SOY OIL PROCESSING INDUSTRY

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SOY OIL PROCESSING INDUSTRY
GREEN PRODUCTIVITY CONCEPT

• PRESENTED BY
• MALAYSIA BOLEH RESEARCH CONSULTANCY

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MALAYSIA BOLEH RESEARCH CONSULTANCY
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MALAYSIA BOLEH RESEARCH CONSULTANCY

1. MR. MOHD HILMI MOHD IDRIS
2. MS. ADLINA SNAWI
3. MR. MUHAMMAD SUFFIAN AHMAD
4. MR. ABDUL MAJID IBRAHIM
5. MR. SHAHRUDDIN KASSIM
6. MR. ZAKARIA ABU HASAN
7. MR. FAZIL MAT ZAIN
8. MS. ZURAIDAH KORNAIN
9. MS. ZAUYAH TARMIZZI
10. MR. MARZUKI ZAINAL ABIDIN

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PROCESS FLOW DIAGRAM
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Process Flow Diagram
Testing
SEED UNLOADING CLEANING SECTION
Yard
Big Silos
Day Silo
screener
De-Stoner
PREPARATORY SECTION
Cracker
Cooker
Flakers
SOLVENT EXTRACTION PLANT
Dryer
Extractor
WET DOC
DT-DC
cyclone
Economiser
Screener
Oversized lump
Evaporator
Lump-crusher
Mixing Packing
Stripper Cum Dryer
Storage Tanks
Storage Tanks
CRUDE OIL
DOC
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SEED UNLOADING CLEANING SECTION
Testing
Yard
Big Silos
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Day Silo
screener
De-Stoner
Cracker
PREPARATORY SECTION
Cooker
Flakers
Dryer
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SOLVENT EXTRACTION PLANT
Extractor
DT-DC
WET DOC
cyclone
Economiser
Screener
Oversized lump
Lump-crusher
Evaporator
Mixing Packing
Stripper Cum Dryer
Storage Tanks
Storage Tanks
CRUDE OIL
DOC
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MATERIAL FLOW DIAGRAM (Hexane)
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Material Flow Diagram
SOLVENT EXTRACTION PLANT
Extractor
DT-DC
(MiscellaHexane)
Economiser
Cyclone
Evaporator
Stripper Cum Dryer
Condenser
(Jet Chiller)
Loss
Water-Solvent Separator
DOC
MISCELLA
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MAJOR WASTE STREAMS/AREAS OF LOSSES
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MAJOR WASTE STREAMS/AREAS OF LOSSES
PROCESS PLACES/AREAS WASTE/LOSS
1 Transportation Conveyor Bucket Elevator Seed Husk Stone
2 Transportation Big Silo to Day Silo Seed Husk Stone
3 Preparatory Section Day Silo to Screener Cracked Seed Dust Husk
4 Preparatory Section De-Stoner Mud Balls Stone
5 Preparatory Section Mechanical Cracker NIL
6 Condensed the soy seed Cooker Steam Water
7 Flaking Flakers Soy Seed
8 Drying Dryer NIL
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MAJOR WASTE STREAMS/AREAS OF LOSSES
PROCESS PLACES/AREAS WASTE/LOSS
9 Solvent Extraction (Crude Oil Production) Rotary Type Extractor (RTE) Hexane
10 Solvent Extraction (Crude Oil Production) Distillation Hexane
11 Solvent Extraction (Crude Oil Production) Stripper Hexane
12 Solvent Extraction (Crude Oil Production) Condenser Hexane
13 Solvent Extraction (Crude Oil Production) Water/Solvent Separator Waste Water Hexane
14 Desolvent DT-DC (De-Oiled Cake Production) Hexane Moisture Heat
15 Cooling DT-DC (De-Oiled Cake Production) Moisture Heat
16 Seaving DT-DC (De-Oiled Cake Production) NIL
17 Packaging DT-DC (De-Oiled Cake Production) NIL
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FISHBONE DIAGRAM
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FISHBONE DIAGRAM
Economiser
Leakage
Hexane supply system
Evaporator
MACHINE
Chiller condenser
Hexane/water seperator
Hexane Loss
Stripper (Dryer)
ENVIRONMENT
RTE
Jetcon
Poor air quality
Hexane recovery system
Inefficient machine
RTE
DT-DC
High humidity
Process control not effective
Human error
Poor soy seed quality
Poor hexane quality
Lack of training
No standard operating procedure
Lack of motivation
Poor steam quality
Poor equipment calibration
MAN
METHOD
MATERIAL
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PROPOSED GP OPTIONS
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GP OPTIONS
GP OPTION DESCRIPTION
1 NEW EQUIPMENT Up to date efficient machine Upgrade Total Preventive Maintenance
2 NEW MATERIAL/ CHEMICAL Replace Hexane (hexane is hazardous to health, substitute with more environmental friendly chemical) Better quality of soy seed
3 ALTERNATIVE SUPPLIER To supply better quality of soy seed
4 METHODOLOGY Develop Standard Operating Procedures (SOP) Implement EMS (ISO 14001) Equipment calibration
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GP OBJECTIVES TARGETS
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GP CONSULTANCY REPORT BY MALAYSIA BOLEH
TEAMSOY BEAN OIL REFINING PROCESS
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GP CONSULTANCY REPORT BY MALAYSIA BOLEH
TEAMSOY BEAN OIL REFINING PROCESS
1 2 3 4 5 6
OBJECTIVE TARGET PROGRAM ACTION RESPONSIBLE PERSONS TIME FRAME
1.2 Reduce moisture content in seed 2.2 Reduce moisture to minimum acceptable limits 3.2 Incoming seed testing 4.2.1 Enforce Contract Specifications 4.2.2 Test for moisture at Incoming Goods 5.2 5.2.1 Head of Dept 5.2.2 Testing Mgr 5.2.3 Testing engineer/technician 5.2.4 Contractors 6.2 Start Immediately monitor within one (1) year. Annual review.
1.3 Reduce husk content in seed 2.3 Reduce husk to minimum acceptable limits 3.3 Incoming seed testing 4.3.1 Enforce Contract Specifications 4.3.2 Test for husk at Incoming Goods 5.3 5.3.1 Head of Dept Contract Operations Sect 5.3.2 Testing Mgr 5.3.3 Testing engineer/technician 5.3.4 Contractors 6.3 Start Immediately monitor within one (1) year. Annual review.
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GP CONSULTANCY REPORT BY MALAYSIA BOLEH
TEAMSOY BEAN OIL REFINING PROCESS
1 2 3 4 5 6
OBJECTIVE TARGET PROGRAM ACTION RESPONSIBLE PERSONS TIME FRAME
1.4 Optimise flake thickness in Flaker 2.4 Optimise flake to acceptable limits 3.4 3.4.1 Implement TPM CBM 3.4.2 Measure flake thickness 3.4.3 Ensure reliability of equipment 4.4.1 Use TPM 4.4.2 Testing for flake thickness using specialised tools. 4.4.3 Use good quality equipment 5.4 5.4.1 Head of Dept Contract Operations Sect 5.4.2 Testing Mgr 5.4.3 Testing engineer/technician 5.4.4 Contractors 6.4 Start Immediately monitor within one (1) year. Annual review.
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GP POLICY
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GP POLICY

• We are committed to
• Answer the societal demands for higher
  productivity in a sustainable manner with
  preserving the environment.
• Ensure the natural environment on which society
  depends is not degraded and polluted.
• Make a better and cost-effective approach in
  implementing efficient and innovative GP
  solution.
• Assist other companies in gaining their
  competitive advantages and cost-effective
  reduction of waste and emissions.

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Terima kasih !!! Thank You For Your Attention,
... Arigatoo Gozaimasta.