PRESENTATION OF

CONTINUOUS
STERILIZATION SYSTEM

PRESENTED BY
MODIPALM ENGINEERING SDN BHD
 FROM FFB FEEDING
CONVEYOR

CAPACITY:
42M - 22.5 T/HR
BUNCH
CONDITIONER

LIVE STEAM
INLET FLAP VALVE
INJECTION CONVEYOR

OULET FLAP VALVE

STERILIZED
BUNCHES TO THRESHER
 FROM FFB FEEDING
CONVEYOR

BUNCH
CAPACITY OF DOUBLE DECK:
CONDITIONER 24M 25 MT/HR
LIVE STEAM
30M 30 MT/HR
INLET FLAP VALVE INJECTION CONVEYOR

STERILIZED
BUNCHES TO THRESHER
 Prior 2000, development and trial at Rantau POM.
2001 Put up the first proto type at CBIP workshop.
2002 Put up and commission the first 5 ton commercial
mill for Retus Plantation, Sibu, Sarawak.
2003 Continuous Steriliser first over sea trip was to
PT. Lonsum, Indonesia.
2003 Introduced side loading FFB conveyor to
facilitate FFB feed control.
2004 Implemented the Electro Mechanical Control
concept.
 2004 Designed and commissioned the first Post Heating
Vessel.
2006 Felda Pasoh, first conventional mill retrofitted with
Modipalm front end system.
2006 Introduced round link chain to replace normal plate
conveyor chain.
2006 Incorporated the split pocket wheel in conjunction
with round link chain.
2007 Developed the quick action end door to facilitate
inspection.
 2007 Continuous Sterilisation THE SYSTEM.
2009 Deployed the all new 50 ton breaking load H1966
Link Chain in our Continuous Steriliser.
2010 Introduced double deck configuration to reduce
overall length of steriliser chamber.
2013 Use of steam dryer to ensure dry steam with higher
enthalpy for sterilisation.
2014 Introduced the Single vertical flab steam lock.

IMPROVED SAFETY & CLEANER WORKING ENVIRONMENT

NOT A PRESSURE VESSEL AND EASY TO OPERATE

AUTOMATED PROCESS, HENCE REDUCING LABOR

SUBSTANTIAL SAVINGS ON LABOR, MAINTENANCE AND

OVERHEAD COST

MORE ENVIRONMENT-FRIENDLY & ENERGY EFFICIENT DUE

TO CONSTANT STEAM DEMAND

HIGHER OIL AND PALM KERNELRECOVERY FROM THE

FRUITS

BETTER OIL QUALITY

COMPACT DESIGN = SMALLER FOOTPRINT MILL

THE BIGGER THE CAGES THE HIGHER THE OIL
LOSS DURING STERILIZATION
(RESULTS WERE TAKEN FROM VARIOUS MILL) HEIGHT
6 METER

HEIGHT HEIGHT HEIGHT HEIGHT

OF CAGE OF CAGE OF CAGE OF CAGE
1.0 1.2 1.5 1.8 20 T
METER METER METER METER
to
30 T
VERTICAL
STERILIZER

10 T
3.5 T
2.5 T
1.5 T

0.5% OIL LOSS 1.2% OIL LOSS 1.5% OIL LOSS 2% OIL LOSS 2.3% OIL LOSS
IN IN IN IN IN
CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE

MILLERS WILL NOT ONLY BENEFIT FROM LABOR REDUCTION,
LOWER OPERATING COSTS, A CLEANER & SAFER WORKING
ENVIRONMENT AND LOWER PROCESSING LOSSES, BUT ALSO
CRUDE PALM OIL WITH HIGH DOBI* VALUE (>3.0)

* - Deterioration of Bleachebility
Index or (DOBI Value) is a unit
of measurement of the degree
of difficulty to bleach the crude
palm oil during refining. DOBI <
2.3 is bad.
MILL PERFORMANCE JERANGAU POM
 Mill Batch Continuous
Capacity Sterilization Sterilization

10 15 8
20 20 10
30 25 12
45 30 12
Intermittent black smoke
Consistently clean emission
emissions from a
conventional palm oil mill from a Modipalm palm oil mill
Scraped Cages in a conventional mill.
Cages renewal every few years is a drain on
natural resources and environmental
damaging.

EASIER TO MANAGE

GOOD WORKING ENVIRONMENT
 Typical Link Chain weight
Dimensions Table
Diameter Pitch Inside Width Outside Width Weight
Type
(d) (P) (a) Min (b) Max Kg/m
H-1143
H-1450
110.4
140.5
430.4
500.5
12.5
17
36.5
48
2.34
3.95
7.36 kg/m
H-1655 160.5 550.6 18.5 52 5.21
H-1864 180.5 640.6 21 61 6.93
H-1964 190.5 640.6 21 63 7.36
H-2064 200.6 640.6 23 67 8.37
H-2272 220.7 720.7 26 75 10.1
H-2286 220.7 860.9 26 75 9.40
H-2486 240.8 860.9 28 79 11.5
H-2590 250.8 900.9 30 82 12.5
Dimension (mm)
Standard Strength Table

Type
JIS Grade B
Test Load Breaking Load
JIS ISO Grade C
Test Load Breaking Load
ISO Grade D
Test Load Breaking Load 570 kN
(kN) (kN) (kN) (kN) (kN) (kN)
H-1143 100 140 120 150 150 190
H-1450 160 230 200 250 240 300
H-1655 210 300 260 320 320 400
H-1864 270 380 330 410 410 510
H-1964 300 420 360 450 450 570
H-2064 330 470 400 500 500 630
H-2272 400 570 490 610 610 760
H-2286 400 570 490 610 610 760
H-2486 480 680 580 720 720 900
H-2590 520 730 620 780 770 960
Typical Plate Conveyor Chain weight

267 kN 11.42 kg/m

Mass to Strength Ratio
Unit Weight Breaking Load

Link Chain 7.36 kg/m 570kN

Plate Chain 11.42 kg/m 267kN

Chain Selection
What happen if we
exceeded Safe working
50 ton load?
Caused by over-sized
40 ton motor drive!!
Cause by one strand of
the chain getting stuck!!
Now we resized the
chain with a SF of >10.
50,000lbf
The New H1966 Chain
H1966 rated at
H1966 50 ton
breaking load
During normal
operation,
Chain Pull
below 5 ton.
 H1655

H1966

H 1966 LINK CHAIN

 Higher breaking load at 50 tons compare to 40 tons only for H1655

 210C

140C 170C

CONTINUOUS STERILIZER
BPV
BOILER
FLUE GAS
270C

RECYCLE WASTE FLUE GAS, INCREASE THE

TEMPERATURE OF THE STERILIZER
LESS CONDENSATE VOLUME DUE TO DRIER STEAM

SINGLEFLAB
VERTICAL STEAM LOCK

REDUCED IMPACT
FORCE OF DROPING
BUNCHES

CUT DOWN NOISE

LEVEL

USED OF LONG LIFE

SELF LUBRICATED
BUSH BEARING

CHAIN
ELONGATION TRIP
MECHANISM

FIRSTTOUCH
WARNING SIGNAL
ACTIVATED

SECOND TOUCH
STOP OPERATION
UNTIL CHAIN IS CUT
- SAFETY : OUR CONCERN
BASE ON EXPERIENCES FROM HORIZONTAL STERILIZER MILLS ( CAPSTAN,
CAGE AND CRANE )
MANY ACCIDENTS HAPPENED

- ENVIRONMENT
STEAM DEMAND RELATIVELY CONSTANT . THIS IS IMPORTANT FACTOR FOR
REDUCING BLACK SMOKE EMISSIONS FROM BOILER

- OPERATION & MANPOWER

SIGNIFICANT REDUCTION IN THE NUMBER OF PROCESS OPERATORS ( COMPARE
TO HORIZONTAL STERILIZER MILL , REDUCE 9 ( NINE ) OPERATORS/SHIFT )
50% LESS OPERATORS AND CAN BE MORE EASILY SUPERVISED

- EFFICIENCY PROCESS MILL

SIGNIFICANTLY REDUCE UNSTRIPPED BUNCHES AND LESS UNACCOUNTABLE OIL LOSSES AT
THE RAIL TRACK

- MAINTENANCE
REDUCE THE NUMBER EQUIPMENT FOR MAINTENANCE ( AVOIDING TRANSFER CARRIAGE,
CRANE/TIPPER, BLOW DOWN SILENCER, TROLEY, ETC )

28 JUNE 2010
An Achievement
The first Continuous Steriliser mill was constructed and
commissioned in the year 2000
15 years later on 20th April 2015, Modipalm Engineering
rolled out the 100th Continuous Stetriliser Mill.
 EFFECT OF MILL CHANGE ON OER

Jan. to Mar.
Mill 2005 2006 2007 2008 2009
2010

Mill 1 19.11 19.44 19.49 20.42+ 20.37 21.00

Ulu Sebol 18.28 18.70 18.55 19.99+ 20.99 22.13

+ Old mill was shut down and FFB processed using a new mill based on continuous sterilization.
 EFFECT OF MILL CHANGE ON KER

Jan. to Mar.
Mill 2005 2006 2007 2008 2009
2010

Mill 1 5.36 5.30 5.26 5.63+ 5.75 5.73

Ulu Sebol 5.67 5.18 5.46 5.58+ 5.62 5.69

+ Old mill was shut down and FFB processed using a new mill based on continuous sterilization.
ULU SEBOL POM
ULU SEBOL POM

The OER and oil quality of mills using continuous sterilization
is better than the conventional mill.

The stripping efficiency in mills using continuous sterilization
is better than in conventional mills, thus reducing the
unquantifiable losses in a mill.

There is a significant reduction in the manpower requirements
compared to conventional mills.

Double Deck Continuous Sterilizer is proven to be more
reliable. It is capable of running 24 hours continuously and at
higher capacity of up to 30MT/Hr per unit

It can meet oil recovery performance without using Empty
Bunch Press and additional oil recovery equipment. Thus,
lower power consumption and lower operating cost
MELALAP 2 POM
MELALAP 2 POM
 SUNTAI POM 12 TPH
FIRST FLOATING MILL IN THE WORLD
TEMBUSU P0M
TEMBUSU P0M
JATI POM
 RAMIN POM
FIRST 45 TPH IN OPERATION - 2005
 SINP POM
(PT ASTRA AGRO LESTARI Tbk)
End of Presentation
Thank You for
Your Attention