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ABSTRACT

Industrial training is a one of the higher learning institutions for students to get used to

the actual working environment. As a Mechanical Engineering student, knowledge and work

skill is needed simultaneously. It allows students to practice the knowledge in the relevant field

and apply it based on their knowledge that lead to better soft skills. This report describes a

three-month industrial training that took place from 29th June 2015 to 18th September 2015 at

a local company named Sawit Kinabalu Apas Balung Mill, Tawau Sabah. Apas Balung Mill is

Palm Oil Mill operate under the auspices of Sawit Kinabalu Berhad. Main activity or

production of this company is to process Fresh Fruit Bunch (FFB) to Crude Palm Oil (CPO)

and Palm Kernel (PK). The product must undergo various test of quality test to control its

quality. Then, this product will be sent to Kunak Refinery for purifying process before it can

be sold to customers. Collaboration between Apas Balung Mill and Kunak Refinery is a long

term contract. 12 weeks of industrial training under supervision from Sir Mohamed Bin Hj.

Tagin (Workshop Supervisor), internship student was exposed to actual working culture and

industrial practice. Several tasks had been given based on main processing station at Apas

Balung Mill, which is Weighting Station, Loading Ramp Station, Grading Station, Sterilizer

Station, Thresher Station, Press Station, Clarification Station, Palm Kernel Station and etc. The

objective of the task is to improve our skills of engineers, theoretical and practical by

troubleshoot problem and finding solutions. The industrial training is reported as task were

carried out throughout the period.

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Table of Contents ABSTRACT ............................................................................................................................................ 1

1.0 INTRODUCTION ............................................................................................................................ 4

1.1 History .......................................................................................................................................... 4

1.2 Structural Of Main Activity .......................................................................................................... 5

1.2.1 Mill Production ...................................................................................................................... 5

1.2.2 Laboratory Activities ............................................................................................................. 5

1.3 Objective Of Practical Training .................................................................................................... 5

1.4 Scope Of Training / Schedule ....................................................................................................... 6

1.5 Company Organizational Chart .................................................................................................... 7

2.0 INDUSTRIAL ENVIRONMENT .................................................................................................... 8

2.1 Adaptation And Adjustment To The Industry .............................................................................. 8

2,1.1 Weighing Station.................................................................................................................... 8

2.1.2 Grading Station ...................................................................................................................... 8

2.1.3 Loading Ramp Station ........................................................................................................... 8

2.1.4 Sterilizer Staton ...................................................................................................................... 9

2.1.5 Thresher Station ..................................................................................................................... 9

2.1.6 Press Station ........................................................................................................................... 9

2.1.7 Clarification Station ............................................................................................................. 10

2.1.8 Sweco Vibrating Screen ....................................................................................................... 10

2.1.9 Crude Oil Tank .................................................................................................................... 10

2.1.10 Pure Oil Tank ..................................................................................................................... 11

2.1.11 Oil Purifier ......................................................................................................................... 11

2.1.12 Sludge Tank ....................................................................................................................... 11

2.1.13 Desander ............................................................................................................................ 11

2.1.14 Decanter ............................................................................................................................. 11

2.1.15 Sludge Seperator ................................................................................................................ 12

2.1.16 Vacuum Drier ..................................................................................................................... 12

2.1.17 Crude Palm Oil (CPO) Tank .............................................................................................. 12

2.2 Practice Of Occupational Safety And Health Environment ........................................................ 12

3.0 INDUSTRIAL EXPERIENCE ....................................................................................................... 14

3.1 Task And Activities .................................................................................................................... 14

3.1.1 Grading Station .................................................................................................................... 14

3.1.2 Sterilizer Station ................................................................................................................... 16

3.1.3 Laboratory Activiti ............................................................................................................... 17

3.1.4 Analyse Machine Effiiency .................................................................................................. 19

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3.1.5 Workshop Activities ............................................................................................................ 19

3.1.6 Boiler Station ....................................................................................................................... 20

4.0 INDUSTRIAL PROJECTS............................................................................................................. 22

4.1 Overview ..................................................................................................................................... 22

4.2 Press Station ................................................................................................................................ 22

4.2.1 Repairing And Maintaining ................................................................................................. 22

4.2.2 Problem And Solution .......................................................................................................... 24

4.2.3 Mechanical Engineer’s Perspective ..................................................................................... 25

4.3 Skimmer, flange and pump base ................................................................................................. 25

4.3.1 CAD Drawing ...................................................................................................................... 25

4.3.2 Technical Skill ..................................................................................................................... 26

5.0 CONCLUSION ................................................................................................................................... 27

6.0 REFERENCE ...................................................................................................................................... 28

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1.0 INTRODUCTION

1.1 History

Apas Balung Mill located at Mile 24, Apas Balung road, Tawau, Sabah wholly owned

by Borneo Samudera Sdn. Bhd under the auspices of Sawit Kinabalu Berhad that operates in

Kota Kinabalu, Sabah. Apas Balung Mill was established in 1971 by two French engineers are

a crude palm oil and palm kernel processing plant with average processing is 60 metric tons

per hour. There are 135 workers at Apas Balung Mill, and the highest position is Mill Manager,

followed by Mill Engineer and assists by Assistant Engineer. Apas Balung Mill has 5 major

divisions which are Production, Laboratory, Workshop, Safety and Utility. Each division has

their own Supervisor to handle and supervise their workers. In addition, Apas Balung Mill

used the double line system during processing, which mean if any minor damage happened at

some machine, they have a backup to continue processing, but if the damage on major

components like conveyor, mill will stop processing because raw material which are FFB

cannot be transferred to another station for further processing.

Sawit Kinabalu Berhad (formerly registered) was formed when the State Government

of Sabah, in its continuing efforts to encourage the people of Sabah to assume a more

responsible role in the growth of the State, decided to corporatize the Sabah Land Development

Board (SLDB). The State Government believed that this will bring about greater efficiency

and effectiveness, thereby optimizing profitability and contributing directly to the economic

growth of the nation.

The Sawit Kinabalu Berhad’s Logo defines its corporate professionalism and

commitment to galvanizing growth. The prominent gold signifies strength and growth into a

new era of the Sawit Kinabalu Berhad’s diversified activities. The deep red shade of a ripe oil

palm seed represents the core activity of the Sawit Kinabalu Berhad in the palm oil industry

and symbolizes maturity and stability of its operation as it further embarks on a journey towards

greater excellence.

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1.2 Structural Of Main Activity

1.2.1 Mill Production

Apas Balung Mill main activity is to process fresh fruit bunch (FFB) to produce Crude

Palm Oil (CPO) and Palm Kernel (PK). To produce Crude Palm Oil (CPO) and Palm Kernel

(PK), a fresh fruit bunch (FFB) will be processed stage by stage according to their station.

Below are the main stations that have in Apas Balung Mill:

i. Weighing Station

ii. Loading Ramp station

iii. Grading Station

iv. Sterilizer Station

v. Thresher Station

vi. Press Station

vii. Clarification Station

viii. Palm Kernel Station

1.2.2 Laboratory Activities

Laboratory act as quality control and quality assurance for Apas Balung Mill because

they will examine, analyze, and record oil quality every day. Besides, they also analyze the

mill efficiency covering the mill machine

1.3 Objective Of Practical Training

Industrial training is one of the requirements for the Bachelor of Engineering (Hons)

Mechanical and also known as EM220 by Faculty of Mechanical Engineering at Universiti Teknologi

Mara (UiTM). The objective of industrial training is:

1) To Expose students to actual working culture and industrial practice in palm oil mill

industry especially in the engineering department

2) To allow students to extend their theoretical knowledge and practice in university use in

working environments.

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3) To motivate the students to work in a right way with good working attitudes and

professionalism to increase their employability potential.

4) To facilitate student to potential employers and work experience.

5) To provide student with basic skills of technical staff

6) To expose students to safe practices and regulations in the industry

1.4 Scope Of Training / Schedule

Training schedule for practical trainee is same as other workers, which are from 7.00

am until 4.00 pm, Monday to Saturday. Below is the working schedule at Apas Balung Mill

and a summary of my activities during ten (12) week industrial training.

Table 1.1: Working Schedule

Days Time

Monday

7.00 am – 4.00 pm

(Rest 12.00 pm – 1.00 pm)

Tuesday

Wednesday

Thursday

Friday 7.00 am – 4.00 pm

(Friday Prayer 11.30 am – 1.30 pm)

Saturday 7.00 am – 4.00 pm

Table 1.2: Summary of Activities

Week Activities

1 Study about Loading Ramp station.

2 Study about Grading system

3 Study about Sterilizer Station

4 Study about Thresher Station

5 Study about Press Station

6 Study about Clarification Station

7 Study about Palm Kernel Station

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8 Study about Boiler

9 Workshop Activities

10 Workshop Activities

9 Workshop Activities

10 Workshop Activities

11 Laboratory Activities

12 Laboratory Activities

1.5 Company Organizational Chart

SIR MILL MANAGER

SIR. HARRIS BIN SANDAMUDDIN

ENGINEER

SIR. MOHD ZAMRI BIN MOKRIN

ASSISTANT ENGINEER

MDM. JELITA BUNGIN & SIR. BARY EYUL

OFFICE AND ADMIN

MDM. DEWI NOOR BT MOHD ADNAN

SAFETY AND HEALTH

SIR ASLIE

PRODUCTION

SIR ADON BERMEN

FFB GRADING

SIR. JAINAL BRAHIM

LABORATORY

SIR. FADLI BIN KASSIM

WORKSHOP

SIR MOHAMED B. HJ. TAGIN (MECHANICAL)

SIR OMAR ALI OTHMAN (ELECTRICAL)

BOILER

SIR. MUKRIM HJ. ASAS

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2.0 INDUSTRIAL ENVIRONMENT

2.1 Adaptation And Adjustment To The Industry

2,1.1 Weighing Station

This station is intended the net weight for the fresh fruit bunch (FFB) that sent to mill

in a day. It’s also enable mill staff to know either their expectation/target will achieve or not

in a month. For this purpose, a computer software Weighman for Windows are used. Basically,

the truck will be weighed twice, which is during the truck are loaded with fresh fruit bunch

(FFB) and unloaded with FFB. To get the net weight, the truck loaded with FFB minus

unloaded with FFB.

2.1.2 Grading Station

The quality of FFB gives effect to the quality of crude palm oil (CPO) that will produce.

Therefore, received fruit will be graded according to standard grading rules that consistent with

the Malaysian Palm Oil Board (MPOB) requirements. According to research, fresh palm fruit

is a fruit that reclaimed not more than 24 hours, while palm fruit that has been stored more than

48 hours categorized as old fruit due to the colour change of the fruit stalk from white to black

followed by shrinkage and finally will become old. Fruits that received by Apas Balung Mill

will be graded to ensure the quality of FFB and how much oil extraction rate (O.E.R) can be

achieved. Furthermore, this is the basic activities to determine the amount to be paid by Apas

Balung Mill to smallholders.

2.1.3 Loading Ramp Station

Fresh Fruit Bunch (FFB) that sent to a mill will place at the loading ramp for placing

after grading process and waited for Sterilization Process. Loading ramp has 60 doors that

divided into two parts, 30 doors at part A and 30 doors at part B. Every door can accommodate

up to 10 metric ton Fresh Fruit Bunch (FFB) and a total of 60 doors is 600 metric tons. Used

First In, First Out (FIFO) systems to ensure the quality of FFB always maintained. To get the

high quantity of Crude Palm Oil (CPO), strict supervision must be taken at Loading Ramp

because lots of loose seeds scattered on the floor. FFB from loading ramp will transfer to

Sterilize by FFB Conveyor.

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2.1.4 Sterilizer Staton

Sterilizer station is a station to cook fresh fruit bunch (FFB) so that the fruits can be

detach easily from the bunch. Apas Balung Mill has four spherical sterilizer and each sterilizer

can accommodate up to 20 – 22 metric ton FFB. Nevertheless, spherical sterilizer cannot be

fully stocked because it requires air spaces to make evaporation process can be completely

done. Overall process to cook FFB in one spherical sterilizer is 61 minutes or 1 hour 1 minute

with average steam 2.80 bars or 40 p.s.i. Steams are used to break up the grafting between fruit

and the bunch. Before the FFB enter Spherical Sterilizer, it will pass through the FFB Hooper

with capacity 10 – 15 metric tons. FFB Hopper has the same design with truck dealer was

controlled manually with Hydraulic Power Pack to enter the FFB into Sterilizer. After 61

minutes, FFB will transfer to Sterilizer Fruit Bunch (SFB) conveyor by Mechanical Bunch

Feeder. The function of Mechanical Bunch Feeder is to control the FFB when entering

Sterilizer Fruit Bunch Conveyor regularly.

2.1.5 Thresher Station

This station is to detach fruit from its bunch to get palm oil. Fruits will rotate inside

the machine called Thresher Drum and will go through Fruit Elevator before entering the

digester. While, the bunch will go through empty bunch recovery before be destructed at bunch

crusher, after that it will pressed at bunch press to get the oil. Nevertheless, if bunch press trap

or conveyor block, empty bunch will go to disposal warehouse. Before FFB enter to Thresher,

it will store at Auto-feeder because Thresher cannot accommodate a lot of FFB at one time.

2.1.6 Press Station

At this station, fruit that has been detached from the bunch will press to get oil and

kernel. Press station is the important part in mill production because from this station, it will

produce two main product of Apas Balung Mill which are Crude Palm Oil (CPO) and Palm

Kernel (PK). Press machine used hydraulic system to move the screw press and the pressure

is about 50 to 65 Bar. If the hydraulic pressure exceeds this range, it will cause nut losses at

high rate. Before the fruit enters the Press Machine, it will store at digester to break up the cell

from the fruit mesocarp that has been sterilized. Temperature in digester is about 90°C to

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100°C and during processing Apas Balung Mill has fixed the temperature at 95°C. In Digester,

there are five sets of expeller and impeller arm. The function of expeller arm is to blend the

fruit while impeller arm to push down the fruit to ease it entering the screw press. The capacity

of digester can accommodate up to 15 tons metric of FFB, and press can produce 15 tons metric

of crude palm oil depends on digester capacity.

2.1.7 Clarification Station

Crude Palm Oil (CPO) from press station must be refined to clean it from dirt like fibre

and sands. A component that has in clarification station comprising Sweco vibrating screen,

crude oil tank, pure oil tank, sludge tank, oil purifier, desander, decanter, sludge separator,

vacuum drier and CPO Tank.

2.1.8 Sweco Vibrating Screen

Sweco Vibrating Screen used as refining the oil from any dirt. This component consists

of many single decks with diameter 20 mm used to trap the dirt from entering the crude oil

tank. To avoid oil from solidified, we need to maintain oil temperature at 90°C to 95°C.

2.1.9 Crude Oil Tank

After oil purifying process finished, Crude Palm Oil (CPO) will stored in Crude Oil

Tank before transfer to Pure Oil Tank and Sludge Tank. This tank has two partitions separate

by plate divider; one part is for crude oil while another part for sludge. Heavy sludge in this

tank will stay at the bottom while crude oil that has light density will fix at the upper position.

Sludge is the voluminous liquid waste that comes from the sterilization and clarification

processes. The raw sludge contains 90 – 95% water and includes residual oil, soil particles and

suspended solids. Crude oil from this tank will enter the skimmer and go into Pure Oil Tank

for purification process and sludge will be pumped out to decanter. Skimmer is a component

that we can adjust the position up and down according to crude oil level. To avoid crude oil

from solidified temperature must be maintained at range 90°C to 98°C. Capacity of crude oil

tank can accommodate 12 metric tons of crude oil.

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2.1.10 Pure Oil Tank

The function of this tank is to store oil from crude oil tank before it enters the purifier

machine. This tank can accommodate 6 metric tons of crude oil. There is steam coil in the

inner part of this tank, the function is to supply steam for oil to avoid it from solidified and the

steam temperature is about 70°C to 85°C.

2.1.11 Oil Purifier

The purpose of oil purifier is to purify oil from any dirt with rotating method. The

speed for bowl rotated is 7500 r.p.m. Dirt and water content in oil before entering oil purifier

is 0.5%, and after the purifying process it will reduce to 0.24% - 0.30% for water and 0.0016%

- 0.0012% of dirt.

2.1.12 Sludge Tank

Function of Sludge Tank is to store the sludge before entering sludge separator

machine. Same with Pure oil tank, the differences are only the material that they saved. Inner

tank has a steam coil to supply steam for sludge.

2.1.13 Desander

The function of desander is to separate sand from the oil. This is important to avoid

sludge separator from damaged.

2.1.14 Decanter

Decanter function as oil filter to separate it from sludge. It have two types of disposal

which are cake (solid remaining after pressing) and oil. Oil from decanter will go into crude

oil tank for purification process while cake will be sold for fertilizer.

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2.1.15 Sludge Seperator

Sludge Separator used to extract oil from sludge. There is 5% oil in the sludge and we

don’t want to waste any oil that we can get from any source. Oil will extract by rotating the

bowl of sludge separator with 5400 r.p.m.

2.1.16 Vacuum Drier

Vacuum Drier is to reduce moisture content of crude palm oil. Presence of high

moisture content enhances oxidative degradation. During entering the vacuum drier, oil at

temperature 70°C - 75°C will burst into fine droplets and the vapour will suck out from the

vacuum at vacuum pressure between 65cm/Hg to 75cm/Hg and oil will drop to bottom channel.

2.1.17 Crude Palm Oil (CPO) Tank

CPO tank used as oil stored after finished clarification process and ready to send to

Kunak Refinery. Apas Balung Mill has three CPO tank and each tank can accommodate up to

1,781,480 litres of CPO. Oil will supply with steam at 59°C to avoid it from solidified.

Basically, capacity of CPO depends on how much FFB mill received in a day and to calculate

the daily capacity of CPO tank, the laboratory staff will make measuring process to get the

value and this will explain on section Laboratory Activities.

2.2 Practice Of Occupational Safety And Health Environment

Personal Protective Equipment, commonly referred to as PPE, is equipment worn to

minimize exposure to a variety of hazards. Examples of PPE include such items as Safety

Helmet, Safety Shoes, Hearing protection, Eye protection, Gloves and Respiratoty.

1) Safety Helmet

a) Class C hard hats

i. Provide lightweight comfort and impact protection, but offer no protection from

electrical hazards

2) Safety Shoes

i. Impact-resistance toes and heat-resistance soles that protect the feet against hot

work surface. The metals insoles of some safety shoes protect against puncture

wounds. Safety shoes may also be designed to be electrically conductive to

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prevent the build-up of static electricity in areas with the potential for explosive

atmosphere or non-conductive to protect workers from workplace electrical

hazards.

3) Hearing Protection

a) Single-use earplugs

i. Made of waxed cotton, foam, silicone rubber or fiberglass wool.

ii. They are self-forming and, when properly inserted, they work as well as most

molded earplugs.

b) Pre-formed or molded earplugs

i. Individually fitted by a professional and can be disposed or reusable. Reusable

plugs should be cleaned after each use.

c) Earmuff

i. Require a perfect seal around the ear.

ii. Glasses, facial hair, long hair, or facial movements such as chewing may reduce

the protective value of the earmuff.

4) Eye Protection

a) Goggles

i. Tight-fitting eye protection that completely covers the eyes, eye sockets and the

facial area immediately surrounding the eyes and provide protection from

impact, dust and splashes. Some goggles will fit over corrective lenses.

b) Welding shields

i. Constructed of vulcanized fiber or fiberglass and fitted with a filtered lens,

welding shields protect eyes from burns caused by infrared or intense radiant

light.

ii. They also protect both the eyes and face from flying sparks, metal spatter and

slag chips produce during welding, brazing, soldering and cutting operations.

5) Gloves

a) Cover and protect hands from wrist to the fingers.

b) Save the user’s hand and fingers from unnecessary wound such as cuts, blisters,

splinters, skin punctures or heat and chemical burns.

6) Respirators

a) Protect the user from breathing in contaminations in the air, thus preserving the health

of one’s respiratory tract.

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3.0 INDUSTRIAL EXPERIENCE

Throughout the training, trainee had been exposed with real situation with real problem

that needed to be solved as a real worker. Wide spectrum of work, ranging from doing

documentation works to being tasked to perform technical works. In this chapter, it will be

more on the production unit regarding on how to manage the mill efficiently without sacrificing

quality and quantity.

3.1 Task And Activities

3.1.1 Grading Station

In order to achieve better production of CPO, it’s compulsory to grade the FFB by choosing

the best from the best. Below is the procedure on how to grade FFB.

1) Grading must be done in the presence of the supplier or his representative like truck

driver or attendant.

2) Selected truck should depreciate their loading on a platform near the loading ramp.

Make sure the bunch in a flat condition which is not accumulating or layered.

3) Randomly, take 100 samples of the bunch and classified it to the following classes:

i. Ripe bunch

a) Reddish orange of fresh bunch and external layer of mesocarp is orange.

b) At least ten (10) fresh fruit socket detach from bunch and more than 50% fruit

still stick to bunch during the grading process. Bunch and detach fruit must

be sent to mill within 24 hours after reclaimed.

ii. Under ripe bunch

a) Has reddish orange or purplish red of fresh bunch.

b) Less than ten (10) fragmentary of fresh fruit socket during grading. Bunch

and detach fruit must be sent to mill within 24 hours after reclaimed.

iii. Unripe bunch

a) Purplish black colored fruits, covering more than 90% of the bunch surface.

b) Didn’t have detached fruit of fresh bunch during grading.

iv. Over ripe bunch

a) More than 80% of the fruits in the bunch appear darkish red.

b) More than 50% of the detach fruit from the bunch, but at least 10% fresh fruit

still stick to bunch during grading.

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c) Bunch and detach fruit must be sent to mill within 24 hours after reclaimed.

v. Long stalk bunch

a) Fresh bunch that have stalk more than 5 cm measured from lowest bunch stalk.

Figure 3.1 : Ripe bunch Figure 3.1 : Under Ripe Bunch

Figure 3.3 : Unripe Bunch Figure 3.4 : Over Ripe Bunch

Figure 3.5 : Long Stalk Bunch

Table 3.1 : Matrix Table for Ripening Stage

Socket

Colour of Mesocarp No socket Less than 10 More than 10

Orange Ripe Ripe Ripe

Yellowish orange Unripe Under Ripe Ripe

Yellow (Hard Bunch) Unripe Unripe Unripe

White (black Bunch) Unripe Unripe Unripe

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3.1.2 Sterilizer Station

Sterilizer is a crucial in gathering oil from the FFB, by using steam produce from the

boiler with certain temperature and pressure to break up the oil cell and detach the fruit from

its branch. If the sterilization process is incomplete, unbroken oil cell may result in oil losses

at high rate.

1) Removal of Air

a. Air is a bad heat conductor; with his presence heat from steam cannot be transfer

to sterilize the fruit completely.

b. To reduce oil oxidation because the oxidized oil is difficult to throw the colour

during deflection process.

2) Removal of Sterilizer condensate

a. To dispose excessive water and steam in Sterilizer

b. If condensate not disposes, water will stagnant and contribute to oil losses from

fruit.

c. Fruit will incompletely sterilize.

Step Time (m) Acc Time (m) I E C Wi Wo W1 W2 W3 W4 Remark

1 1 1 FFB loaded & Release

condensed

2 5 6 Input steam

3 4 10 Input steam continue

4 6 16 Input steam continue

5 0.30 16.30 Release exhaust steam

6 5 21.30 Input steam

7 0.30 21.60 Release exhaust steam

8 8 29.6 Holding steam

9 13 42.6 Holding steam

10 1 43.6 Release condensed

11 7 50.6 Holding steam

12 4 54.6 Release condensed

13 6 60.6 Completed

I = Input, E=Exhaust, C=Condensate, Wi=Water in, Wo=Water out

Table 3.2 : Sterilizer Operation

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No Equipment Quantity Load R.P.M Status Remark

1 Spherical Sterilizer 4 15kW 1450 F/R DOL Sterilizer fruit

2 Hoist 4 15kW - DOL Load / unload sterilizer door

3 Hydraulic Power

Pack

4 4kW 1440 DOL Controller the fruit into

sterilizer

4 Compressor 1 7.5kw - DOL Open / closed steam valve

5 Mechanical Bunch

Feeder

4 4kW 1440 DOL Controlled the fruit into SFB

conveyor

6 SFB Conveyor 2 18.5kW 980 DOL Deliver SFB into Auto feeder

7 Condensate

Recycle Pump

2 11kW 1460 S/D Pump out the condensate into

condensate pit

8 Oil Recycle Pump 2 4Hp 1460 S/D Pump recycle oil to sterilizer

Table 3.3 : Components in Sterilizer

3.1.3 Laboratory Activiti

Free Fatty Acid (FFA) content in oil must be analyse to make sure it didn’t exceeds the

prescribed rate which is less than 5.00%. If FFA content is high, it will cause a metal solubility

process like copper and iron easily happened. Below are the procedure, material and apparatus

to analyse FFA content in oil.

a) Apparatus

1. 2 units of 150 ml conical flask

2. 2 unit of 100 ml beaker

3. Stirring Hotplate

Figure 3.6 : Stirring Hotplate

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4. Precisa 205AM-FR SCS weighing

Figure 3.7 : Precisa 205AM-FR SCS weighing

b) Materials

1. Isopropyl Alcohol

2. Phenolplithalein Indicator

3. Sodium Hydroxide 0.098%

4. 0.1N Sodium Hydroxide

c) Procedure

1. Record the weight of empty 150 ml conical flask.

2. Put in the oil in the conical flask until the weight exceeds 5.00 g.

3. Heat isopropyl alcohol at stirring hotplate.

4. Put in five drops of Phenolplithalein Indicator and Sodium Hydroxide 0.098%

into isopropyl alcohol.

5. Heated oil sample.

6. Put in 50 mm mixed chemical at step 4 into the oil and 0.1N Sodium Hydroxide

until the oil colour change to reddish.

7. Record how much litres 0.1N Sodium Hydroxide enter into oil until the colour

change.

8. Calculate FFA content using formula

𝐻𝑜𝑤 𝑚𝑢𝑐ℎ 𝑙𝑖𝑡𝑟𝑒𝑠 0.1𝑁 𝑆𝑜𝑑𝑖𝑢𝑚 𝐻𝑦𝑑𝑟𝑜𝑥𝑖𝑑𝑒 × 0.1 × 25.6

𝑆𝑎𝑚𝑝𝑙𝑒 𝑊𝑒𝑖𝑔ℎ𝑡

9. Repeat step 1 until 8 for second sample.

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3.1.4 Analyse Machine Effiiency

The purpose of this analysis is to make sure the efficiency of Nut Cracker exceeds 97% to

avoid a lot of kernel losses during processing.

a) Apparatus

1. Precisa 205AM-FR SCS weighing

b) Materials

1) Palm Kernel

c) Procedure

1. Take a kernel sample from cracked mixture conveyor

2. Weigh the sample until the weight become 1 kg

3. From that sample, separated Nut and Partial Cracker Nut (PCN) for weighing

process.

4. To get the efficiency of king cracker, the weight of 1kg sample minus with the

weight of Nut and PCN

3.1.5 Workshop Activities

Workshop is the important division in Apas Balung Mill because they will fix any

breakdown and troubleshooting occurred on the machine. Every 1st day of a month, mill will

do preventative maintenance to repair and install new components at any broken machine.

Below is the example of maintenance that was done during the industrial training.

Figure 3.8: Type Of Maintenance

Maintenance

Unplanned Maintenance

Breakdown Maintenance

Planned Maintenance

Corrective Maintenance

Routine Maintenance

Preventive Maintenance

Predictive Maintenance

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3.1.6 Boiler Station

Boiler is components used to produce steam for generating turbine rotor via alternator

and for sterilization process. There are two types of Boiler, which are Water Tube Boiler and

Fire Tube Boiler. In Apas Balung Mill, they used Water Tube Boiler because it can generate

steam faster than Fire Tube Boiler. In addition, steam pressure limit of the fire tube boiler lies

between 20 – 30 bar and the pressure limit of the water tube boiler is much more than the fire

tube boiler and is unlimited within the design limit. Water tube Boiler at Apas Balung Mill

used fiber and dry kernel as fuel for providing the heat.

Figure 3.9: Conservation of energy

Main component:

1) Boiler

Boiler is the heart of the factory, it’s the main component to generate steam to run the

factory. By physical appearance, rectangular in shape and full of water that will be

heated to transform water into steam. It has the same principal as boiling water in a

kettle at boiling point, but at a larger volume. In this mill, it has 2 steam boiler which is

water tube. During process, 1 boiler is sufficient to generate steam needed by this mill.

a) Boiler No. 5

- Capacity of 35 ton of water

- Maximum temperature at range 1000-2000 ⁰C

- Consist of 1000 pipe inside the boiler

b) Boiler No. 4

- Capacity of 20 ton of water

- Maximum temperature at range 1000-2000 ⁰C

- Consist of 700 pipe inside the boiler

2) Steam Turbine

Steam turbine function to create rotational motion that generates by steam from the

boiler. Boiler will produce high speed and pressurized steam into the steam turbine

Kinetic Energy Mechanical Energy

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3) Feed Pump

Water pump function to pump water from storage tank into desired location. In this

mill, it consist of 2 types of pump which is pump that powered by electrical motors and

steam.

4) Condenser

Steam that enters the turbine will slowly change into liquid due to its kinetic energy

inside the water molecule decreasing. Because of that, steam that changes into liquid

will transfer into the condenser and most of the liquid will pass through a copper pipe

with full of cold water. This proses called heat transfer where steam changing into

water.

5) Storage Tank

Any resources needed to run the boiler are stored here. There are 2 types of storage tank

which is water storage tank and fuel storage tank.

6) Cooling Tower

Cooling tower function as water supplier for all of the tube inside the condenser. Water

that enter the condenser will be hot due to heat transfer. So, water pump needed to pump

the hot water into the condenser.

Figure 3.10: Boiler No 5 Figure 3.11: Boiler No 4

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4.0 INDUSTRIAL PROJECTS

4.1 Overview

As workers in workshop department, maintaining and repairing machine is our priority.

This department responsible to make sure that all machines work well and repair it if the

machine breaks down. Some modification might needed to ease the flow of the process or the

machine was too ancient to be used anymore. In this chapter, it will emphasize on workshop

and repairing machine suit as a Mechanical Engineering student.

4.2 Press Station

4.2.1 Repairing And Maintaining

If all of the press machines break down, this will be a major break down where all process

will be stopped. By using line production, we can avoid this by changing the line process with

the other line. In this mill, it has 2 lines with 3 press machine in each line. Major issues caused

by this machine are its screw press always breaks may be due to worn out because of long

usage or unnecessary object enter the press machine and stuck into the screw press that lead to

the screw to break in half. As an engineer, we should able to determine the problem and come

out with the solution. Troubleshooting should be done by observing the machine, leaking in its

bearing or amount of fibre suddenly decreasing is one of the signs to show that there is problem

about the machine. Below is the procedure about overhauling press machine.

1) For safety measures, open the pulley cover and v belt even if the fuse from the circuit

board had been turned off. Then, we can proceed by loosening all bolts on the press

body using spanner size 15, 21 and 24. Bringing adjustable spanner might come in

handy.

2) Using multiple chain block that attached to the ceiling, remove the press body and cone

section. Chain and belt might be used to attach the body with the chain block. Workers

should wear PPE such as gloves when handling the chain block.

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Figure 4.1: Cone section Figure 4.2: Press body

3) Screw press consists of Right Hand Side (RHS) and Left Hand Side (LHS), rotate RHS

anticlockwise and LHS clockwise to remove the screw press. Make sure that screw

press was hold using chain block. After that, screw cage can be lifted out using chain

block.

4) Remove the coupling cover so that both long shaft and short shaft can be removed.

Long shaft will connect with the coupling and using spur gear to rotate both shafts.

Each shaft will contain 3 bearings which are 2 roller bearings and 1 cone bearing.

Figure 4.3: Long and short shaft with bearing

5) If the bearing was broken, removing the bearing by tapping slowly using hammer. The

other method is by heating the bearing or cut it using oxyacetylene. This process might

take a while, but it’s the proper way because using oxyacetylene or heating might result

in expanding the shaft. Manufacturer of the bearing is FAG.

Code number of roller bearing:

i. 22220-E1-C3

ii. 22216-E1-C3

Code number cone bearing:

i. 24420-E1

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6) Clean the spacer and install new bearing with the same code number. Apply High

Temperature RTV Silicon Gasket Marker. This function as a gasket to avoid any leak.

After installing the coupling cover, refill the lubricating oil which is OMALA 320.

Figure 4.4: Installing new shaft

7) Install cone section and press body, tighten all the bolt securely. Run and test the

machine to make sure that it’s working fine. If any unusual sound or sign occurs,

recheck the machine so that there will be no more break down.

4.2.2 Problem And Solution

Some problem might occur with or without our will, the best solution is to calm down

and find the solution. Discussion among workers and supervisors is important if any undesired

problem occurs. When repairing press machine, various problem happens that require us to

take apart the machine twice. The first problem is the bearing wouldn’t come out and the shaft

cannot be separated from the old bearing. After being tapped using hammer couple of times,

the bearing still wouldn’t come out. The best solution is to cut the shaft by half, even though

that the shaft can be reused. The shaft needs to be cut to separate the bearing so that the time

taken to overhaul the machine wouldn’t take too long. The second problem is that the screw

cage need to be replaced after the machine run for 48 hours. Comparing its performance from

before, quantity of fibre came out from the machine is less than usual. After getting reports

from production unit, the machine need to be taken apart again to change the screw cage. Most

of the workshop’s workers came to help so that the machine can be repaired as fast as could.

The third problem is the coupling wouldn’t come out from the shaft. The best way is to cut the

shaft without damaging the coupling using oxyacetylene.

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Figure 4.5: Cutting the shaft Figure 4.6: Cutting the bearing

4.2.3 Mechanical Engineer’s Perspective

It takes 2 weeks to repair press machine, the first step in performing a task should be planning.

Workers didn’t take planning as a serious matter and most of the time they will require a long

period of time to repair a minor breakdown. By having planning, time taken can be reduced so

that workers can perform their task on time.

4.3 Skimmer, flange and pump base

An oil skimmer is a machine that separates a liquid from particles floating on it or from

another liquid. A common application is removing oil floating on water. Pump base is base

structure that holds the pump and the motor in place. Task had been given to fabricate the part

on maintenance day, which is the first week of every month. As a trainee, most of the work

was done by the workers. But the learning process still can be done by helping them.

4.3.1 CAD Drawing

As a mechanical engineering student, CAD drawing was taught at UiTM in the third year. By

applying the skill to help the company to fabricate the part easier. After drawing using CATIA,

the drawing with dimension distributed among the workers.

Figure 4.7: Skimmer Figure 4.8: Flange

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4.3.2 Technical Skill

Both knowledge and technical skill is necessary in the engineering field. Lack one of this

component, might fail the purpose of the industrial training. After applying the knowledge

taught at university, learning the skill is compulsory at industrial training. The important

process of fabricating parts in this factory is by welding, cutting, milling and lathe machine.

Commonly, cutting was done using oxyacetylene. Having exposed to the real work experience

was scared for the first time, but after doing it frequently make me get used to it.

Figure 4.9: Cutting using oxyacetylene

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5.0 CONCLUSION

As an undergraduate of the University Of Technology MARA (UiTM) I would like to

say that this training program is an excellent opportunity for us to get the ground level and

experience the things that we would have never gained through going straight into a job. I am

grateful to the University Of Technology MARA (UiTM) and Apas Balung Mill for giving us

this wonderful opportunity.

The main objective of the industrial training is to provide an opportunity for undergraduates to

identify, observe and practice how engineering is applicable in the real industry. It is not only

to get experience on technical practices, but also to observe management practices and to

interact with fellow workers.

It is easy to work with sophisticated machines, but not with people. The only chance that an

undergraduate has to have this experience is the industrial training period. I feel I got the

maximum out of that experience. Also, I learnt the way of work in an organization, the

importance of being punctual, the importance of maximum commitment, and the importance

of team spirit. The exposure has definitely contributed a lot in developing me to become a well-

rounded future engineer and provide me the insights of employment and endeavour me to

undertake in the future.

In my opinion, I have gained lots of knowledge and experience needed to be successful

in a great engineering challenge, as in my opinion, Engineering is after all a challenge, and not

a job.

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6.0 REFERENCE

1. Leo Finkelsten, jr., Pocket Book of Technical Writing for Engineer and Scientist, Third

Edition, McGraw, 2008 (ISBN: 978-0071259255)

2. Howard F. Gospel, Industrial Training and Technology Innovation: A Comparative and

Historical Study, Vol. 4, Taylor & Francis, 2010 (ISBN: 978-0415043403)

3. Howard K. Morgan, Industrial Training and Testing, BiblioBazaar, 2011 (ISBN:978-

1406713954

4. Lokesh Choudhary, Industrial Training and Education, Mittal Publication, 2007( ISBN: 978-

8183242363)

5. Diana Reep, Technical Writing: Principles, Strategies and Readings, Pearson Education

Canada, 2010 (ISBN: 978-0205721540)