MANAGEMENT

OF
HIGH FFA OIL

DISCUSSION TOPIC
1) Oil Sampling
2) Tank Filling
3) CPO Blending

4) Tank Cleaning

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Overview
1. Mill operation during the high croping month with high FFB balance in
the field.
2. Mill cannot cope up with volume with FFB delivered with high FFB
balance in the mill ramp.
3. Raining season effecting the crop evacuation. This causes the mill
production FFA to be more than 4.5 %.

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Factor affecting FFA Rise

(a) Harvesting Practises
The degree of ripeness of palm fruits affect FFA rise. Over-ripe fruits are
more easily bruised resulting in lipase enzymes being liberated from the
cell vacuoles. This results in hydrolysis of oil and FFA formation.
(b) Handling And Transport Of FFB
Bruising of fruits during handling and transportation will lead to FFA rise.
It has been shown that FFA rise is a function of the severity of the
damages on the bunches. The oil mill reception station must be designed
to minimize handling of FFA. Trampling and squashing of spilled fruitlets
must be avoid.
(c) Time Lag Or Delay Between Harvesting And Processing
Sterilization inactives the lipase enzymes. To minimize FFA rise, FFB
should be processed as soon as harvested, within the same day (FFB
should be transported to the mill within 12 hours).
The first - in - first - out principle to FFB processing must be applied.

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Factor affecting FFA Rise

(continue)

(d) Processing Technique

FFA rise is affected by time, temperature and cleanliness. All equipment
should be kept clean.
(e) Production Oil
Moisture content of production oil should not be allowed to exceed 0.18%.
It can be control by purifier and vacuum drier.
(f) Oil Storage
Production oil before being transported to the storage tank should be
cooled to about 50C. When necessary, segregation of high and low FFA
oil should be carried out. The temperature of oil stored in storage tank
should be not be allowed to exceed 55C (or drop below 35C to prevent
solidification).

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Oil Sampling

Every hour during processing about 100c.c of production oil are

collected from the outlet of each drier after purging the sampling line.
Hourly sample collected is analyzed for FFA throughout milling hours.

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Tank Filling
FFA Oil between 4.5% -5.0%
Assistant Engineer/Assistant Manager must inform the Mill Manager, if
the FFA level for hourly production oil analysis is reported to be
between 4.5% and 5% by the Laboratory Analyst.
Mill Manager must decide and instruct filling of such oil in a separate
tank
FFA level in storage tanks must be monitored daily
The FFA result is checked and verified by the Mill Engineer.
Once the production FFA is back to normal at below 4.5%, the Mill
Manager must prioritize the despatch of CPO oil with FFA level between
4.5%-5.0% by blending it with good oil below 4.5.% FFA.

Presentation Title

 The blended CPO for despatch should have a FFA level of less than
4.5% but not more than 4.7%.
When the designated storage tank is cleared of oil (4.5%-5.0%
FFA),the tank is to be cleaned immediately and kept ready for filling of
production oil.
Assistant Manager/Assistant Engineer must inform Mill Manager
for decision to switch filling to normal storage tank (FFA level between
3.0% and 4.5%),.if FFA level for hourly production hour dropped to
below 4.5%

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Tank Filling
FFA Oil between 5.0% -6.0%
If FFA level for hourly production oil analysis is above 5% but below 6%,
Assistant Engineer must inform Mill Manager for decision to store the oil
separately.
The Mill Manager must identify a tank for this purpose. This matter must
be brought to the attention Head of Zone immediately.
FFA level in storage tanks must be monitored daily
The FFA result is checked and verified by the Assistant Engineer
Once the production FFA is back to normal at below 4.5%, the Mill
Manager must prioritise the despatch of CPO oil with FFA level between
5.0%-6.0% by blending it with good oil below 4.0.% FFA. The blended
CPO for despatch should have a FFA level of about 4.5% but less than
4.7%.

Presentation Title

 When the designated storage tank is cleared of oil (5.0%-6.0% FFA),

the tank is to be cleaned immediately and kept ready for filling of
production oil.
If FFA level for hourly production oil dropped to below 5.0%,Mill
Engineer must inform Mill Manager for decision to switch filling to
storage tank with FFA oil level between 4.5% and 5.0%.
The Head of Zone and Marketing Manager of Commodities Trading
Malaysia (CTM) must be consulted for the following decision:
a)
Mix/blend the oil to meet specified requirements, or
b)
Recycle oil from storage tank through production process
High FFA oil can only be despatched to buyer based on instructions
from CTM.

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Tank Filling
FFA Oil above 6.0%
If FFA level is above 6% for hourly production oil analysis, Assistant
Engineer must immediately inform Manager for decision to store the oil in
another separate tank.
The sampling frequency for FFA test of such oil should be increased from
an hourly to half hourly basis. The result is checked hourly and verified by
Mill Manager.
Mill Manager must investigate the reasons for high FFA oil and propose
corrective measures to rectify the situation. This matter must be discussed
with Head of Zone immediately.
Mill Manager must write and advise the party concerned for follow up
action with copy extended to Regional Head/Processing /Zone HEAD and
CTM for information.

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 Mill Manager will assess the adequacy of the corrective actions taken
and inform Head of Zone.
The Head of Zone and Marketing Manager of Commodities Trading
Malaysia (CTM) must be consulted for the following decision:
a)
Mix/blend the oil to meet specified requirements, or
b)
Recycle oil from storage tank through production process
High FFA oil can only be despatched to buyer based on instructions
from CTM
If FFA level for half hourly production oil dropped to below
6%,Asssiatant Engineer to inform Mill Manager for decision to switch
filling to storage tank with FFA oil level between 5% and 6%.

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Formula of CPO Blending

Let N = Tonnage of CPO to despatch at 4.5 % FFA

A = Tank I FFA (%)
B = Tank II FFA (%)
FFA for Tank A > FFA B

X = Tonnage of CPO at A % of FFA to be blended

4.5 N = AX + B(N-X)
4.5 N = AX + BN BX
X = (4.5 B ) N
A-B

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Example

Let N = 100 MT FFA 4.5 %

A=6%
B=4%
FFA for Tank A > FFA B

X = Tonnage of CPO at A % of FFA to be blended

4.5 N = AX + B(N-X)
4.5 N = AX + BN BX

X = (4.5 4.0 ) 100

6.0-4.0

= 25 MT

25 x 6 % = 1.5 %
75 x 4 % = 3.0 %
Total FFA = 4.5 % with 100 tonne of CPO despatch.

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Tank Cleaning
Storage tanks are to be cleaned as soon as possible upon clearing of high
FFA oil and inform Head of Zone.
In normal cases, tank cleaning is to be done at least once a year where
practicable and whenever possible subject to stock level.
When the tank is emptied, the mill should check the heating coil, if possible
hydraulically tested, service steam trap and thermostatic control valve.

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15

THANK YOU

We actively seek
out opportunities,
have an
entrepreneurial
attitude and an
open mind, we
always look for
ways to be more
sustainable.

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