INDUSTRIAL TRAINING REPORT

SIMEDARBY JOMALINA SDN. BHD

BATU 9, JALAN BANTING-KLANG

42500 TELOK PANGLIMA GARANG INDUSTRIAL ESTATE

SELANGOR DARUL EHSAN.

WAN SITI NOORHASHIMAH BT W.KAMARUZAMAN

KA 09135

IJAZAH SARJANA MUDA KEJURUTERAAN KIMIA

FAKULTI KEJURUTERAAN KIMIA DAN SUMBER ASLI

UNIVERSITI MALAYSIA PAHANG

JUNE- SEPTEMBER 2012

DECLARATION

“I hereby acknowledge that this Industrial Training Report has been verified and it does not contain any CONFIDENTIAL information to be released to the public”

Signature : …………………………………………………………………..

Official stamp :…………………….…………………………………………

Date :……………………………………………………………………….

ACKNOWLEDGEMENT

In preparing this report, I was in asking with many people especially in

Simedarby Jomalina Sdn. Bhd. They have contributed towards my understanding and

thoughts. In particular, I wish to express my sincere appreciation to my supervisor’s,

Mr.Varadaraj for encouragement, guidance, critics and friendship. I am also very

thankful to all executive, Mr. Masdar Beri, Mr. Suresh Onichandran, Ms. Nurdiyana, all

operators especially in refining plant, and all lab assistant in QC Department for their

guidance, advice and also motivation. I am also indebted to Faculty of Chemical

Engineering and Natural Resources (FKKSA) lectures for their support during my

practical in Simedarby Jomalina Sdn. Bhd.

My sincere appreciation also extends to my industrial supervisor’s from

Universiti Malaysia Pahang (UMP), Ms.Siti Hatijah bt Mortan, manager of Simedarby

Jomalina Sdn. Bhd., Dr.Razam bin Abdul Latif and other who have provided

assistance at various occasions. Their views and tips are useful indeed. Unfortunately,

it is not possible to list all of them in this limited space. I am grateful to all

communities of Simedarby Jomalina Sdn. Bhd and friends in the same batch with me

who also contribute to industrial training.

LIST OF ABBREVIATIONS

SHORT NAME FULL NAME

CPKO Crude Palm Kernel Oil

CPO Crude Palm Oil

COL Crude Olein

CPP Consumer Packing Plant

CST Crude Stearin

DNOL Deodorized Neutralized Olein

DNPO Deodorized Neutralized Palm Olein

FFA Free Fatty Acid

I.V Iodine Value

JGQRBDPO Jomalina Guaranteed Quality Refined Bleached Deodorized

Palm Oil

JGQRBDOL Jomalina Guaranteed Quality Refined Bleached Deodorized

Olein

M & I Moisture & Impurities

M.Pt. degrees Melting Point

MEOMA Malaysian Edible Oil Manufactures Association

MT Metric Tonne

NBDPO Neutralize Bleached Deodorized Palm Oil

PAO Palm Acid Oil

PKFAD Palm Kernel Fatty Acid Distillate

PFAD Palm Fatty Acid Distillate

PORAM Palm Oil Refiners Association Malaysia

RBD Refined Bleached Deodorized

RBDPKO Refined Bleached Deodorized Palm Kernel Oil

RBDPO Refined Bleached Deodorized Palm Oil

RBDOL Refined Bleached Deodorized Olein

RBDST Refined Bleached Deodorized Stearin

CHAPTER 1

INTRODUCTION

1.1 General Background

The overall development of the palm oil in Malaysia is described

as having been more colorful. Oil palm was first introduced to Malaysia

(then Malaya) in 1875. Early interest in oil palm was as an ornamental

plant, and from about 1917 onwards the palm oil sector began its

development into what it witnessed today as a multi-billion Ringgit

industry. Malaysia has one of the most ideal climatic conditions for

growing oil palm, and it is in Malaysia that the crop’s full potential has

been realized and exploited.

Malaysia is the largest producer of the palm oil in the world.

Simedarby Jomalina Sdn. Bhd is formerly known as Golden Jomalina

Food Industries Sdn. Bhd. It is commenced refining operation in 1977.

The area is 4 hectares of factory complex area. The company is

acquired by Golden Hope Plantation Berhad in 1984. The Merger of

Golden Hope Plantation Bhd., Kumpulan Guthrie and Sime Darby Group

to become the new Sime Darby Group in November 2007. They

changed to present name in 29 March 2010.

As part of the Sime Darby group, Sime Darby Jomalina is

distinct from other refiners by ways of securing continuous premium

quality crude palm oil supply from the plantations. Sime Darby Jomalina

is a leading sustainable solutions provider to the edible oils and fats

industry. Our company is certified to the strict requirements of HACCP,

ISO 9001, ISO 14001, OHSAS 18001 and others. We produced

customized premium quality products to meet customer’s requirements in

the business-to-business segment.

Our premier quality products are widely used in food industries

globally, with applications in dairy products manufacturing, food

preparation, as well as natural and healthy colorants for food ingredients.

The main brands marketed under our company are Golden JomaTM,

JomaTM, SAFaRTM and D’FaRTM.

We are committed to meeting and fulfilling our customer’s

stringent requirements. With our production expertise and professional

marketing team, we provide high quality products and excellent service

with timely delivery.

Sime Darby Jomalina Sdn. Bhd. produces a wide range of high

quality traceable refined palm oil and palm kernel oil products which

include industrial shortening, margarine, frying palm oil, dairy fat

replacer, animal fat replacer, dough fat, vegetable ghee and cooking oil.

Our products are exported to Far East, South East Asia, the Middle East,

Europe, Africa and United States of America. Locally, we well position

in the Malaysian market.

Sime Darby Jomalina Sdn. Bhd also manufactures tailor-made

products to meet consumer’s specific requirements as well. We are being

supported by highly trained and dedicated Innovation Centre Asia under

Sime Darby Research Sdn. Bhd which has well over 200 technocrafts,

scientist and technicians. They work very closely with our sales and

operations team tp serve customer better in providing solutions that meet

and extend customer’s need.

These specialty produced from our very own Premium Quality (PQ)

Crude Palm Oil includes:

1. Special Animal Fat Replacer (SAFaRTM ) – vegetable fats to replace

animal fats in frozen food products

2. Jomalina Guaranteed Quality (JGQTM) - products-products made from

Premium Quality CPO

3. Golden JomaTM Red Palm SuperOlein - red palm oil with very high

beta carotene content

4. Customised oil products with specific parameters for frying,

application in dairy products, colourants and as healty food ingredient

Head of Factory Operation

Head of Department, Production 

Senior Executive, Planning 

Executive, Production 

Senior Operator 

Operator 

Process Control Technician 

Attendant 

Clerk, Production 

Organization Chart

CHAPTER 2

TRAINING ACTIVIES

1.1 Scope

This chapter will cover all the information data related to Physical

Refining Plant (Plant 22) operations and control from feed raw material of

Crude Palm Oil (CPO) to the processing parameters and control in order to

get the desired quantity and quality of products that meet or exceed the

customers requirements. This plant has a capacity of 700MT/day. The main

product from this plant is Refined Bleached Deodorized Palm Oil (RBDPO)

and by products Palm Fatty Acid Distillate (PFAD).

CPO 

Pumping to Bleacher Feed Tank 

Degumming 

Bleaching under vacuum 

Niagara Filter 

Aluvion & Pocket Filter 

Bleached Palm Oil Holding in the tank 

Pumping to deodoriser P22 

Cartridge Filter 

Daeration & Pre-heating 

Deodorization 

Phosphoric Acid 

Bleaching Earth 

Cooling  Fatty Acid Scrubbing & Condensation

 

RBDPO storage  PFAD storage

 

1.2 Refined Bleached Deodorized Palm Oil (RBDPO) Process Flow

1.3 Palm Fatty Acid Distillate (PFAD):

Palm Fatty Acid Distillate is by product obtained from condensation of

fatty acid and other volatile materials during the deodorization stage in the

physical refining of crude palm oil. The fatty acids produced from the

various fat splitting processes are purified and separated into fractions or

even individual fatty acids by distillation and fractionation. Fatty Acid

Distillation. of crude fatty acids removes both the low and high boiling

impurities as well as odor bodies. Fatty acids are extremely sensitive to

heat, oxidation, and corrosion effects. This is due to the reactive acid group

at the end of the long carbon chain. These factors are taken into

consideration in the design of the distillation unit and its operating

parameters.

Distillation is carried out under high vacuum and lower temperatures and

with the shortest residence time allowable. Technical design of most

distillation units features high vacuum with no allowance for air leakage,

effective heating to achieve short contact time, good circulation for effective

mass transfer between vapor and condensate, and steam economy. Internal

arrangements of the column vary among suppliers with the ultimate purpose

of achieving the design objectives. The basic steps in processing are about

the same.

Figure 1: Continuous Fatty Acid Distillation

Crude fatty acid is predried and degassed under vacuum and fed to the

distillation unit, which is operated at a vacuum of 1.2 kPa or less and a

temperature of approximately 200℃. Modern stills use thermal oil or high

pressure steam as the heat source. Stripping steam is provided to improve

circulation and reduce partial pressure, thus lowering the temperature and

reducing degradation losses. The steam facilitates the removal of low boiling

impurities as well as odor and color bodies from the vapor exiting the system

and from the light ends.

The distilled fatty acid has an almost water white color and is free of

the major impurities. The heavy ends consist of the higher boiling components,

usually of lower quality, which can either be withdrawn separately or recycled

directly for redistillation The bottoms or residue are charred viscous

polymerized material, which is disposed of by blending with heavy residual oil

and used as boiler fuel. It may also find use as an asphalt additive.

Master of Product Code and Customers.

Product Type Code Customers Brand

190kg Drum PFAD-45/48-

DR(JM)-01-001

Polymeric

Technology S/B

-

190kg Drum PFAD-45/48-

DR(JM)-01-002

Sun Rythym S/B -

Process and QC Limit

i) PFAD-45/48- DR(JM)-01-001

Packing

Clearance

Despatch

Control

Buyer Spec

Packaging 190kg Drum

FFA (Palmitic)

% min

70 70 70

M & I % max 0.5 1.0 1.0

Total Fatty

Matter % min

95 95 95

ii) PFAD-45/48- DR(JM)-01-002

Packing

Clearance

Despatch

Control

Buyer Spec

Packaging 190kg Drum

FFA (Palmitic)

% min

70 70 70

M & I % max 0.5 1.0 1.0

Total Fatty

Matter % min

95 (basic 97) 95 (basic 97) 95 (basic 97)

Determination of Free Fatty Acid (FFA)

1.1 Principle

The fat is dissolved in an appropriate solvent after which the solution is

titrated with Potassium Hydroxide (KOH) solution. The amount of KOH

solution consumed is a measure of the acidity of an oil or fat. Free

fatty acid (FFA) content is calculated as percentage by weight of fatty

acid of specified molecular weight, according to the type of oil or fat

under investigation. Noemally, Palmitic acid with a molecular weight of

256 is taken. In a number of cases an average molecukar weight, more

appropriate to the nature of the oil or fat is used. In each report, the

basis must be clearly stated.

1.2 Reagents

Solvent : ISO Propyl Alcohol (IPA). Neutralize shortly before use

with 0.1N KOH solution by drop wise addition using

phenolphthalein as indicator.

KOH solution : 0.1N aqueous solution accurately standardized

Phenolphthalein indicator: 1% in IPA. 5g Phenolphtalein powder

into 500g IPA.

1.3 Apparatus

Electric sources hot plate with stirrer

Magnetic stirrer bar

Beaker, 150ml

Digital burette, 25ml

Analytical balance, capable of weighing to the nearest 0.001g

1.4 Method

1. Dissolved the oil or fat in at least 50ml of the solvent, if necessary

by gentle heating.

2. Titrate while swirling (the magnetic stirrer) using Phenolphtalein as

indicator

Titration is carried out at room temperature

3. The end point is reached when a permanent pink colour is obtained.

This should persist for at least 30seconds

4. The weight of the oil and the normality of titrant are chosen as

follows:

Oil type Approx amount of

oil to be weighed

(g)

Accuracy of

weighing (mg)

Normality of alkali

(N)

Crude Oil 3 1 0.1

Refined oil,

neutralised oil

20 10 0.1

Acid oil, fatty acid

distillate

0.5 1 0.1

1.5 Calculation

Free Fatty Acid (FFA) % : VNM10W

Where,

W: Weight (g) of the sample

V: Volume (ml) of KOH solution

N: Normality of KOH

M: Molecular weight of fatty acid

Normally, assume a molecular weight (MW) of 256 for palm oil. The

following values are often used:

Type of acid Molecular weight

Lauric Acid 200

Palmitic Acid 256

Oleic Acid 282

In the analysis report, the value which is applied should be clearly

mentioned. Report results as follows:

FFA <5% to nearest 0.01%

FFA between 5-10% to nearest 0.05%

FFA>10% to nearest 0.1%

Determination of Lovibond Colour

1.1 Scope

The test specifies a method for the determination of the Lovibond

colour of palm oil and palm oil products.

1.2 Apparatus

Lovibond Tintometer Model E (Manual)

Lighting Cabinet

Glass cell 5.25’’ (1334.1mm) or 1’’ (25.4mm)

1.3 Method

Refined samples are first heated if cloudy, filtered to

remove impurities if any. (Refer SOP QC Section 8-

Heating Instruction for Quality)

Read colour in 5.25’’ or 1’’ cell depending on stages of

refining the oil has undergone

Colour is reported as Red (R) and Yellow (Y) Lovibond

units. Sometimes, Blue (B) and Neutral (N) filters are used

to improve the colour matching

1.4 Expression of Result

Expression the results in term of the following:

1. The numbers of red, yellow and blue or neutral standars

necessary to obtain the match

2. The optical path length of the cell used

Only standard cell sized shall be used. Colour measurement taken

in one cell sized shall not be used calculate colour values for

another cell sized.

Note: 1) Samples must be in liquid form

2) Tintometer shall NOT be set up facing a window

or in direct sunlight

3) Glass cell must be throughly clean and dry

before use

Determination of Slip Melting Point (SMP)

1.1 Definition

The slip melting point is the temperature at which the fat

softenes or becomes sufficiently fluid to slip or run

1.2 Apparatus

Capillary glass tubing, internal diameter 0.8-1.2mm, wall

0.2-0.3mm, and length approxiamately 7cm

Thermometer -20℃ to 60℃ (graduated 0.2℃

Glass beaker 500-600ml

Test tube, internal diameter about 10mm, 1mm thickness

length 7cm with cap

Heat sources or electric stirring hot plate with rheostat

magnetic stirrer

Thermostat water bath or incubator set 10 +/- 1℃ or

refrigerator freezer also can be used but care should be

exercise to avoid opening it frequently once the samples

being tempered in it.

1.3 Method

1) Melt the sample and filter through filter paper to remove any

impurities and the last traces of moisture. The sample must be

absolutely dry

2) Dip at least 3 clean capillary tubes into the completely liquid

sample so that the fat stands approxiamately 10mm high in

the tubes. Solidify the sample at once by holding the ends of

the tubes that contain the sample pressed against a piece of

ice untill the fat has solidified. Do not allow the open ends

of the tubes to touch the ice. Wipe the tubes against a piece

of tissues paper as quickly as possible.

3) Place the capillary tubes in a test tube with a tight cover into

a beaker and hold in a refrigerator at 4 to 10℃ (40 to 50℉)

over night (16 hours). Remove the tubes from the refrigerator

and attach with a rubber band or by any other suitable means

to the thermometer so that the lower ends of the tubes are

even with the bottom of the mercury bulb of the thermometer

4) Suspend the thermometer in a 600ml beaker of a clear

distilled water. The bottom of the thermometer is immersed in

a water to a depth of +/-30mm

5) Adjust the starting temperature of the bath to 8-10℃ below

the expected slip point of the sample. Agitate the water bath

by means of a magnetic stirrer and heat slowly so as to

increase the batch temperature at the rate of 1℃ per minute

slowing down to 0.5℃ per minute as the slip point is

approached.

6) Continue heating until the fat column rises in each tube.

Observe the temperature of the water at which each column

rises and calculate the average of all tubes. The diffrence

between the three values should not be more 0.3℃

1.4 Expression of Result

Record the average value of triplicate results as the slip melting

point, expressed in one decimal place.

Sources:

1. http://camtrip.biz/fatty_acid.html