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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.
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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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 Berhads 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 Berhads 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.
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.
iii.
Grading Station
iv.
Sterilizer Station
v.
Thresher Station
vi.
Press Station
vii.
Clarification Station
viii.
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
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
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
Tuesday
7.00 am 4.00 pm
Wednesday
Thursday
7.00 am 4.00 pm
Friday
Saturday
Activities
Workshop Activities
10
Workshop Activities
Workshop Activities
10
Workshop Activities
11
Laboratory Activities
12
Laboratory Activities
ENGINEER
ASSISTANT ENGINEER
LABORATORY
SIR ASLIE
FFB GRADING
PRODUCTION
WORKSHOP
BOILER
100C and during processing Apas Balung Mill has fixed the temperature at 95C. 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.
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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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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.
ii.
They are self-forming and, when properly inserted, they work as well as most
molded earplugs.
c) Earmuff
i.
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.
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 users 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 ones respiratory tract.
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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.
iii.
Unripe bunch
a) Purplish black colored fruits, covering more than 90% of the bunch surface.
b) Didnt have detached fruit of fresh bunch during grading.
iv.
c) Bunch and detach fruit must be sent to mill within 24 hours after reclaimed.
v.
No socket
Less than 10
More than 10
Orange
Ripe
Ripe
Ripe
Yellowish orange
Unripe
Under Ripe
Ripe
Unripe
Unripe
Unripe
Unripe
Unripe
Unripe
Colour of Mesocarp
Wi Wo W1 W2 W3 W4
Remark
10
16
0.30
16.30
21.30
Input steam
0.30
21.60
29.6
Holding steam
13
42.6
Holding steam
10
43.6
Release condensed
11
50.6
Holding steam
12
54.6
Release condensed
13
60.6
Completed
No
Equipment
Quantity
Load
R.P.M
Status
Remark
Spherical Sterilizer
15kW
1450
F/R DOL
Sterilizer fruit
Hoist
15kW
DOL
Hydraulic Power
4kW
1440
DOL
Pack
sterilizer
Compressor
7.5kw
DOL
Mechanical Bunch
4kW
1440
DOL
Feeder
conveyor
SFB Conveyor
18.5kW
980
DOL
Condensate
11kW
1460
S/D
Recycle Pump
8
condensate pit
4Hp
1460
S/D
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Unplanned
Maintenance
Breakdown
Maintenance
Corrective
Maintenance
Maintenance
Routine
Maintenance
Planned
Maintenance
Preventive
Maintenance
Predictive
Maintenance
Figure 3.8: Type Of Maintenance
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Kinetic Energy
b) Boiler No. 4
-
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
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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.
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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.
other method is by heating the bearing or cut it using oxyacetylene. This process might
take a while, but its 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
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.
7) Install cone section and press body, tighten all the bolt securely. Run and test the
machine to make sure that its working fine. If any unusual sound or sign occurs,
recheck the machine so that there will be no more break down.
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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 wellrounded 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:9781406713954
4. Lokesh Choudhary, Industrial Training and Education, Mittal Publication, 2007( ISBN: 9788183242363)
5. Diana Reep, Technical Writing: Principles, Strategies and Readings, Pearson Education
Canada, 2010 (ISBN: 978-0205721540)
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