Advantages of Mechanisation in Oil Palm:

With mechanisation, workers productivity and efficiency are enhanced, thus

reducing labour requirements and overcoming labour shortage in the

plantations.
Increase in harvesting coverage area because it helps individual daily

harvesting productivity and increasing pruning task.

Mechanization has been proven very effective, enabling the workers to earn
more. The production cost can be lowered by substantial labour reduction.

Disadvantages of Mechanisation in Oil Palm

The high cost of machine.

It requires skill as well as energy to ensure an effective cutting operation. A

difficulty in getting skilled harvesters has become the problem.

The productivity of some machine is affected by several factors such as
cropping level, variability of palm height, ground condition, field layout and
effective working hours.

Technology used in Oil Palm Plantation

Divided by four components which are:

1.
2.
3.
4.

Fresh Fruit Bunches (FFB) Harvesting

FFB Collection and Evacuation
Loose Fruit Collection
Field Maintenance

FRESH FRUIT BUNCHES (FFB) HARVESTING

Mechanical harvesting of oil palm fresh fruit bunches (FFB) remains an issue that
needs to be solved. The current methods involve the use of a Sickle and Chisel
(Figure 1) , which requires manual labour. It requires skill as well as energy to ensure
an effective cutting operation. A difficulty in getting skilled harvesters and ways on
how to improve harvesting productivity has become a necessity. The current manual
harvesting (using a sickle or chisel) can only produce 50 to 60 FFB hr-1. Estates are
now looking for more efficient harvesting tools which can double the productivity in
order to increase individual daily harvesting productivity and finally reducing the
number of workers.

Figure 1.0. Current method of harvesting using Sickle and Chisel.

i.

Mechanized Harvesting for Short Palms

Ckat (Figure 1.1) is a mechanical chisel, comprises of a cutting head, pole and
two-stroke petrol engine of 25.4 cc (1.3 hp). It is 1.5 m long and weighs 5.0 kg. It was
designed for harvesting palm below than 2 m height.

Figure 1.1. Ckat in operation.

The machine is used by a team of two the cutter solely cutting the FFB with a
helper for the other chores like stacking the cut fronds, collecting loose fruits and
evacuating the FFB. CkatTM was tested and the average harvesting productivity was
about 160 FFB hr-1 compared to about 110 FFB hr-1 in manual harvesting using a
chisel. Thus, the worker productivity with this was 45% higher. Fuel consumption
was 1.6 litres hr-1. Taking the average weight of FFB as 5 kg, the daily productivity
using Ckat is 6.4 t, or 3.2 t per man-day. The harvesting productivity, however,
depends very much on the cropping level as well as the topography.

ii.

Mechanized Harvesting for Intermediate Palms

Motorized cutter known as Cantas (Fugure 1.2). It was introduced in 2006, has
been well received by the industry, doubling the income of the operator. The
motorized cutter or Cantas is used for harvesting oil palm FFB and for pruning
fronds. Designed for palms lower than 5 m in height, it employs a specially designed
sickle, (patented C-sickle) driven by a vibrating mechanism to perform the cutting
operation mechanically. The C-sickle has been proven to give a higher cutting
efficiency. The design minimizes the vibration transferred to the body of the operator
due to the parallel transfer of forces during the cutting operation. Powered by a two
stroke petrol engine, it is equipped with a telescopic pole and a cutting head (the
vibrating mechanism and C-sickle).

Figure 1.2. Effective harvesting method using Cantas.

iii.

Mechanized Harvesting for Tall Palms

Mechanical harvesting machine track type

The maximum height that this boom can reach is 10 m. The arms, having both a
cutter blade member and fruit catching mechanism (FCM), can be extended upwards
and retracted using hydraulic cylinders. A tracked vehicle is known to contribute less
compaction to the ground while providing good traction both on rough terrain as well
as on soft ground.

Figure 1.3. Mechanical harvesting machine.

Mechanical harvesting machine wheel type

The harvesting mechanism consists of telescopic boom sections where a claw type
cutter and grapple are mounted on it. The machine design is based on a single
chassis concept with 4-wheel drive capability powered by a diesel engine. This
machine is made up of four basic modules, which are chassis, crane/boom, cutter
and bucket.

Figure 1.4. Stabilizers deployed for better working stability.

FFB COLLECTION AND EVACUATION

Another crucial area that determine the quality of FFB is the method of collecting and
evacuating bunches from the field to the collecting point. Mechanization proved that
the FFB can be evacuated efficiently and with less damage to the fruits. A
multipurpose concept was given an emphasis during the development to make the
transporter more versatile.

i.

Motorcycle Trailer

The motorcycle trailer is used to transport the FFB from the palm to the roadside
collecting point. This implement is affordable and could assist smallholders to lighten
their normal field activities such as transporting FFB, weed control and fertilizer
application. The trailer can be attached and detached with ease to and from
motorcycle. The motorcycle trailer is not only useful for smallholders but also for
workers in the plantation sector. It is not confined to FFB collection but can be used
for other purposes, be it agricultural or industrial.

Figure 1.5. Tilting for ease of unloading.

ii.

Badang L100 Dumper

Badang L100 Dumper likes the wheelbarrows with three wheels. Besides carrying
FFB, it can be used to carry water, herbicide, and tools for harvesting the oil palm. It
can carry up to 750kg of FFB. This machine powered by 10HP Yanmar air cooled
diesel engine.

Figure 1.6. Badang L100 Dumper.

iii.

The Compact Transporter

This single chassis machine with four low-pressure tyres provides good
manoeuverability in palm rows, narrow terraces, undulating terrain and soggy areas.
To a certain extent, this machine is more practical compared to the mini tractor or
other off-road vehicles as it can manoeuver on all types of terrain and gradients,
whilst leaving little impact on the ground. This machine is not only useful for
smallholders but also for workers in plantations. Besides for in-field transportation of
FFB, It can also be used for other activities such as fertilizer application, weed
control and field maintenance.

Figure 1.7. The compact transporter.

iv.

Half-track

The main use of this machine is for FFB evacuation in a soft and soggy area. The
rear wheels are on track hence giving good traction during wet season. This machine
can operate in all weather conditions.
The tracks can be mounted and detached as and when necessary. During wet
weather where the ground is soft, the track is installed to the machine. However,
during dry weather, the track is taken out allowing the machine to run on wheels only.
It was found that this prototype machine has no traction problem on shallow peat. On
average, the productivity of the machine was found to be between 2.4 t to 3.6 t hr-1.

Figure 1.8. A half-track machine being tested in an area where

a wheeled-type vehicle would have poor traction.

LOOSE FRUIT COLLECTION

Oil palm loose fruits contain maximum oil, which is why they need to be fully
collected. Large amounts of loose fruits are scattered due to impact as a result of
bunches falling to the ground during the harvesting activity. A cost-effective loose fruit
collection system remains the main requirement of oil palm estates. Various
inventions on loose fruit collecting machine have been introduced but the success is
rather questionable due to the mix of several technical limitations, constraints as well
as economic reason.

i.

A Roller Loose Fruit Picker

The Roller Picker (RP) collects oil palm loose fruits by picking and retaining the loose
fruits in a case without tedious and laborious efforts. It is designed to be manually
operated and is practical and affordable. The functions of RP are to collect and pick
up loose fruits from the ground and to separate the loose fruits from the debris.
The invention is an oval-shaped case made of plurality of wires or rods. The novelty
is that, during operation, the RP is rolled with a little pressure against the ground
causing the wires or rods of the case to split open and to trap the loose fruit inside
the case. Once the loose fruits are entrapped inside, the rods of the case will return
to their original position. All debris smaller than the spaces between the rods will
drop from the case, and therefore will result in only debris-free loose fruit being
collected.

ii.

Figure Loose
1.9. Collecting
method using
Roller Picker.
Air-assisted
Fruit Separating
Machine

The reasons for having clean loose fruits before sending it to the mill is to have a
higher oil extraction rate (OER). The large amount of trash will affect the mill
productivity, as trash will absorb the oil hence resulting in the reduction of OER.
There are also certain mills that penalize the estate if they keep sending large
amount of trash (together with loose fruits) to them.
The separator machine is a mobile type, hence, it can be moved from one place to
another. The separation will be carried out on a vibrating bed. In this development,
the objective of the separating mechanism is to give zero debris and zero damage.

Figure 1.10. Fruits from fertilizer bags are emptied onto the receiving hopper
and with the help of vibration mechanism and air stream, the clean fruits are
collected just after the second bed.

FIELD MAINTENANCE

Field maintenance includes fertilizer application, weeding and pest, and disease
control activities. With the labour shortage today, there is no option for the plantation
except to mechanize their field maintenance activities. Large amount of commercial
implements for these particular area are available in the market. R&D continues to
improve further the system.

i.

Compact Transporter with Sprayer (CT-Spray)

MPOB has developed a small in-field transporter powered by 200 cc petrol engine,
single chassis, compact but able to carry a load of 300 kg. The machine runs on four
low-pressure tyres to minimize soil compaction and also to provide the necessary
traction in all conditions in all terrains. It is thus, more versatile than a mini tractor or
other off-road vehicles. With only minor changes, the machine can be fitted out as a
sprayer.
The machine as sprayer is operated by a three person team the driver with a
worker handling the hose on each side. The spraying attachment is meant for wide
flat areas, with all the components specially designed and custom-made.
The machine is capable of working on all terrains. The tank is more than 10X as
large as that of the knapsack sprayer, reducing the frequency and time required for
refilling. With the price of CT Sprayer of RM 16 000 and output per day of 15 ha, the
investment is financially feasible. The nozzle can be changed from high to low
volume application. With the two hoses, spraying can be done on both sides of the
vehicle covering a swath of one one-palm row.

Figure 1.11. Multipurpose transporter fitted as sprayer - CT

Sprayer.

ii.

Mechanical Fertilizer Spreader for Young Palm

Fertilizing young palms since their early stage is always necessary to establish
vigorous healthy trees (Caliman et al., 2001). It is also often recognized that future
performance of poorly fertilized palm during immaturity might be affected for its
whole life cycle. Therefore, early manuring has been considered as an important
activity that has to be included in the establishment cost.
The placement of the fertilizer during testing was at the right place without spillage to
undesired areas. The lifting mechanism (frond lifter) functions well without spoiling
the fronds of the young palm. The use of four-wheels-steered prime mover gave
good manoeuvrability around the palm circle and easy access to the canopy. This
machine could save at least 60% of the labour required in the manual application
and possible reduction of 24% of application cost.

Figure 1.12. Mechanical Fertilizer Spreader in action.