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Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Company A Palm Oil Mill Upgrading Summary Reports


LOADING RAMP AND CAGE FEEDING STATION

Company A Winch & Bollard System Dolphins Integrated Control System

Work Station current conditions:- Proposal:-


a) FFBs are transfer into the cages by This can be improved by using Dolphins
human manual operations i.e. labor integrated loading ramp doors and loading
intensive and human dependent process. ramp conveyor System comprised of;
b) Lots of loose fruit and FFB were found a) Loading Ramp Hydraulic Systems
on the floor under the loading ramp station;
b) FFB Conveyor c/w Twin Drive Hydraulic
Mill operators need to collect the loose Systems
fruit and FFB, otherwise the losses will
c) Cage Feeding Chutes c/w Twin Hydraulic
be substantial including loss of oil and
systems
kernel (OER and KER) and increased in
FFA will result in an overall loss of oil (The illustrations below were taken from a
quality mill using Dolphins systems for more than
six (6) years)
High oil loss, low OER & KER recovery
and low productivity.
c) Not able to conduct good 5S (Clearing,
Cleaning, Arrangement, Cleanliness &
Discipline) and Housekeeping Practices due
to mill design and layout;
Operators are tired and stressed which
leads to low operator efficiency and high
labor turnover.
Poor flooring and slippery floor conditions
are causing a dangerous and hazardous
working environment.

Loading Ramp PH & EA Controls Automation


with Camera Surveillance

Loading FFB into the Cages Hard Work Human Loading FFB Hydraulic Conveyor c/w Twin
Manual Operation Drive System

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 1 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Loading Ramp Station Fruits & FFB on the floor Hydraulic Loading Ramp Work Station Conditions

FFB Cage Feeding Winch & Bollard System FFB Cage Feeding Hydraulic Indexer System

Advantages of Dolphins Loading Ramp and Cage Handling Indexer System:-


1. More consistent and reliable throughput leading to higher oil recovery i.e. system
dependent.
2. Reduced operator fatigue leading to improved operator safety and efficiency.
3. Ensures a cleaner and safer working environment.
4. Reduce labour inputs (e.g. 60/90 FFB TPH throughput mill requires not more than four
(4) operators to manage the marshalling yard).
5. Equal opportunities for female operators as most manual functions in the loading ramp /
fruit discharge to cages have been eliminated.
6. Able to conduct and maintain Good 5S and Housekeeping Practices due to the mill design
and users friendly integrated system, thus creating a cleaner safer working environment

Female Operator Operating the PH & EA Controls Station, monitoring the conveyor system and they are
operating on the overhead platform for safety and with good visibility

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 2 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

STERILIZER STATION

Company A Winch & Bollard System Dolphins Integrated Control System

Work Station current conditions:- This can be improved by using Dolphins


Integrated Cage Handling and Sterilization
a) High levels of labour input causing cage
Control System;
handling inefficiencies and poor throughput
productivity a) Hydraulic actuation of most moving
Frequent occurrences:- parts
Derailment of cages due to excessive wear b) Automated Motion Control of
and tear (i.e. Winch & Bollard System). hydraulic actuators
Deformed and corroded cages due to the c) Dolphin STERPAS Sterilization
old design (i.e. bumper to bumper force Control
bumping). d) Automated Sterilizer Door,
b) Deteriorating marshalling yard floor and Integrated Drawbridge & Articulated
building structure including cracked Indexer Control System
flooring, built-up slime on the floor and
rusty building structure is causing
hazardous working conditions;
Unable to conduct good 5S and
Housekeeping practices due to poor
mill design and layout (The illustrations below were taken from a
Hot stressful and unsafe working mill using Dolphins integrated motion and
environment is causing high labour motion control systems for more than six (6)
turnover and poor productivity years)

Loading Cages Into Sterilizer using Winch and


Bollard System with Human dependent Loading Cages Into Sterilizer using PH & EA
and Indexer Controls System

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 3 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Drawbridge/Sterilizer Working Conditions


Drawbridge/Sterilizer Working Conditions (6 Years)

Close/Open and Lock/Unlock Sterilizer Door


Hard Work Human Manual Operations Closed/Open and Lock/Unlock PH & EA
Controls Automation

Load/Unload Cages into the Sterilizer Hard


Work Human Manual Operations Load/Unload PH & EA Controls Automation and
Indexer Controls System

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 4 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Cracks, Oily, Slimly & Slippery Flooring Good Rail Tracks & Floor Condition (6 Years)

Bumper To Bumper Push/Pull Cage was done by Push/Pull Cage Indexing & Coupling No cage
forced bumping and this will easily damage the bumping and eliminates cages being damaged
cages there-by increase maintenance cost there-by reduce maintenance cost

Damaged Cages and Wheels Deformed & Corroded Good FFB/SFB Cages Conditions (6 Years)

Advantages of Dolphins Integrated Cage Handling and Sterilization Control System:-


1. More reliable hydraulic motion and motion control systems ensures consistent
throughput, minimum human intervention, a safer working environment and considerably
reduced maintenance.
2. Considerable improvement to FFB throughput due to minimum unforeseen mechanical
failure.
3. Integrating cage handling and sterilization control not only ensures a safer working
environment but ensures a process driven throughput for optimum productivity and fruit
preparation for maximum oil recovery.
4. Lower maintenance due to slower linear movement of cages, no derailing, and no forced
bumping of cages.

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 5 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

5. A higher and more consistent OER and KER recovery due to optimum sterilization
conditions made possible by STERPAS
6. The integration of material handling and process with minimum human intervention
ensures a safer working environment, labour savings and overall improvement in labour
productivity.
7. Equal working opportunities for both men and women due to the elimination of unsafe
and heavy working conditions.
8. Able to conduct and maintain Good 5S and Housekeeping Practices due to the mill design
and users friendly integrated system, thus creating a cleaner safer working environment

Female Operator Operating the PH & EA Controls Station, monitoring the conveyor system and they are
operating on the overhead platform for safety and with good visibility

TRANSFER CARRIAGE STATION

Company A Winch & Bollard System Dolphins Integrated Control System

Work Station current conditions:- This can be improved by using Dolphins


Integrated Cage Handling and Transfer
a) High levels of labour input causing
Carriage Control System;
cage handling inefficiencies and poor
throughput productivity; a) Hydraulic actuation of most moving parts
Frequent occurrences:- b) Automated Motion Control of hydraulic
actuators
Derailment of cages due to excessive
c) Dolphin Transfer Carriage Control System
wear and tear (i.e. Winch & Bollard
System).
(The illustrations below were taken from a mill
Deformed and corroded cages due to using Dolphins integrated motion and motion
the old design (i.e. bumper to bumper control systems for more than six (6) years)
force bumping).
b) Deteriorating marshalling yard floor and
building structure including cracked
flooring, built-up slime on the floor and
rusty building structure is causing
hazardous working conditions.
Unable to conduct good 5S and
Housekeeping practices due to poor
mill design and layout.
Hot stressful and unsafe working
environment is causing high labour
turnover and poor productivity

Transfer Carriage PH & EA Controls Station

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 6 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Hazardous conditions around Transfer Carriage


Transfer Cages by Indexer System

Oily, Slimly & Slippery Flooring


Good Floor Conditions (6 Years)

Advantages of Dolphins Integrated Cage Handling and Transfer Carriage Control


System:-
1. Carriage regulated with high-low speed allows smooth forward and reverse movement of
the carriage to ensure a precise lane positioning of cages.
2. Automatic self-locking mechanism will align carriage to rail track for safe and smooth
cages mobilization.
3. The integration of material handling and process with minimum human intervention
ensures a safer working environment, labour savings and overall improvement in labour
productivity.
4. Equal working opportunities for both men and women due to the elimination of unsafe
and heavy working conditions.
5. Able to conduct and maintain Good 5S and Housekeeping Practices due to the mill design
and users friendly integrated system, thus creating a cleaner safer working environment.

Female Operator Operating the PH & EA Controls Station, monitoring the conveyor system and they are
operating on the overhead platform for safety and with good visibility

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 7 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

TIPPER STATION

Company A Winch & Bollard System Dolphins Integrated Control System

Work Station current conditions:- This can be improved by using Dolphins


Integrated Cage Handling and Tipper Control
a) High levels of labour input causing cage
System;
handling inefficiencies and poor
throughput productivity; a) Hydraulic actuation of most moving parts
Frequent occurrences:- b) Automated Motion Control of hydraulic
Derailment of cages due to excessive actuators
wear and tear (i.e. Winch & Bollard c) Dolphins Tipper Control System
System).
Deformed and corroded cages due to
the old design (i.e. bumper to bumper
force bumping).
b) Deteriorating of building floor and
(The illustrations below were taken from a mill
structure including cracked flooring,
using Dolphins integrated motion and motion
built-up slime on the floor and rusty
control systems for more than six (6) years)
building structure is causing hazardous
working conditions.
Unable to conduct good 5S and
Housekeeping practices due to poor
mill design and layout.
Hot stressful and unsafe working
environment is causing high labour
turnover and poor productivity

Tipper Station Working Conditions Tipper Station with PH & EA Controls Station

Hazardous conditions around Tipper Station Tipper Station Working Conditions (6 Years)

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 8 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Hazardous conditions around Tipper Station Tipper Station Working Conditions (6 Years)

Oily, Slimly & Slippery Flooring Dolphins integrated tipper chute door to control the flow
of SFB to the SFB conveyor

Advantages of Dolphins Integrated Cage Handling and Tipper Control System:-


1. Rotation of tipper is regulated with the dual high-low speed control hydraulic system and
rotary positional control.
2. Constant SFB feeding to downstream processes.
3. The integration of material handling and process with minimum human intervention
ensures a safer working environment, labour savings and overall improvement in labour
productivity.
4. Equal working opportunities for both men and women due to the elimination of unsafe
and heavy working conditions.
5. Able to conduct and maintain Good 5S and Housekeeping Practices due to the mill design
and users friendly integrated system, thus creating a cleaner safer working environment.

Female Operator Operating the PH & EA Controls Station, monitoring the conveyor system and they are
operating on the overhead platform for safety and with good visibility

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 9 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Advantages of Dolphins Integrated Control Systems


1. More reliable hydraulic motion and motion control systems ensures
consistent throughput, minimum human intervention, a safer working
environment and considerably reduced maintenance.
2. Considerable improvement to FFB throughput due to minimum
unforeseen mechanical failure.
3. Lower maintenance due to slower linear movement of cages, no derailing,
and no forced bumping of cages, thus improve overall labour
productivity.
4. Dolphins Integrated System not only ensures a safer working
environment but ensures a process driven throughput for optimum
productivity and fruit preparation for maximum oil recovery.
5. A higher and more consistent OER and KER recovery due to optimum
sterilization conditions made possible by STERPAS.
6. Create an equal working opportunities for both men and women due to
the elimination of unsafe and heavy working conditions.
7. Able to conduct and maintain Good 5S and Housekeeping Practices due
to the mill design and users friendly integrated system, thus creating a
cleaner safer working environment.

Clean, Safe and Conducive Working Environment towards


Quality, Productivity and Safety

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 10 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

MILL AND EQUIPMENTS MAINTENANCE

Company A Winch & Bollard System Dolphins Integrated Control System

Sterilizer/Drawbridge Good Conditions (6 Years)


Sterilizer/Drawbridge Bad Conditions

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 11 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Sterilizer Door/Drawbridge Bad Conditions Sterilizer Door/Drawbridge Good Conditions (6 Years)

Cracks, Oily, Slimly & Slippery Floor Conditions Good Rail Track & Floor Condition (6 Years)

Bumper To Bumper System Cage Forced Bumping Indexer Linkages System No Cage Bumping

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 12 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Damaged Cages and Wheels Deformed & Corroded Good Conditions of FFB/SFB Cages (6 Years)

Control Panel Bad Conditions Dolphins Control Panel (6 Years)

Hydraulic Power Pack Bad Conditions Dolphins Hydraulic Power Pack (6 Years)

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 13 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

Control Panel Bad Conditions Dolphins HP & AE Controls Panel (6 Years)

Advantages of Dolphins Integrated System:-


1. Less down time due to automated system use in the marshalling yard using studied
electro-hydraulic actuators and control electronics.
2. Lower maintenance due to slower linear movement of cages, no derailing, and no forced
bumping of cages.
3. Using Winch & Bollard System, there will frequent maintenance for changing Boggy Wheel
Bushing or Bearing, Boggy Wheels, Cage Body, Wire Rope, Rail Track and Concrete Floor.
4. Using Dolphins Integrated System;
- Cages Boggy Wheel Bush to be change after six (6) year
- No Cage Body, Rail Track and Concrete Floor Repairing
- No Cage Derailment

Changing of Cages Boggy Wheels Bushing after 6 years

Company A Palm Oil Mill YESTERDAY and TODAY


Automation and Environment in
Harmony
COMPANY A YESTERDAY COMPANY A TODAY

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 14 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

BLOWN DOWN CHAMBER BLOWN DOWN CHAMBER

CONVENTIONAL LOADING RAMP AUTOMATED LOADING RAMP

CONVENTIONAL CAGE FEEDER AUTOMATED CAGE FEEDER

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 15 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

CONVENTIONAL RAILING SYSTEM AUTOMATED INDEXER SYSTEM


(Winch & Bollard System) (PH & EA Automation)

CONVENTIONAL SYSTEM OPEN/CLOSED & AUTOMATED STERILIZER DOOR,


LOCK/UNLOCK STERILIZER DOOR AND INTEGRATED DRAWBRIDGE AND
DRAWBRIDGE ARTICULATED INDEXER CONTROL SYSTEM

FFB/SFB CAGE STORAGE AREA FFB/SFB CAGE STORAGE AREA

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 16 of 17
Systems Evaluation: Dolphins Integrated Control Systems and Winch & Bollard Conventional Systems

CONVENTIONAL HAZARDOUS WORKING AUTOMATED CLEAN AND SAFER


ENVIRONMENT WORKING ENVIRONMENT

CONVENTIONAL DEFORMED & AUTOMATION GOOD CAGES


CORRODED CAGES CONDITIONS CONDITIONS

CONVENTIONAL TIPPER STATION AUTOMATION TIPPER STATION


CONDITIONS CONDITIONS

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it
shall not be reprinted or given to third parties.
Page 17 of 17