safety and health of all
our employees at work. In the operation of our activities, we strive to maintain a safe and
healthy working environment for our employees, customers and the public.
We value our work place Safety and Health as of paramount importance to the well
being of all our employees and our respective Managers/Heads of Departments are
and promote a safe and healthy work environment in full compliance with legislative
requirements.
• Equip and train employees to use appropriate protective equipments and to develop a
own well being as well as those of the personnel and facilities under their control.
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• Required contractors working on our behalf and supplier doing business with us to
It is the Policy of United Plantations Berhad to produce Palm Oil and related Second
to None in Quality.
• Upholding the name and reputation of United Plantations as a top producer of top
• Ensuring only the best quality palm products are produces, for customer’s needs.
methods.
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This topic will describe about my training at 5 different sections during industrial
training. First month at fruit cages section, where I learn about how to use cutting torch and
welding set. The machine involve are oxyacetylene cutter and arc welding. Second month at
Locomotive section. Here I learn about loco operation, which involve hydraulic pump and
motor; 2 speed gear box and 4 and 6 cylinders Volvo Deutz engine. Third month at palm oil
mill machinery section, where I learn about high speed gear box, low speed gear box, blower
fan, reduction gear box, heavy machinery, etc. Forth month at vehicle mechanics section,
where I learn about diesel engine, tractor, heavy machinery, etc. Final month at machinery
section. Here I learn how to use 4 jaw lathe machine, shaping machine and drilling machine.
3.1.1WEEK 1
3.1.2WEEK 2
3.1.3WEEK 3
3.1.4WEEK 4
4. Public holiday
3.1.5WEEK 5
1. Tighten belt
2. Transfer engine
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6. Service locomotive
3.1.6WEEK 6
2. Tighten belt
6. Repair trailer
8. Service locomotive
3.1.7WEEK 7
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3. Public holiday
6. Service locomotive
3.1.8WEEK 8
1. Assemble crane
3. Public holiday
5. Service locomotive
3.1.9WEEK 9
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7. Repair silencer
9. Assemble locomotive
3.1.10WEEK 10
6. Public holiday
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3.1.11WEEK 11
3.1.12WEEK 12
3. Public holiday
3.1.13WEEK 13
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3.1.14WEEK 14
6. Public holiday
3.1.15WEEK 15
4. Assemble radiator
5. Service tractor
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3.1.16WEEK 16
2. Service tractor
8. Public holiday
3.1.17WEEK 17
2. Assemble engine
4. Service tractor
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3.1.18WEEK 18
3.1.19WEEK 19
3.1.20WEEK 20
3. Make shaft
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Most of the plantations transport the fruit bunches from the field to the mill using
tractors or truck. At United Plantations they used unique light railway system to transport the
fruits to the mill. All the fruit bunches will be filled into the fruit cages and transported to the
nearest palm oil mill. The fruit cages can be filled up to 2.5 tans of fruit bunches. Before the
fruit bunches been cook by steam in steriliser, the fruit bunches are filled full in the fruit
cages.
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At this section I was assigned to repair the fruit cages that been serious damages. At
this section I work with Mr. Muniandy and Mr. Murali. The main objective I was assigned to
this section is to learn about use of oxyacetylene torch cutter and arc welding.
1. Oxyacetylene cutter
Major damage always occurs on the bottom part of the fruit cages and the lifting part.
This happen because the fruit cages get smashed on to the under wagon during the
transferring from other under wagon. The thickness of the plate also decreases day by day
If the plate that places the lifting ring was tear apart than that plate need to be replaced
with the new one. First step is to cut the lifting ring off the old plate. It was cut using the
oxyacetylene cutter around the ring. In side the lifting ring also need to be cut. Then the lifting
ring is grinded smoothly. On the new plate, the lifting ring is set at the centre of the plate. The
lifting ring has to be centre. If not when the fruit cage is lifted by the over head crane it will
not stable and well balance. The welding is done using the arc welding. The weld needs to be
very tough and strong. The weld should able to lift about 2.5 tons of fruit bunches or more
After that the plate is weld to the fruit cages. The weld should be done inside and
outside. They use arc weld to weld the plate into place. After that the fruit cage is turn over.
On the bottom the lifting plate and the bottom plate is weld together. All the plate is made of
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mild steel. The thickness of the plate is 3/16 inches. Only the bottom plate holes of diameter 1
inch. Holes plates are used only on the bottom of the fruit cage because it allow the rain water
to be drain out of the cages. If there are no holes then fruit bunches will get rotten and will
produce very low quality crude oil and kernel. The second reason is to allow the steam to
follow trough it. By this way all the fruit can be cooked well in a short amount of time.
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Rail line is used to move the fruit cages filled with fruit bunches in marshal field. This
rail line is cover all over plantation field. It mean that the under wagon can keep on moving
no matter where it is on he field. There are 7 sterilisers used in this factory. It mean that in this
marshal field there are 7 rail lines for sterilisers, 2 for incoming fruit cages from field and one
for out going fruit cages. There also many junctions connect all this rail line together.
The rail line junctions always get damages because the factory run 24 hours per days
accepts Friday. The damages occurs because of the under wagon wheels and corrosion that
occur. Most of the damages occur when the under wagon run off the rail line at the junction.
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At the junction there are 2 moving rail which help to navigate the under wagon. When the
under wagon run off the rail line, the wheel put more that 2 tons of pressure to the bolt that
connect the rail line. As days goes by, the bolt and nut will get cut by the under wagon wheel.
So every week the junctions need to be repaired to help smoothen the operation of the factory
Sometimes not only the rail line junctions get damaged but the stopper at the end of
the rail line in the steriliser get ripped off. The stopper function is to stop the under wagons
from slamming the end of the steriliser. However it not designed to stop pressure more that 20
tons. The workers always pushed the under wagons to fast in to the steriliser until the stopper
The tools involve in repairing the rail line and stopper are:-
1. Oxyacetylene cutter
3. Cord grinder
First the old the rail junction will be cut off from it base. Then the base is cleaned and
grinded. A new rail bar is measured at the right length and cut with the oxyacetylene cutter.
After that the rail bar placed on the base and bolted to the rail line. The bolt can’t be
tightening too much because the rail bar should be moveable by human force. The bolt and
The same steps are taken when repairing the stopper in the steriliser. First the stopper
is removes from it base. The base is cleaned from any weld scar by melting away the scar
using the oxyacetylene cutter. Then the base is grinded with the cord grinder. After that a new
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stopper is made using L bar with dimension 5 inches (h) X 3 inches (w) X 1/4 inches (t) X 18
inches (l). The new stopper is then fixed to the end of the rail line in side the steriliser. The
new stopper weld securely to the rail line using the arc welding machine and stainless steel
rod. Now the steriliser can be operated for steaming the fruit bunches.
Advantage
Disadvantage
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Suggestion
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• Engine oil
• Air filter
• Fuel filter
• Chain tension
• Hydraulic pump
• Hydraulic motor
• Hydraulic host
• Locomotive frame
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United Plantation Berhad has unique light railway system that stretches over 500
kilometres. This company used diesel locomotive to pull a train of fruit cages containing fresh
fruit bunches. The fresh fruit bunches are filled into the fruit cages in the field. Then the fruit
cages are pulled to the oil palm extracting mill. This system has existed since 1930’s since this
There are two types of locomotive that been used in this company. One is driven by
hydraulic power motor and another one use two speed gear including reverse. Both of the
system used four pistons Volvo Deutz Engine. This type of engine is air cooler type. There are
also 6 pistons Volvo Deutz Engine. And lastly use normal Ford engine. Four pistons Volvo
However they use chain to transfer the energy from the gear box to the wheels. The
locomotive are capable of pulling 30 fruit cages when fully loaded each weight 2.5 tons.
This locomotive really power full. The locomotive is serviced every month to make it
at it top performance.
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At this section, I learn to completely how to overhaul the Volvo Deutz Engine. Before
starting any assembly all the part are soaked in oil to remove any impurity. Firstly the piston is
connected with piston rod. There should be some gap for the piston to move at the piston rod.
After that crank shaft bearing is installed. The bearing is made of aluminium and not like any
bearing. It shape like a semicircle plate made of aluminium. The bearing will eventually wear
off. Then crank shaft is fitted in. The bolts are tightening about 70 lbs/in. The main objective
of using torck wrench is that all the bolts are tighten even and to avoid any damage on the
tread. After that each piston are fitted into the cylinder. Then the cylinder and piston installed
to the engine block. The piston rod is connected to the crank shaft. Aluminium bearing is
installed between the crank shaft and piston rod. The piston rods bolts are tighten at 50 lbs/in.
The flywheel is fitted to make the next step easier. The cam is installed into the engine
block. Before installing part each of them are applied a film of lubrication oil. At the end of
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the engine block the idle gear is installed that connect the crank shaft and cam shaft. The
timing of the gear has to be precise. After that fuel pump gear is installed. The front is fitted
into the place. Oil reserve cover also fitted to the place. After that the engine are place on the
oil reserve cover. At this stage, rocker rods are inserted until reach the cam shaft at the bottom.
Then the engine head are mounted on top of the cylinder. The engine head tighten at 90 lbs/in.
Figure 3.5 Engine block fitted with piston rod and gear system
Before proceed to next step the fuel pump is installed into the place. All the bolts
tighten as hard as possible. The nozzle and fuel line from fuel pump to nozzle installed. The
flywheel turned to see any disturb in rotation of the engine. Then the rocker installed and
relief gap set at 0.12mm for each valve. Finally the blower, starter and belt fitted to the
engine.
The engine is ready to be mounted to the locomotive frame. However it still missing
hydraulic pump. A new mounting cover is made to mount the hydraulic pump to the engine at
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the flywheel. The hydraulic pump is fitted to the cover and then to the engine. The complete
gear box change with the new one. Then the hydraulic motor pump is fitted to the gear box.
Finally the gear box is fitted to the 2nd secondary frame. Then it fitted to the primary frame.
After 1st secondary frame fitted, the engine is mounted to the locomotive frame. Hydraulic
host connect the hydraulic pump and hydraulic motor pump and actuator. The locomotive is
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Advantage
Disadvantage
• Short of time
• Did not able to learn more about the air coolant type engine
Suggestion
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Threshing Sludge
Centrifugation
Winnowing
Kernel Drying
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Fresh fruit bunches arrives from the field as bunches and loosen fruit. The fresh fruit
bunches arrives in fruit cages. It then weighted on a scale so that quantities of fruit arriving at
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3.4.1.2 Steriliser
Fresh fruit bunches in the cages will push into steriliser by using skid steer loader Cater
Pillar 910. There are 7 sterilisers in the factory. One steriliser can fill 7 fruit cages or 17.5 tons
in one time for sterilization process. Here the fresh fruit bunches will cook by steam at
pressure 40 psi which was supply from boiler to steriliser. The objective of sterilization is:-
• To stop appeared enzymes in Free Fatty Acid (FFA) so get stop increase FFA
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Then fresh fruit bunches will pull out from steriliser by using skid steer loader Cater
Pillar 910. There are 4 over head cranes in this station. Over head crane will pick up cages to
If over head crane get transfer the fresh fruit bunches in a cages in 2 minutes, so:-
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60 minutes = 75 tons
From this calculation, we know that capacity of factory is 75 tons per hour.
After sterilization the sterilized fruits are threshed to remove fruit from bunches.
Sterilized bunches are fed continuously into the rotary drum which is a made of channel bars
which run longitudinally along the drum and that drum is diameter 6 feet or 1.8 metre and
rotate 1440 rpm. The bars are so positioned as to allow fruit to past through but not the
stripped empty bunch which is conveyed out of the thresher. Some empty bunches are
incinerated and the ash from this process is used as fertiliser. Other empty bunches will go
through a single stage presser to suck out the oil left in bunches. Then it sends to the field to
be used as fertiliser.
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Figure 3.12 The fruit bunches been poured on the Auto feeder
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The stripped fruits then are fed continuously into digester where they are converted
into a homogeneous mash suitable for pressing. The digester are cylindrical vessels containing
After digester the mash is transferred to double screw presses which extract the oil by
pressure. The mash is subjected to increasing pressure as it is conveyed along the press by as
crew. The press cages are perforated to allow oil pass through. Pressure at the end of the press
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After pressing the dried press cake, consisting of nuts and de oiled monocarp fibre and
solids, passes to an air column which separates nuts from fibre. The fibre will sniff up to
boiler station through fibre cyclone fan. The nut will move down into nuts polishing drum.
A= area (ft3)
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Nuts will transfer into nut polishing drum to clean nuts from fibre. In the same time
this machine also has other function which to remove impurities like stone, wood, electrode
and etc. Then nuts move out from drum through the hole at drum in size 3.5 cm to move down
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After nuts polishing nuts transfer into nuts silo by nut elevator. Nuts will through
drying process in nut silo with temperature 60°c - 80°c for 16 hours. Steam receiver from
boiler is 30 psi. This process is to make nut cracker get crack nuts easily. During heating
process the fan will sniff air to carry heat into nuts silo. There are have shaking grate to make
nuts move down slowly and chute under nuts silo to flow nut into nuts cracker. Capacity of
Nuts cracker is function to crack nuts to gets kernel. After this process appeared the
kernel and shell in mixing condition. There are has a rotor in the nuts cracker which rotate in
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3.4.1.10 Winnowing
Winnowing is a process to sniff up the light partial in Crack Mixture conveyer like
small shell to shell bunker through Light Partial Fan (LPTS). The shell will as fuel for boiler.
This section is to separate kernel and shell. Kernel and shell which move in Crack
Mixture conveyer will allow transfer into Hydro Cyclone. The Hydro Cyclone was divide 2
part which one for kernel side and one more for shell. Water was used as a medium in ¾
Hydro Cyclone. The water will bring kernel and shell in mixing condition into Cyclone by
using pump. There is having Vortex, Spacer Ring and Discharge Cone in a Cyclone. Cone for
kernel is size 80 mm and cone for shell is size 60 mm. Rotation of water with high speed will
happed in cone for kernel and will cause kernel and shell will separate. Then kernel transfer
into dripping drum kernel and shell transfer into shell side in Hydro Cyclone. Shell will pump
into cone for shell side at 10 psi through a pipe. Rotation of water in high speed happened in
cone side shell too with same principle. So there are 2 steps before get nice kernel. The kernel
transfers into dripping drum one more time for last. The dripping drum is function for
dripping process for kernel. Then kernel will flow down into vibrating screen through the
chute.
Wet kernel will flow down into bucket vibrating screen. Vibrating screen is function
for dripping process by using vibrating system. The Vibrating system out of the centre method
at the shaft. There are 2 vibrating screen. When bucket is vibrating the kernel will move down
into Wet Kernel elevator. Then wet kernel elevator will carry the kernel into Kernel Silo for
In kernel silo kernel through drying process in temperature 50°c - 60°c for 16 hours.
There are 3 kernel silos which each one have 2 heather and steam receiver from boiler is 30
psi. That steam will heat the heater and the kernel silo fan will sniff up into kernel silo dry the
kernel. Capacity of kernel silo is 14 tons. Basic rule is same like nuts silo. Kernel drying
process is important because to get the oil in kernel. Kernels also have the oil beside from the
nuts. Beside that, this process also is avoid the bacteria appear from happened. The wet kernel
condition will cause the free fatty acid will also increase quickly.
The dry kernel will transfer into dry kernel conveyer after through kernel drying
process. Next the conveyer will carry the dry kernel to dry kernel elevator to enter into kernel
winnowing which will bring the dry kernel into the kernel bunker.
The kernel bunker is last station which is use to storage the kernel. The kernel which
was passes all process will stored here. Lastly that kernel transferred to other factory to
process to make the product like cosmetic and many more. The kernel will transfer by using
the lorry.
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3.4.1.14 Clarification
3.4.1.14.1 Vibrator
Oil from press will through Oil Gutter where is located under press to Oil Tank Press.
Then oil will through three junction pipe to vibrator. The vibrator screen is function to remove
impurities sand and sludge in oil. There are 2 type of filter of vibrator screen which is 20
meshes and 40 meshes. Next the oil will flow into Crude Oil Tank.
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Oil from vibrating screen will flow into Crude Oil Tank. There are two columns in the
Crude Oil Tank. Oil in first column will pump to Auto Decanter. The Auto Decanter is
From Auto Decanter oil will flow into second column before pump to Distributer
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Distributer tank is function to collect the oil from Crude Oil Tank at press Station.
Then the oil will divide to Continuous Clarifier Tank and releases of oil pressure before send
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Continuous clarifier tank is function to separate the oil and sludge depend the different
of density. There are 3 columns in Continuous Clarifier tank which is separate with 3 plates in
vertical position. Here separation process of oil and sludge happened. The layer of oil will
appeared and the sludge is below the oil layer. The layer of oil is average in 10 cm. Capacity
in Continuous Clarifier tank is 20 tons which temperature needed is 90°c - 98°c. The period
The operator will collect the oil by using the skimmer that oil will transfer into the oil
tank and the sludge will transfer into the sludge tank. The capacity both of tank is 10 tons for
each one.
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Oil in oil tank will transfer into oil purifier. The oil purifier is function to remove all
dusty in oil by using centrifugal force in high speed. Temperature is needed in oil purifier is
90°c. Oil will flow from oil tank through inlet pipe to flow regular and next to distributer to
move to disc set. In disc set separation of dusty and oil happened in rotation of disc. Then the
dusty will flow out to discharge pipe and then the oil will move to float tank to go to vacuum
dryer. Rotation in oil purifier is 1480 rpm for Alfa Laval type. Beside that from rotation will
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Oil from oil purifier will pumped to vacuum dryer to remove moisture in oil at 760
mm/hg where the water will remove at temperature 100°c. The capacity of vacuum dryer is 10
tons/hour. In vacuum dryer the oil will spittle through nozzle dryer which is of nozzle is 0.48
cm.
Steam will sniff out by using the pump. When the steam change to water and will
transfer to hot tank. The oil flow down to below area in vacuum dryer and flow out to
transport pipe. The oil will pump transfer to bulk storage tank.
Sludge separator is used to get oil in sludge because the oil still has sludge fluid and it
using high speed with disc. Solid and water get separated to bowl hood and flow out by
nozzle. The size of nozzle is 1.6 mm. Oil is more light of weight will flow by disc stack.
Beside that the sludge separator also uses auto flashing to clean the sludge separator.
Cleaning process will spent 1 minute after run in 30 – 45 minutes. The oil from sludge
separator will pump into reclaim tank and sludge into sludge trap.
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Reclaim Tank
Reclaim tank is function to keep the sludge in short time and heat the mixing oil and
sludge which flow from sludge separator and drained from oil tank. Then the oil from reclaim
tank will pump back to continuous clarifier tank to recycle back through same process.
Sludge Trap
Sludge is use to trap back the sludge to get oil which free from sludge separator, and
pre-cleaner. The oil will collected by using skimmer and transfer to reclaim tank. The sludge
will allow flow to mixture raw effluent and through effluent treatment before allow to the
river.
Mixed raw effluent is a mixer of sludge trap and steriliser condensate. Mixed raw
effluent will pump to aerator by power 15 KW and rotation of motor is 1440 rpm. At aerator is
being cool process at this level. Sludge will pump from mixing pond to anaerobic digester.
From here the sludge will arrest for 20 days. In this period will appear a few reactions.
After all process for effluent treatment water will pass into the river. That water is safe to use
daily. Quality of water out from this company is same with water in river and safe to use.
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3.4.1.19 Boiler
Boiler is heat machine which using to provide the steam for processing and generate
electric power. Type of boiler is water tube. Water from steam feed pump will pass through
check valve. The check valve is to allow water flow in one way only. Water will enter the
steam drum at half level of steam drum. That water will be heated into partial steam-water.
Partial steam-water will pass through superheat tube at header of boiler to get superheat steam
and the superheat tube size is 1 inch. The superheat steam will pass through main stop valve
to generate steam turbine. Main stop valve is function to allow the steam flow in one direction
only.
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alternator is 500 KW and rotates at 4962 rpm. From alternator steam will transfer to reservoir
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a) Wet storage – water mixes the chemical and fills into boiler. The boiler needs to be
b) Dry storage – this step taken when boiler not used for 6 month. The boiler need to be
Component Function
Safety valve To release over pressure in boiler by blow out off the steam and
avoid the boiler from explode
Main stop valve Allow the steam to flow out only
Gauge glass Show the level of water in boiler
Check valve Allow the water to enter into boiler only
Fusible plug For safety
Water alarm Show water level in drum
Fuel cut off To cut off the fuel
Pressure gauge Show the steam pressure
Test gauge connection Testing the steam pressure
Feed pump Pump the water into boiler
Blow down To reduce water quantities in boiler
Register plate The number which was registered
Manufacturing plate Supplier
Table 3.1
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Overhaul Boiler
3. Provide the tool such as chipping hammer, transformer, hand lamp, dust respirator, goggle,
4. Safety first
5. Doing outside work like chimney I.D fan, open mud box, cover header, make platform in
7. When boiler really cool remove water through blow pipe and drain header.
8. Open the gauge glass and put the caps and gauge glass carefully.
9. Open plate in steam drum and water drum by using cleaner tube with pressure air metre
electric pump.
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Shoot blower is a device a fitted to the boiler to keep it at optimum performance. The
shoot blower main purpose is to clean the ashes from the steam pipe in the boiler. It functions
by shooting high velocity steam through tiny holes along the pipe. This pipe can be rotated 90
degree only. The holes are perfectly made in the pipe according to the arrangement of the
steam pipe in the boiler. During the boiler operation, the fire is blown between the steam
pipes. At that time the ash also fly that way. As times passes by the ashes start to collected
between the steam pipes it self. If the ashes did not been remove it will start to solidify. When
that happen the water can not be heathen effectually because most of the heat are absorb by
This shoot blower pipe inject high velocity steam to the solidify ashes. The steam will
shatter the solid ashes into tiny pieces. Then it blew away by the steam. Some of the ashes get
Firstly the boiler has to be shut down. It let to be cooled over night. Then the shoot
blower pipe is pull out of the boiler. Using chipping hammer solid ashes that grabbed on to the
pipe surface are cleaned away. Then high velocity air is blown into the pipe to clean the tiny
holes. All the remaining ashes are washed away with water. New heat proof paint is painted
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on to the shoot blower pipe. Then the shoot blower pipe is fitted back to the boiler and
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The overhead crane is the main important machine in this oil palm factory. It
responsible to transfer the sterilized fruit bunches into the fruit thresher. The wheel and the
cable of the crane need to withstand more than 3 tons in hot condition. Firstly the overhead
crane is shut down from operation. The hook is lowered to the floor to reduce the total weight.
Then a chain block is attached to the on wheel of the overhead crane. The wheel is lifted of
the rail. Then the bolts that hold that wheel are taken off. The wheel then taken off the main
body. The wheel brings to the hydraulic machine. Using hydraulic machine the old bearing
push off the wheel. The wheel then disassembles from the holding bar.
A new wheel with fitted new bearing assembled to the holding bars. After that the
wheel fitted back to the crane. The bolts are tightening. The wheel then lowered back to the
wheel. The same procedures are applied to all other 3 wheels. After all wheels have changed,
the wheels are aligned properly to the rail to avoid any accident. The gearing part is applied
One end of the cable is loosened. Then the rest of the cable is pulled off the hook
pulley by hand. Then the other end of the cable also loosens off. A new cable which measured
49.5 m (length) X 11 mm (diameter) is fitted to the drum. The other end is fitted through hook
pulley and back to the drum. The clippers that hold the cable to the drum are tightening.
Finally a lot of grease is applied along the cable and the drum.
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This company produce its own electricity power. The electricity power not only use
for the factory but also supplied to the estate houses of this company. They have 2 huge steam
turbine alternator that been use since electric been use in this factory. They even have 4
They cut the production cost for electricity because they have their own turbine.
Before electricity been use, this factory use massive belt drive system to operate the entire
machine. At that moment the biggest problem was, when a belt is broken off then the entire
factory has to be shut down to repair it. At time production was at slow past. When the electric
motor introduced the belt system immediately changed to it. Then the production rate get
boost by electricity.
The number 2 steam turbine alternator was reported to be producing weird sound
during operation. One of the alternator bearing is wearing off. So the bearing has to be
changed. Firstly the steam supply to the turbine is cut off. It has to be done to dismantle the
alternator. Then all the output electric cables are loosening off. The boxes that bring the cable
also need to be removed. Then an A frame is assembled directly on top of the alternator. The
coupling that joints the turbine and alternator dismantled on by one. The bolts that hold the
Using two chain blocks the alternator lift off the base and carefully lowered to the
floor. A few pipes placed below the alternator that acts like rollers. The alternator is carefully
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A few days later the alternator has repaired. The same technique use to drag the
alternator back into the engine room. Then the alternator lifted of the floor and placed on the
base according the original coordination. All the cables, bolts and coupling fitted in. The
There was a report that saying purifier number 2 is no working very well and it
transmission oil is leaking. Firstly the purifier is shut down and let to cool down for few
hours. After that the inlet and outlet are taken off. The clamping shoes are loosening to open
the top cover and collecting cover. The flow regulator also loosens. When the cover is opened
Then the lock rings are unlocked. The packing, gravity disc diameter 90, seal ring and
bowl hood are separated from the machine. The whole distributer, bowl disc and top disc are
taken out completely. The cap nut and screws are loosed. The distributer cone, lining and
sliding bowl complete are taken off the machine. The screws that hold the bowl body are
Then the horizontal part also dismantled to pieces. During that time the transmission
oil is drained through the drain nut. The bowl spindle is dismantled as well. Then all the frame
parts are taken off including hinge bolt, pawl and buffer, hood for paring disc device, sludge
discharge bend, vibration damper, bottom bushing, brake and motor bracket. All the gearing
All the parts including the frame are washed and dried. All the oil seals, bearings, o
rings, packing are changed with new one. Then the purifier is assembled together the same
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way that it been disassembled. After assembled about 10 litres of new transmission oil is
purred in. Then it let to run for few minutes then it ready for it purification process.
Firstly the ripper mill is brought to the work shop. Then the ripper mill is dismantled
into pieces. After that the bottom case of the ripper mill that holds the nut cracking rods is
grinded. All the nut cracking rods are taken off because it has worn off. At the inlet of the
bottom case the wall also worn off. At that section filler weld done to get it thicker than
before. After weld that section is grinded to get smother surface. Then new set rod measuring
17 inches long and 1 inch diameter inserted into the place of the bottom case.
The drum also dismantled and a new set of rod inserted measuring 15 inches long and
1 inch diameter. The rods are placed forth and backward in the drum. Then the walls that
containing bearing and adjustment screw are fitted to the drum. After that the bottom case is
fitted between the two walls. Finally the top case fitted together. All the bolts are tightening.
The adjusting screws are adjusted until the gap between the drum rods and the bottom case
rod are just about half inches. Then the ripper mill is mounted to the bottom of the silo. The
motor is fitted.
Advantage
Disadvantage
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• Less guidance
Suggestion
Other than the locomotive this company also uses vehicle like tractors and heavy
machinery to maintain the field and factory. In side the factory especially on the marshal field
they use two Cater Pillar 910 to push and pull the fruit cages. In the field they use Massey
Ferguson tractors and John Deere. The size varies from small to big. The engine capacity
Every tractors and heavy machinery are service monthly keep it at optimum
performance. Before the use of tractors and other heavy machine, this company was using
traditional transportation like bull wagon. After the introduction of the heavy machinery the
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This ipto clutch serve as a drive shaft for the machine that tow behind the tractor like
grass cutter and trench digger. Firstly the tractor is parked under roof. Then the tractor lifted
and placed on the supporter for further operation. The transmission oil drained out the
transmission box. Then the bolts than hold the body together are loosed. Carefully the body is
The ipto clutch is taken out of the transmission box. The clutch is dismantled into
pieces. When examined all the plates and the discs are worn out. A new set of the discs and
plates are ordered to replace. The discs and plates are arranged in alternate and placed in the
housing. It then secured with snapring. After that the ipto clutch attached back to the
secondary transmission in the transmission box. After that the tractor is joined together and
filled with transmission oil. A few test run done to test the new clutch disc.
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Firstly the tractor is jacked up. Then the rear wheel is taken up. The transmission oil in
the rear axle housing is drained through the drain plug. After that the nuts unf and bolts unf
are loosed. The cover is slowly taken off and the parts are dismantled. All seals and the
bearing replaced with new units. The parts are cleaned in the diesel oil and dried. Then it put
Some grease is applied inside the pinion and the needle stack inside. The grease will
hold the needle together like glue. All three pinions done in the same way. After that the
pinion pads with the washers and slowly slides into the carrier. The clevis pin inserted and
locked with pin. Then the shaft inserted into cover and locked with circlip. The carrier slide on
to the shaft. Then the annular gear fitted on to the cover. Finally the rear axle housing is fitted
back to place. The rear wheel fitted and the gear oil filled up again.
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Firstly the engine block is cleaned up with the diesel. A thin film of engine oil apply
on the inside surface. The pistons are fitted with the oil rings and piston rings. Then it fitted to
the piston rod. A thin film of oil is applied to the pistons. After that it fitted to the crank shaft
fly wheel mounted to the crank shaft. The engine oil pump is mounted at the bottom side of
the engine. After that the aluminium cover which contains the water pump is mounted. Then
the gears fitted according the mark on it. If the gears not fitted correctly it will result some
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damage to the engine and may the engine will not start at all. Then the fuel pump is fitted on
the gear. The bolts that hold the fuel pump are tightening.
Figure 3.32
After the gears aligned the front black cover is fitted. The vacuum pump fitted on top
it. Then the oil reservoir is fitted to the bottom of the engine. After that a temporally engine
mounting is made. This is made to avoid the engine from placed on the oil reservoir and
damage it. The temporally engine need to be strong and stable because the test run will be
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Figure 3.33
Then the engine head is fitted on top of the engine. The engine head hold the valve and
etc. The rocker arm then fitted to the engine head. On top of the rocker arm the cam shaft
installed. Then the cam shaft pulley installed. After that the timing belt fitted and the timing of
After that the valve clearance adjusted according to firing order. The firing order of
this engine is 1 – 3 – 4 – 2. The valve clearance is set at 0.13 mm for inlet an outlet. Then the
cover is fitted. After that the nozzle is fitted with the fuel pipe from the fuel pump. The air
intake manifold and exhaust manifold are fitted in place. After that the radiator fan, alternator
and starter are fitted to the engine. The engine oil and engine coolant filled in. Then a
temporally fuel line is fitted. Then the engine started for the first time. A few adjustments
done until the engine start. The engine let to run at low rev for few days.
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Figure 3.34
After satisfy with the running condition all the temporally parts taken of including the
radiator, fan and starter. Then the engine lifted of and lowered into the pickup. The engine
mounted on the engine mounting. The battery, fuel line, starter, fan, air conditioner
compressor, radiator and wires are fitted properly. The engine started and done some test run.
Figure 3.35
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Advantage
Disadvantage
Suggestion
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4.1 Conclusion
Department, I get a lot of knowledge, skill and experience about manufacturing of palm oil
mill and maintenance of the machine involve with the process. From processing the oil palm
activity but I get much knowledge and experience in what I did. Here I did the welding
process, cutting using oxyacetylene, overhaul gear box, overhaul engine, repairing, solve the
problem in maintenance activity and many more. That means all jobs for workshop need to be
done.
Actually the job for maintenance is very important because if any breakdown
happened during process and it is workshop responsibility to settle it. So the members of the
workshop department need to take this responsibility to solve the problem. If not, this
company can to get to process the oil palm. Workshop need to repair or solve any problem to
make sure this company will runs in 100%. By this way, this company will able to continue
Beside that we work under engineer department need to make sure that all
maintenance in all section done well. So the engineering department need to preventive
maintenance to avoid the machine breakdown. It also can reduce cost budget for this company
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This is our responsibility when work under engineering department. All members of
engineering department need to take this responsibility including my self. We need to take
care of our company. Actually our job is to improve the productivity of this company and
knowledge and skill which can guide me when I join the workforce upon completion my
study in UTeM. Besides learning something which relate to the subject I learn, I also been
given an opportunity to learn about the product, work as a team workers, communicate with
is a good experience obtained while industrial training at United Plantations Berhad Ulu
Bernam Engineering Department. I learn how to apply the tool and technique that I have
learnt before.
4.2 Recommendation
In engineering field, the maintenance only is not good. To become and engineer need
to solve the problem and improve it to get improve the productivity. In industrial training
activity for 20 weeks I saw a few problems which need to solve and need to improve here.
Here I hope will get improve productivity for this company. There are a few of problems
stated below:-
Problem
1. The kernel falls down on the road during transfer operation into the lorry under kernel
bunker. These problems will reduce the productivity product because that kernel is high
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Solution
1. Need to check the source the problem whether it from the kernel bunkers or mistake
Problem
2. The kernel also moves out during transferring into dry kernel elevator. It cause the
Solution
1. Make the cover around the chute to avoid the kernel move out around the dry kernel
elevator.
3. Can do rivet joining on the chute because the chute already made from hard material.
Problem
3. The kernel in bucket vibrating screen always flow out while it running. The kernel
Solution
1. Modified at bucket to more big and make sure the wall high enough to stop the kernel
2. Second method is just adding the nets at body of bucket by using the bolt and nut
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5.0 REFERENCE
Anniversary, 2006.
6) www.unitedplantations.com
Plantation Berhad.
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6.0 APPENDICES
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