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IMPROVING PRODUCTIVITY OF PALM SUGAR INDUSTRY THROUGH THE

GRANULATOR DEVELOPMENT BASED ON ULTRAVIOLET LIGHT

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IMPROVING PRODUCTIVITY OF PALM SUGAR INDUSTRY
THROUGH THE GRANULATOR DEVELOPMENT BASED ON
ULTRAVIOLET LIGHT
Sutrisno(1), Mohamad Endy Yulianto(2), Didik Ariwibowo(1), Qurrotun A’yuni Khoirun Nisa’(2)
(1)Department of Mechanical Engineering, Vocational School, Diponegoro University
(2) Department of Chemical Engineering, Vocational School, Diponegoro University
*Corresponding author: masstresno@gmail.com
ABSTRACT
This works aim to increase the productivity of
palm sugar through introduction of a developed ultraviolet
granulator. The works carried out to fabricate granulator
to produce brown palm sugar. The dimension of
granulator in length x width x height are 1000 x 1200 x
750 mm, subsequently. The granulator consists of main
parts, those are: a hemisphere basin, stirrer and its drive,
gas burner, and support frame. The basin capacity is 25
liters. The drive motor was equipped with a gearbox that
produces speed around 24 rpm, by power of 0.5 horse
power (hp). The results show that the equipment was
reliable, indicated in uniformly size of brown palm sugar
throughput. Financial analysis indicates that the Break
Even Point (BEP) will be at 23rd-month, and suggests that
investing funds in the application of this equipment will
be more profitable than investing by funds deposits in the
Bank because Internal Rate of Return (IRR) value is
86,19%, which is higher than the 12% of the Bank
discount factor. The analysis of Benefit/Cost ratio (B/C
Ratio) and Net Present Value (NPV) gives a result of 1.45
and Rp. 217,617,184, indicating that the application of the
equipment is feasible. Thus, the equipment meets the
requirements techno-economically.
Keywords: granulator, palm sugar, palm extract, ultra
violet, financial feasibility
1. INTRODUCTION
Brown palm sugar is product, produced from
palm sap. At a tropical country, palm trees can be found
in several areas. The development of palm plantations in
Semarang regency has increased from year to year. In
2015, the planting area of palm is spread in several
districts such as Banyubiru (112,96 ha), Jambu (142,58
ha), Sumowono (156,14 ha), and West Ungaran (28,84 ha)
(BPS, 2017 ).
The 12th SEATUC Symposium
OS08-01
Palm sugar industry in the District of West
Ungaran Semarang supported by the many palm trees that
grow in this area, so the raw material of palm sugar in the
form of sap is available. Palm sugar craftsmen in West
Ungaran District are located in 10 villages including
Lerep, Branjang, Kalisidi, and 7 other villages. There are
20 business units number of palm sugar industry in
Indrokilo Lerep. Currently, the manufacture of palm sugar
is still as a side business and is still a home-scale craftsman
so its productivity is low and quality is not uniform.
Palm sugar block and powder are two of the
superior products from Lerep village. In order to develop
Tourism Village in Lerep in 2018, the taking part in palm
sugar production process become a tour package.
Therefore, Head of Lerep Village directs the craftsmen of
palm sugar to improve the quality, both the quality of
production process and product quality.
At Indrokilo, there was a small firm “KUBE
Manggar Lestari”, belongs to Mrs. Koriah. The firm
manufactures palm sugar in form of block and powder,
and has a production capacity of 130 kg per month. The
sugar was sold in around Semarang with price range at Rp
18,500 / kg - Rp 20.000 / kg.
The product acceptance in market has not
encountered significant obstacles, because all the products
have been directly absorbed by the market, even still can
fulfill the market requirement. Some buyers around
Indrokilo village also come directly to the producers.
Although it has been able to compete in seizing market
share but the impact was not so affected, because the
quality of palm sugar product still contains impurities.
Further, the production capacity was relatively low. The
impurity of palm sugar product could cause the price fell
between Rp 12.500,00/kg - Rp 17.000,00/kg.
Sap from the tree owned by Koriah has good
quality as raw material of palm sugar. Powder palm sugar
is not a product that continuously produced. It is only
produced by order. This is because the cost of palm sugar
production is relatively high. Mrs. Koriah sells powder
palm sugar Rp. 60,000.00 per kilogram. The process of
production of palm sugar was considered complicated. To
produce 1-1.25 kg of palm sugar it takes about 25 liter of
sap. In addition, the stirring process, which is done
manually, takes a long time. Total time for palm sugar
production was about 5 hours, 1 hour longer than sugar
block. Currently the price of palm sugar block in the
market reaches Rp. 23,000 - Rp. 29,000 in 250 gram
packs. This market opportunity makes Koriah to produce
continuous palm sugar, besides to fulfill the superior
product of the tourist village in Lerep. Therefore, an
efficient means of production of palm sugar today is
indispensable.
The cooking of palm sugar in KUBE Manggar
Lestari was still constrained by caramelization reaction
and maillard reaction that occurred at 121 C after 90
minutes evaporation process (Varina, 1990). The
evaporation process is carried out at relatively high
temperatures to avoid bacteria and surviving pathogenic
microorganisms. Therefore, by adapting a mechanical
stirring cooker is considered to solve the problem in the
firm.
The development of ultraviolet light-based
granulator in the palm sugar industry is a novel invention,
as it improves techno-economic efficiency. The
application of ultra violet ray-based granulator technology
at Manggar Lestari would be able to avoid caremelization
and maillard reaction. Sub-crystallization using vacuum
granulator causes the evaporation process of water vapor
and granulation carried out at a relatively low temperature
of 60 oC. While ultra violet rays are capable of inactivating
enzymes, killing bacteria and pathogenic microorganisms.
Therefore, it is necessary to develop granulator
applications based on ultra violet rays in palm sugar
industry Manggar Lestari to improve productivity, energy
efficiency, work efficiency, yield improvement and
quality improvement of palm sugar.
In recent years, UV technology applications have
grown very rapidly both in household scale and
commercial scale industries. The safe and non-toxic UV
oxidizing properties make UV as a disinfectant in drinking
water treatment (US Patent No. 5,780,860) and
degradation of organic wastewater components (US
Patent No. 2006/0163168 A1 and US Patent No.
7,279,092), UV is also widely used for purification and
sterilization in food production processes (US Patent
No.7.391.041 and US Patent No. 2007/0114465 A1). The
use of ultraviolet light is also developed to inactivate
enzymes cellular destruction methods followed by affinity
styles have also been developed physically through UV
rays (Penna and Ishii, 2002). It is necessary to apply the
UV-based granulator sugar ester granulation.
2. WORKS
2.1 Works equipment
The works of this programme include: (i) design
and manufacturing of UV light granulator with capacity of
25 kg/batch, (ii) equipment functional-test, (iii) equipment
reliability test, and (iv) techno-economic analysis.
Design and manufacture of 25 kg/batch UV light-
based granulator was conducted at Teguh Jaya Tehnik
Workshop Semarang for 1 month. The UV-based
granulator equipment scheme is shown in Figure 1. The
specifications of UV-based granulator are as follows:
Material: Stainless steel
Size:
- Tank height: 32 cm
- Tank diameter: 50 cm
Construction:
- Tank is equipped with ultra violet lamp.
- Stirred blade, motor drive 1450 rpm which is reduced
...to 30 rpm.
Instrument:
- Speed Reducer.
Fig 1. Ultra Violetbased granulator
2.2 Metholdology
2.2.1 Functional Test of UV-Light Generator
After mechanical completion, UV light-based
granulator will be functionally tested in the Laboratory of
Energy Conversion Vocational School Diponegoro
University, then sent to location. This UV light-based
granulator machine is operated and used to support the
production process of palm sugar. Before the granulating
machine is implemented, socialization and training to
potential users and machine operators will be conducted
first. The next step were adaptation test, implementation
of UV light-based granulator in production process, and
evaluation of its reliability.
2.2.2Adaptation Test and Implementation Evaluation
UV light-based granulator adaptation test was
conducted at Manggar Lestari Ungaran for 1 month.
Adaptation test activities were also monitored by
Government Bereau of Technolgy Development Central
Java Province and coordinated by Diponegoro University.
The adaptation test of sugar palm granulation process
using UV granulator was done by UVC ultra violet
irradiation for 10 minutes to kill bacteria, virus and fungus construct using 1” stainless steel pipe SS 304 with flat and
and enzyme inactivation. After 10 minutes the UVC rays scrap blade type. Electrical panel box was equipped to
are turned off, because a small amount of water vapor has centralised electric control. Two ultraviolet lights were
begun to evaporate under vacuum condition. installed above basin to lighten product so that the micro-
The parameters observed during the test include organism was killed
the physco-chemical properties of palm sugar,
environmental conditions, engine performance and
economy. Physco-chemical properties parameters
include: (i) the requirements of UV granulator of palm
sugar, (ii) the initial moisture content of the material, (iii)
the final moisture content of the material, (iv) the density
of material, (v) the granulation temperature, (vi)
environment, and (vii) relative humidity. Engine
performance parameters include: (i) granulation time, (ii)
fuel consumption, (iii) evaporation and granulation
processes, (iv) energy use efficiency, and (v) granulator
space capacity. The socio-economic parameters include:
labor cost, investment, economic age, cost of goods,
operational cost, b/c ratio and others.

3. ANALYSIS
3.1 Governing Equations
3.1.1. Techno-Economic Analysis
Techno-economic analysis was conducted at Fig 2. Powder palm sugar granulator
Manggar Lestari Ungaran for 1 month. This activity aims
to determine the feasibility of palm sugar business by 4.2 Fabrication Process
applying UV granulator. Palm sugar granulator was manufactured in
Teguh Jaya workshop, Kaloran, East Ungaran, Semarang.
3.1.2. Technical Analysis
Manufacturing activities carried out for 5 (five) weeks.
Technical analysis includes: required uv
granulation process, energy supply for granulator heating, After completion of the manufacturing, functional tests for
and fuel consumption. palm sugar granulator are performed. The results of
functional test shows that every component in the
3.1.3. Economic Analysis equipment was functioning properly, then the equipment
The economic analysis of the use of granulator- is ready for adaptation test in firm.
uv palm sugar machine is based on the calculation of fixed
costs and non-fixed costs. Fixed costs include: 4.3 Adaptation / Implementation Test
depreciation expenses, interest expense and tax expense. Sugar granulator is sent to Manggar Lestari for
Fixed costs include: fuel costs, electricity costs, labor functional testing and adaptation or application.
costs and component repair costs. This economic analysis
Functional and adaptation test activities are presented in
is used to find the operational cost of uv granulator
Figure 3. The results of functional test show that the entire
machine (Rp/kg of palm sugar).
components were in order accordance with its
In addition, there was also an investment analysis
to determine the financial viability of the application and specifications.
use of granulator-uv palm sugar machine. To determine Under no-load conditions, the total power
whether the usage of granulator-uv sugar machine is consumption of the machine was 250 Watt, which is the
feasible based on Benefit-Cost Ratio (B/C Ratio), Net
Present Value (NPV), Internal Rate of Return (IRR) and
Break Even Point (BEP).
4. RESULTS AND DISCUSSION
4.1 Palm Sugar Granulator Design
Powder palm sugar granulator is designed with
dimension of 1000 mm x 1200 mm x750 mm. The
machine frame was made from hollow mild steel material
40 mm x 40 mm x 3 mm, and support equal angle bar 40
mm x 40 mm x 30 mm. Stirrer is driven by 0,5 horse power
power to rotate the stirrer and turn on the ultra-violet light.
electric motor with 1400 rpm. The stirrer was equiped
Fig 3. Functional test of palm sugar granulator
with gear box 1:60 to reduce speed. The stirrer was
 The adaptation test of the granulator was done by
pouring a thickening-sap from cooker into a half-spherical
tank or basin, then the basin was placed on the cradle in
the granulator. The thickening-sap was stirred while
heating to evaporate until crystal formed. During the
process, ultra violet lamps were on to kill pathogenic
bacteria. The evaporation process was divided into two
stages: (i) the concentration or aging stage of the solution
carried out during the low viscosity of the sap, and (ii) the
granulation sugar formation stage. Stage (i) occurs with a
constant rate-CR gradient while stage (ii) occurs with a
falling rate (FR) gradient. Thus, the user can vary the
heating by adjusting the lower heater LPG setting in step
(i) and then set the heating up in step (ii). The duration
stages (i) and stage (ii) can be user-defined empirically
through experiments using this granulator machine. The
machine can be used for the production of powder palm
sugar from sap that has been through the concentration
stage in the range 20 - 30 mm2/s, and by controlling the
appropriate heating temperature.
The time required for a single production process
of palm sugar was in the range of 5-10 minutes, depends
on the amount of processed sap and heating level.
Granulation with optimal heating will give the best
process time. Therefore, the setting of heating process
would determine the quality of the final product.
The results of manufacturing and adaptation
test/application are used as the basis for determining the
specifications of the ultra violet granulator equipment, as
well as being the basis of manual preparation of the
operating procedures of the equipment. Specifications of
uv granulator tools are as follows:
Dimension: length x width x height
1000 mm x 1000 mm x 1250 mm
Capacity : 25 liters of nira/batch
Heater : LPG burner
Mixer : 20 rpm, Modified turbine blade stainless steel -
…………..Teflon
Electric motor: 0.5 hp
UV-lamp: 2 x 10 W
4.4 Techno-economic analysis
Techno-economic analysis tool was performed to
determine the effectiveness of the equipment used as a
means of production of palm sugar made from raw palm
sugar, and to determine the financial feasibility. The
effectiveness of the equipment or the technical aspects of
the equipment indicates that the equipment could be used
effectively or capable of producing palm sugar with
specific energy costs of Rp. 2.135,-/kg of sugar produced.
The equipment could be used repeatedly with relatively
uniform production, with an installed capacity of 12
kg/hour.
The financial aspect is a way or reference to
determine the investment plan through the calculation of
expected costs and benefits, by comparing expenditures
and income. In investing a high profitability calculation is
required so that the expectation of getting more value in
the future can be achieved. As a benchmark of financial
analysis, parameters derived from previous analysis,
between production capacity, market share, technology
used, equipment choice, number of manpower, supporting
facilities and projected prices (Hidayat, 2013).
To determine the estimated cost of the necessary
assumptions on which the cost calculation is based. The
assumptions are (i) the project's economic life is planned
for 10 years, the life of this project is determined based on
the length of manufacturing, setting, installation and
testing of the machine, (ii) the machine's remaining value
of 0 percent from the initial value in the year to- 10, (iii)
the production capacity to be achieved and the calculation
of the mass balance are as follows:
a) requirement of raw material: fresh palm juice 50
ltr / day
b) production capacity of 2 kg / day
c) duration of operation: 6 hours / day, with number
of working days 300 days / year
d) tax is assumed to remain for a 10 year period of
10% per annum as Value Added Tax (VAT)
e) the prices used in this financial analysis are based
on the price at the time of the 2017 eligibility
analysis and during the planning year affected by
the 12% discount factor in the bank
f) raw material and product prices are assumed to
increase by 5% per year
The process of pricing and economic analysis will be
conducted to determine Break Even Point (BEP), Benefit-
Cost Ratio (B/C Ratio), Net Present Value (NPV), and
Interset Rate of Return (IRR) and Cash Flow from sugar
production business. Calculations on these parameter
values are executed with the help of MS software.
The results of the financial feasibility analysis show
that the Break Even Point (BEP) tool occurs on the 23rd
month. The Benefit-Cost Ratio (B / C Ratio) value of 1.45
indicates that the applied equipment provides greater
benefits than the cost incurred (B / C Ratio> 1). Net
Present Value, which is the difference between revenues
and expenditures assessed at the start of the project. The
NPV value of the analysis is positive Rp. 217.617.184.
This means that the project will lead to profit rather than
loss. Internet Rate of Return (IRR) is an investment
worthiness indicator whose value is compared to the
Bank's discount factor. Discount factor Bank is assumed
to be 12%. The calculated IRR value is 86.19%. This value
is far greater than the Bank's discount factor so it can be
used to decide that investing funds in the tools of the sugar
industry will be more profitable than investing by
depositing funds in the Bank.
Overall, the analysis of B / C Ratio, NPV and IRR
indicates that the appliance development in the palm sugar
industry is feasible. Thus, the tool meets the requirements
technically and financially or economically.
5. CONCLUSIONS
Ultraviolet light-based granulator has been well-
engineered and adapted in the palm sugar industry. The
results show that the reliability of the tool is relatively high
enough with uniform palm sugar production. Financial
analysis shows that the Break Even Point (BEP) tool takes
place in the 23rd month, and suggests that investing funds
in the tools of the sugar industry will be more profitable
than investing by depositing funds at the Bank. Overall,
the analysis of B / C Ratio, NPV and IRR indicates that
the appliance's development in the palm sugar industry is
very feasible. Thus, the equipment meets the requirements
technically and financially or economically.
ACKNOWLEDGMENT
On this occasion, the authors would like to give
thanks to Allah SWT and thank you so much to the
Diponegoro University for giving financial support in
Community Service activities at PKUM 2017 program.
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PHOTOS AND INFORMATION

Sutrisno B.E (1984) Mechanical
Engineering Education Semarang
State University, M.Eng (2012)
Master of Mechanical Engineering
Diponegoro University and now has a
functional position as lectors.
Currently as Lecturer in Mechanical
Engineering Department of
Vocational School Diponegoro
University. The interest of research
that is explored is scaling, dryer and
appropriate technology.

M. Endy Yulianto B.E (1996)

Chemical Engineering Education
Diponegoro University, M.Eng
(2000) Master of Chemical
Engineering Bandung Institute of
Technology and now has a
functional position as lectors.
Currently as Lecturer in Chemical
Engineering Department of
Vocational School Diponegoro
University. The interest of research
that is explored is operation of
chemical engineering, applied
mathematics, bioenergy, computer
application of chemical
engineering..

Didik Ari Wibowo B.E (1997)

Mechanical Engineering Education
Sepuluh Nopember Institute of
Technology, M.Eng (2012) Master
of Mechanical Engineering
Diponegoro University and now
has a functional position as expert
assistant. The interest of research
that is explored is heat transfer,
pneumatic, hydrolic, and
informatics technology.

Qurrotun A’yuni Khoirun Nisa’

currently as a student in chemical
engineering department of

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