Par16 Revised Assignment1

UNIVERSITAS INDONESIA
FISH OIL PLANT
Revised Assignment 1
GROUP 16
GROUP PERSONNEL:
ATIK SUHROWATI (1406643066)
ELSA PRISNA WIDYASMARA (1306392790)
IVANDER CHRISTIAN SIHOMBING (1306449126)
JUAN OCTAVIAN DANIEL SIDAURUK (1306449315)
KARINA KALMAPUSPITA IMAS (1306392992)
M. IKHLAS IBRAHIMSYAH (1306392802)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
DEPOK
SEPTEMBER, 2016
EXECUTIVE SUMMARY
Fish oil, derived from the tissue of oily fish species, is widely adopted in
numerous human and animal nutrition applications as a food and feed supplement
due to its high content of essential long chain omega 3 fatty acid, such as EPA and
DHA and linelonic acid which are essential nutrients for both humans and
animals. Additionally, the popularity of omega 3 fish oil in various applications,
such as supplements and functional food and pharmaceutical, also boosted its
market.
In Indonesia. there are various types of fish that can be used to produce
fish oil, such as kembung, lemuru, tongkol, kakap, tuna etc. One of the most
potential species for fish oil production in Indonesia is kembung/long jawed
mackerel fish (Rastrelliger Sp.). We chose this specific fish due to the
consideration of huge amount of production in 2013 which was 938,991 ton and
also the fact that the higher content of omega-3 or other essential fatty acid
compared to other common feedstock of fish oil, such as salmon and tuna.
The production capacity of a plant could be determined by market analysis
that had been made. Market analysis indicated any opportunities that could be
taken by the new manufacturers to invest in fish oil industry. Opportunities could
be maximized among the competition with other manufacturers, both the existing
manufacturers and new manufacturers. Moreover, we knew that fish oil still had
been a imported commodity in Indonesia and the stakeholeders of fish oil plant
commonly came from foreign countries. By considering the supply and demand of
kembung fish and fish oil in Indonesia, we proposed to produce 341.12 kg of fish
oil everyday that was derived from 17,056 kg of fresh long jawed mackerel
(Rastrelliger Sp) fish.
Plant location would be projected to be in Gresik since we considered the
affordable distibution cost to our targeted market, particularly in Java region.
Regarding the process selection, we chose to have 5 main stages before the final
product would be packaged and distributed, which included cooking, pressing,
decanting, polishing and drying.
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Universitas Indonesia
In addition, we also calculated the mass and energy balance in daily basis.
We obtained that the mass balance efficiency of the process was 24.26%, energy
required for each operation unit was 4,538,838 kiloJoule and energy required for
component stream was 5,775,127 kiloJoule.
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LIST OF CONTENTS
EXECUTIVE SUMMARY ................................................................................... ii

LIST OF CONTENTS ......................................................................................... iv
LIST OF FIGURE ............................................................................................... vi
LIST OF TABLE ................................................................................................ vii
CHAPTER I INTRODUCTION.......................................................................... 8
1.1 Background .............................................................................................. 8
1.2 Literature Review ..................................................................................... 9
1.2.1 Fish Oil Content and Sources .......................................................... 10
1.2.2 Structures and Properties................................................................. 11
1.2.3 Supplemental sources of Omega-3 fatty acids ................................ 11
1.2.4 Nutrient ................................................................................................ 12
1.3 Market and Capacity Analysis ............................................................... 13
1.3.1 Demand of Fish Oil .............................................................................. 14
1.3.2 Supply of Fish Oil ................................................................................ 15
1.3.3 Capacity Analysis................................................................................. 16
1.4 Raw Material Analysis ........................................................................... 16
1.5 Plant Location Analysis .......................................................................... 19
1.5.1 Proximity to the Raw Material Source Location ............................ 19
1.5.2 Proximity to Market Location Products Company .............................. 19
1.5.3 Utility ................................................................................................... 20
1.5.4 Labor .................................................................................................... 21
CHAPTER II PROCESS SELECTION ........................................................... 22
2.1 Alternative Process ................................................................................. 22
2.1.1 Degumming Process ....................................................................... 23
2.1.2 Bleaching Process ........................................................................... 24
2.2 Proses Selection ...................................................................................... 25
2.2.1 Degumming ..................................................................................... 25
2.3 Process Description ................................................................................ 27
2.3.1 Homogenization .............................................................................. 27
2.3.2 Cooking ........................................................................................... 27
2.3.3 Dryer Pressing ................................................................................. 28
2.3.4 Separation ........................................................................................ 30
2.3.5 Polishing.......................................................................................... 32
2.3.6 Fish Meal ......................................................................................... 35
2.4 Waste Treatment For Fish Oil Plant ....................................................... 36
2.4.1 Scrubber .......................................................................................... 36
2.4.2 Gases Treatment .............................................................................. 37
2.4.3 Water Treatment.............................................................................. 37
2.5 Block Flow Diagram .............................................................................. 38
2.6 Process Flow Diagram ............................................................................ 39
CHAPTER III MASS & ENERGY BALANCE .............................................. 43
3.1 Mass Balance for Each Operation Unit .................................................. 43
3.2 Overall Mass Balance ............................................................................. 52
3.3 Energy Required per Operation Unit ...................................................... 53
iv
3.4 Energy Required for Component Stream ............................................... 60
3.5 Overall Energy Balance .......................................................................... 61
BAB VI CONCLUSION ..................................................................................... 62
REFERENCES .................................................................................................... 63
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LIST OF FIGURE
Figure 1. 1 Chemical Bonds of EPA and DHA.................................................... 11

Figure 1. 2 Graph of Demand and Supply of Fish Oil in Indonesia .................... 15
Figure 1. 3 Rastrelliger Sp. (Kembung Fish / Long Jawed Mackerel) ................ 17
Figure 1. 4 Distribution of Long Jawed Mackerel in the world (FAO) ............... 18
Figure 1. 5 Plant Location .................................................................................... 21
Figure 2. 1 Carbon Treatment Process ................................................................. 32
Figure 2. 2 Alkali Refining Process ..................................................................... 33
Figure 2. 3 Block Flow Diagram of Fish Oil Plant .............................................. 38
Figure 2. 4 Process Flow Diagram of Fish Oil Plant ........................................... 39
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LIST OF TABLE
Table 1. 1 Nutrient in long jawed mackerel per 100 g ......................................... 12

Table 1. 2 Indonesian Population ......................................................................... 14
Table 1. 3 Consumption of Fish Oil in Indonesia ................................................ 14
Table 1. 4 Supply of Fish Oil per Year ................................................................ 15
Table 1. 5 Number of Unemployment People in East Java.................................. 21
Table 2. 1 Parameter of Scoring for Selection Degumming Process ................... 26
Table 2. 2 Scoring Result of Degumming Selection ............................................ 26
Table 3. 1 Mass Balance Unit Pressing ................................................................ 43
Table 3. 2 Mass Balance Unit Decanting ............................................................. 44
Table 3. 3 Mass Balance Unit Carbon Treatment ................................................ 45
Table 3. 4 Mass Balance Unit Acid Degumming ................................................. 46
Table 3. 5 Mass Balance Unit Alkali Refining .................................................... 48
Table 3. 6 Mass Balance Unit Water Washing .................................................... 49
Table 3. 7 Mass Balance Unit Bleaching ............................................................. 50
Table 3. 8 Mass Balance Unit Winterization ....................................................... 50
Table 3. 9 Mass Balance Unit Evaporation .......................................................... 51
Table 3. 10 Overall Mass Balance ........................................................................ 52
Table 3. 11 Energy Balance Unit Cooking ........................................................... 54
Table 3. 12 Energy Balance Unit Drying ............................................................. 55
Table 3. 13 Energy Balance Unit Carbon Treatment ........................................... 55
Table 3. 14 Energy Balance Unit Bleaching ........................................................ 56
Table 3. 15 Energy Balance Unit Centrifugation ................................................. 57
Table 3. 16 Energy Balance Unit Evaporation ..................................................... 58
Table 3. 17 Energy Balance Unit Winterization .................................................. 58
Table 3. 17 Energy Balance Unit Winterization (continued) ............................... 59
Table 3. 18 Energy Balance Unit Alkali Refining ............................................... 59
Table 3. 19 Energy Balance Component .............................................................. 60
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CHAPTER I
INTRODUCTION
1.1 Background
Fish oil is widely adopted in numerous human and animal nutrition
applications as a food and feed supplement due to its high content of essential
long chain omega 3 fatty acid. Fish oil is derived from the tissue of oily fish
species and contains a high percentage of long chain omega 3 fatty acids, such as
EPA and DHA, which are essential nutrients for both humans and animals. As a
prime ingredient in aqua feed, the growth of fish oil market is largely proportional
to the growth of aquaculture industry. Additionally, the popularity of omega 3 fish
oil in various applications, such as supplements & functional food (nutraceutical)
and pharmaceutical, is also providing boost to the market. However, the global
fish oil industry is largely affected by the demand-supply gap, caused by stringent
fishing quotas and adverse climatic conditions.
More than 50% of the global fish oil is produced in Latin American
countries namely Peru and Chile; however, most of it is consumed in the Asia
Pacific and Europe. The rising aquaculture production in Asian countries such as
China, India, Vietnam and Indonesia, leads to increased usage of aquaculture
grade fish oil in the region. North America and Europe have larger consumption
of pharmaceutical and supplements & functional food fish oils; collectively
accounting for about two-third of global revenues for these applications. In Japan,
the consumption of nutritional and pharmaceutical grade fish oil has significantly
increased due to rising health concerns among the country's geriatric population.
Geographically, the market in Indonesia is segmented across Java, Bali, Sumatera
and Kalimantan. The Indonesias Ministry of Industry (Kemperin) is encouraging
the fishery-based food industry to grow rapidly in the last couple of years. It was
recorded that the amount of imported fish oil in Indonesia had reached
approximately 10,150 tons while the exported one was around 253 tons. With that
in mind, Kemperin lists the fishery-based food industry into the prioritized sector
within the National Industrial Development Plan or Rencana Induk Pembangunan
Industri Nasional in 2015-2035. Specifically, Kemenperin predicts that fish oil is
8
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one of the most of potential processed food product that can be further developed
in Indonesia. However, nowadays, the producer is just capable of producing the
crude categorized fish oil which needs to be processed to be consumed. The
government highlights that if the stakeholders can process it effectively, the added
value obtained by the final fish oil product will be 10 folds from the original value
of fish solely. Besides, the things that should be taken as the main focus is the way
of encouraging all entrepeneurs, scientists and related stakeholders to play a role
as main actor in producing the fish oil products to fulfill the demand within local
level without depending too much on imported fish oil products.
1.2 Literature Review

Fish oils are made up of the long chained omega-3 polyunsaturated fatty
acids (PUFA) eicosapentaenoic acid (EPA) and docosahexaenoic acid (DHA).
EPA and DHA are synthesized from -linolenic acid and are found in the tissue of
oily fish such as mackerel, sardines, herring, salmon, trout, tuna and mullet. Over
time the consumption of omega-3 and omega-6 fatty acids by humans has
changed substantially. Sources of omega-6 fatty acids include polyunsaturated oils
-sunflower, safflower, soybean, corn and grape-seed oil, polyunsaturated
margarines, nuts - brazil, walnuts, and seeds sunflower and safflower. Humans,
thousands of years ago, probably consumed omega-3 to omega-6 fatty acids in a
ratio of 1:1 to 1:2. Today, humans consume approximately 20-25 times more
omega-6 fatty acids compared to omega-3 fatty acids. This dramatic increase in
omega-6 fatty acids, from studies, is associated with an increase of
proinflammatory markers (leukotrienes and prostanoids) which can cause an
increase in blood thickness, blood vessel spasm, and blood vessel constriction,
and decreases in bleeding time in humans.
Omega-3 fatty acids possess anti-inflammatory properties along with
antithrombotic, antiarrhythmic, hypolipidaemic, and vasodilatory properties. The
anti-inflammatory effects appear to have a direct action on immune function
through neutrophil and monocyte production of mediators, chemotactic responses,
and the production of cytokines.
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1.2.1 Fish Oil Content and Sources

Fish oil is a term used to refer to a certain solution of fatty acids (a
component of dietary fat) called eicosapentaenoic acid (EPA) and
docosahexaenoic acid (DHA); they are referred to as oils from fish (despite a
small presence in poultry and presence in neural tissue of all species) as serum
EPA and DHA concentrations tend to scale with fish intake, with Americans
usally having lower serum levels of these two fatty acids than Japanese people.
Fish oil is the bioactive of Cod Liver Oil (alongside Vitamin A and Vitamin D)
and Krill Oil (in the form of phospholipids rather than triglycerides).
Any fish oil product may contain more omega-3 fatty acids that are neither
EPA nor DHA (for example, the intermediate called DPA) and may contain fatty
acids that do not belong to the omega-3 class; exact levels of fatty acids and
omega-3 fatty acids depend on the source of fatty acids and processing, and tend
to be stated on the label.
With other additives that may or may not be included, depening on
processing:
Methylmercury contamination although this is dependent on initial source
of the oil (fish) and company dependent processing.
PCB/dioxin contamination.
Organochlorine contamination.
Generally any toxin that is released into the water and is fat-soluble in
nature (and thus can be stored in the tissues of fish) has potential to be found in
fish oil supplementation. If possible, fish oil supplements from non-predatory and
non-bottom feeding fish (such as sardines, herring, or mackerel) should be used,
as mercury levels (used as a standard by which to assess 'contaminants' in general)
typically are elevated in fish that consume other fish and build up stores of
mercury and PCBs, and bottom-feeders that feed on carcasses of fish and
accumulate toxins and minerals. Depth of forage may also be correlated with
mercury levels, making surface fish safer.
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1.2.2 Structures and Properties

The active components of fish oil are generally considered to be the two
omega-3 (also written as n3 or 3) fatty acids eicosapentaenoic acid (EPA) and
docosahexaenoic acid (DHA). Both fatty acids are similar in structure, although
DHA a tad longer (eico- refers to a fatty acid with 20 carbons in its chain, while
docosa- refers to a carbon chain 22 in length). The term Omega() is used to refer
to the 'end' of the fatty acid, and the omega designation of any fatty acid is the
distance from the end of the chain where the first double bond occurs.
Any fatty acid that has a double bond is unsaturated (if only once,
monounsaturated; if many times like both fish oils, polyunsaturated or PUFA) and
thus has an omega designation; saturated fatty acids lack double bonds and thus
have no omega designation. The diagram below indicates double bonds via
parallel lines. Figure 1.1 shows the chemical bonds of EPA and DHA.
Figure 1. 1 Chemical Bonds of EPA and DHA
(Source : www.iffo.net)
1.2.3 Supplemental sources of Omega-3 fatty acids

For dietary ingestion of EPA and DHA from fish products, there are a few
choices; triglycerides, reesterified triglycerides, ethyl ester (the pharmaceutical
Lovaza), and phospholipid (crustacean sources such as Krill Oil). These four all
confer dietary EPA and DHA, but krill oil is approximately a third better absorbed
than triglyceride form and ethyl ester the reverse (if fish oil triglycerides are
standardized to 100% absorption, ethyl esters reach 73%), which seem to confer
less benefits relative to triglycerides on a gram per gram basis. Re-esterification of
triglycerides appears to enhance their absorption (124% of triglycerides), but
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although this is somewhat comparable to phospholipid formation, the two have

not been directly compared.
Due to fish oil supplements being derived from fish, they are not classified
as vegan. Currently, the only significant vegan source of DHA is microalgae
(phytoplankton) and its supplement referred to as 'algae oil'. The DHA component
is equivalent to fish sourced DHA in cardiovacular health and seems to have
comparable safety suggesting that they are interchangeable.
Other vegetarian sources of omega-3 fatty acids tend to have the parent
structure of alpha-linolenic acid (ALA; not to be confused with Alpha-Lipoic
Acid which shares the acronym) and significant plant sources of ALA include
Hemp Protein and flaxseed, while supplements with a smaller ALA quantity
include Spirulina and Chlorella.
1.2.4 Nutrient
Nutrient of long jawed mackerel
Long jawed mackerel contain a nutrient such as mineral and vitamins.
Mineral salts contained in fish meat is mainly in the phosphate salt component is
bound to the adenosine triphosphate (ATP), which are compounds that play a role
in the process of glycolysis. In addition mackerel is also seen as a source of
calcium, iron, copper and iodine. Vitamins are found in fish is divided into two
parts, namely vitamin B complex and fat-soluble vitamins such as vitamins A, D,
and E. Table 1.1 shows the nutrient in long jawed mackerel per 100 g.
Table 1. 1 Nutrient in long jawed mackerel per 100 g
Nutrient Amount Recommend (%)
Sodium 90 mg 3
Niasin 9.08 mg 51
Piridoksin 8.71 mg 21
Magnesium 76 mg 21
Vitamin K 5 g 7
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Table 1. 1 Nutrient in long jawed mackerel per 100 g (continued)
Kalium 217 mg 10
Energy 205 Kcal 21
Protein 18.6 g
Vitamin A 167 IU 4
Total fat 13.89g
Calsium 12 mg 1
Iron 1.63 mg 10
Vitamin E 1.52 mg 9
Folat 1 g
Zinc 0.63 mg 5
Pantotenat Acid 0.399 mg 22
Riboflavin 0.312 mg 163
Thiamin 0.176 mg 13
Carbohydrate 0g
(Source : www.FAO.org)
1.3 Market and Capacity Analysis

Fish oil is derived from the tissue of oily fish species and contains a high
percentage of long chain omega 3 fatty acids, such as EPA and DHA, which are
essential nutrients for both humans and animals. Fish oil is largely used as a feed
ingredient in numerous animal and human nutritional applications, which include
aquaculture feed, animal nutrition & pet feed, pharmaceuticals, supplements &
functional food. Fish oil is one of the product development from fishery
commodities which potential to be developed. The global usage of fish oil in 2002
are edible (14%), industrial (5%) and aquatic (81%). Demand is driven by
aquaculture applications and direct human consumption.
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1.3.1 Demand of Fish Oil

The fish oil market in Indonesia is expected reach 1% from World
Demand fish oil is according to ApacMarket.com. Demand of fish oil in 2015 is
7314.37 ton/year. To know the growth of fish oil demand we used the rate of the
population growth for our consideration. The database is based on BPS shows in
table 1.2.
Table 1. 2 Indonesian Population
Year Population (million)

2015 255,46
2016 258,78
2017 262,15
2018 265,55
2019 269,01
2020 272,50
(Source : www.BPS.co.id)
From the data above, the population growth is 1.3% and total population in
2020 is 272,504,089. Fish oil consumption is 500 mg/day per person. From that
we can estimate percentage total consumption of fish oil in Indonesia per year is :

500 1 9 365 272,504,089 = 49731.9 /

7314.37 /
= 15,68%
49731.9 /
So, total consumption of fish oil in Indonesia is 15,68% from total
population. And the growth of fish oil demand shows in table 1.3.
Table 1. 3 Consumption of Fish Oil in Indonesia
Year Consumption (ton)

7314.37
2015
7409.46
2016
7505.78
2017
7603.35
2018
7702.20
2019
7802.33
2020
(Source: Authors Data)
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1.3.2 Supply of Fish Oil

The fish oil supply from import data in indonesia is 5260 tonnes in 2015
and it growth 0.5% per year according to Elsevier Aquaculture Journal. So we can
estimate supply of fish in oil in 2020 with it and it shows in table 1.4.
Table 1. 4 Supply of Fish Oil per Year
Year Demand of fish oil (tonnes)

2015 5260.0
2016 5286.3
2017 5312.7
2018 5339.3
2019 5366.0
2020 5392.8
(Source : Groups Personal Data)
9000
8000
7000
6000
Tonnes
5000
4000 Demand
3000 Import
2000
1000
0
2015 2016 2017 2018 2019 2020
year
Figure 1. 2 Graph of Demand and Supply of Fish Oil in Indonesia
(Source : Groups Personal Data)
Figure 1.2 shows the graph of demand and import supply, from that we
know there is a gap between demand and supply in 2020 is 2409.51 tonnes/year.
With that condition, we decided to have 5% market share from fish oil market.
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1.3.3 Capacity Analysis

The production capacity of a plant can be determined by market analysis
that has been made. Market analysis indicates any opportunities that can be taken
by the new manufacturers to invest in fish oil industry. Opportunities can be
maximized among the competition with other manufacturers, both the existing
manufacturers and new manufacturers.
Capacity analysis is needed to determine the production capacity
according to manufacturers ability. Although there is an opportunity to benefit
from the gap between demand and supply, there should be anticipation of the
possibility of competition between manufacturers of fish oil. Rivalry can be a
competition with manufacturers which had already producing and new
competitors that could emerge later on.
We know that our market share is 6% so the production capacity of our
plant is 119.392 tonnes/ year. So our capacity production per day is :
119392 kg/ year
= 341.12 /
350 /
1.4 Raw Material Analysis

Various types of fish that can be used as a good source of fish oil are:
mackerel, rainbow trout, trout, halibut, herring, sardines, swordfish, oysters, tuna,
blue fin tuna, yellow fin tuna, anchovies and salmon. The most common is to get
fish oil such as albacore tuna, herring, mackerel, sardines, trout and salmon. The
quality of fish oil is highly dependent on what kind of fish oil is processed to be
taken. But the common fish for fish oil are not available in Indonesia.
Indonesia has a lot various type of fish that also can be used for fish oil
production such as kembung, lemuru, tongkol, kakap, tuna etc. Big potential for
fish oil production in Indonesia are made from kembung fish. Because in
Indonesia, Rastrelliger Sp. (kembung fish) production in 2011 is 291,863 ton and
in 2015 is 938,991 ton which is be commodities with the highest production after
Layang fish (Scad) 405,808 ton and Cakalang fish (Skipjack tuna) 372,211 ton
(KKP 2012).
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Characteristic of Rastrelliger Sp. (Kembung Fish / Long Jawed Mackerel)

Rastrelliger Sp. (Kembung Fish / Long Jawed Mackerel) has a body
moderately deep, its depth at margin of gill cover 4.3 to 5.2 times in fork length;
head longer than body depth. Maxilla partly concealed, covered by the lacrimal
bone, but extending to about hind margin of eye; gillrakers very long, visible
when mouth is opened, 30 to 46 on lower limb of first arch; a moderate number of
bristles on longest gillraker, 105 ons one side in specimens of 12.7 cm, 140 in
specimens of 16 cm, and 160 in specimens of 19 cm fork length. Intestine 1.4 to
1.8 times fork length. It has color narrow dark longitudinal bands on upper part of
body (golden in fresh specimens) and a black spot on body near lower margin of
pectoral fin; dorsal fins yellowish with black tips, caudal and pectoral fins
yellowish; other fins dusky. Figure 1.3 shows long jawed mackerel fish.
Figure 1. 3 Rastrelliger Sp. (Kembung Fish / Long Jawed Mackerel)
(Source : FAO.org)
Habitat and distribution of Rastrelliger Sp. (Kembung Fish / Long Jawed

Mackerel)
Long jawed mackerel has a habitat in coastal water and offshore side
which has salt content more than 32.5 % in the depth of the sea greater than 20 m
with a sandy bottom side and crystal clear water.
Long jawed mackerel which classified into groups of mackerel spreading
vertically and horizontally. Limit of the distribution vertically become important
to be knowledge for the information of the fishing method. Distribution of long
jawed mackerel are Indonesia, Indo-West pacific, red sea, east Africa, and
Australia until Mediterranean Sea through Suez Canal (FAO)
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Figure 1. 4 Distribution of Long Jawed Mackerel in the world (FAO)
(Source : www.FAO.org)
Distribution in Indonesia is widely available in the side between Java

Island and Kalimantan Island and also near Sumatra Island and it shows in Figure
1.4. In 2015 production of long jawed mackerel in Indonesia is 938,991 tons and
total fish production in that year is 5,707,012 tons (KKI, 2015). From that we can
estimate a percentage a population of long jawed mackerel in total fish production
as follows:
(2015) 938,991 tonnes

=
(2015) 5,707,012 tonnes
= 16.4 %
We can estimated that long jawed mackerel is 16.4% from total fish
production in Indonesia. So, long jawed mackerel as a raw material has a big
potential for fish oil industry which we can determine amount of fish to be used as
follows :
119.392 /
=
2%
= 5969.6 /
From calculation above we know that demand of fish to be used in our
plant is 5969.6 tonnes fish/year.
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1.5 Plant Location Analysis

The geographical location of a plant has a great influence on the system of
economic production. This is due to many factors that affect the layout of
machinery and plant facilities. Plant, either by itself will contribute a lot in efforts
to minimize the cost. The best location of the factory is the location where the unit
cost of production and distribution process will be low, while prices and sales
volume will be able to generate maximum profits for the company. Therefore, our
plant will be located in Gresik Industrial Estate, East Java. Our considerations is
compose this factors below:
1.5.1 Proximity to the Raw Material Source Location

The raw material used in our plant is long jawed mackerel fish. Indonesia's
fishery production totalled 15.26 million tonnes in 2012, with wild capture
accounting for 5.81 million tonnes and aquaculture for 9.45 million tonnes,
according to the Ministry of Marine Affairs and Fisheries. The UNs Food and
Agriculture Organization (FAO) in 2011 ranked Indonesia third in the world in
terms of inland and marine catch as well as fourth in aquaculture output. East Java
as the countrys foremost production area accounts for roughly a third of
shipments.
1.5.2 Proximity to Market Location Products Company

East Java is the province with the second largest population after West
Java. In 2011, the population reached 37.7 million people (about 15% of the total
population in Indonesia). The capital of East Java, Surabaya, is the second largest
city in Indonesia after Jakarta. In economic terms, East Java has a regional gross
domestic product second largest in Indonesia after Jakarta. In 2011, the regional
gross domestic product reached 366,984 billion at constant prices of 2000. East
Java even came in second place for the number of regional gross domestic product
in the three sectors. For the primary sector, East Java is in second position after
East Kalimantan. For the secondary sector, East Java is in second position after
the West Java. For the tertiary sector, East Java is in second position after Jakarta.
It shows the competitiveness of East Java with a comprehensive cleaner
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performance in various aspects of the economy. So, East Java it is a potential

market for our product marketing.
1.5.3 Utility
Gresik Industrial Estate is equipped with the following infrastructure :
Main facilities :
- Street
- Factory Waste Water Treatment.
- Sewer System for Rain Water Jetting.
- The drainage system is designed with a variety of sizes depending on
land area (1-3 meters wide). Trenches built in an open space for rain
water harvesting.
- Port
Supporting facilities :
- Telecommunications, PT TELKOM has provided 400 telephone lines can
be connected on request to accommodate customer needs.
- Electricity, electric power is supplied by the state electricity company.
- Gas, PGN has built a network of natural gas and the industry to meet the
needs of investors.
- Water, PT PKG supply the needs of industrial water taken from the river
Bengawan Solo amounted to 144,000 m3 each month.
- Waste Management, Gresik Industrial Estate to handle waste based on
the individual contract.
- Cost Management, services provided on cost management, including: 24-
hour guard, maintenance and repair of infrastructure and equipment,
among others; drainage systems, pipelines and street lights in the
common areas.
- Service and maintenance of roads in the common area.
- Facilities for public worship, the mosque
- Online banking services, there are many international-level banks that
can be reached in less than 10 minutes.
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1.5.4 Labor
This labor availability is shown in the table 1.4 below:
Table 1. 5 Number of Unemployment People in East Java
Registered Job Vacancies Fulfillment

Year Unemployment
Job Seeker Listed of Labor
2014 295,495 247,180 185,801 109,694

2013 200,464 172,480 93,970 106,494
2012 260,740 25,948 12,851 247,889
2011 110,123 24,154 18,823 91,300
(Source : BPS, 2014)
From Table 1.4 we can conclude that the number of unemployment people
in East Java is still high. There number is increasing in 2011 to 2014. So, even our
plant is built, we can give job field for them and help East Java develop their area.
This is the picture of Industrial Estate Gresik, East Java and the location of
our plant and its shows in figure 1.5.
Figure 1. 5 Plant Location
(Source : Google Maps)
CHAPTER II
PROCESS SELECTION
2.1 Alternative Process

The production of fish oil generally employs the same principles and
technique as the production of other edible fats and oil. The wet reduction method
are cooking, pressing, separation of the oil phase from the water phase, and
storage of covered oil called as crude fish oil. Crude fish oils are inedible because
they contains free fatty acids, primary oxidation products, minerals, pigments,
moisture, phospholipids and insoluble impurities, which reduce their quality.
Therefore, it is important to remove these impurities from the extracted oils to
produce purified oils with acceptable shelf life and commercial value. This is the
general process of the fish oil plant, and the process will be explained more in the
process description.
Homogenization
Homogenization is to make the same size of the fish. This process is to make
sure the fish will be cooked very well.
Cooking
Steam cooking ruptures the fat cells, coagulates the protein and releases the oil.
Pressing
Pressing mechanically expresses the free liquid from the solids producing a
press liquor (oil and water) and a press cake (semi-moist meat and bones).
Separation
The press liquor contains, apart from water, most of the oil from the fish, and
also dissolved proteins, salts and fine particles. The latter are removed in a
decanter and transported to the drier to be mixed in with the presscake. The
liquid from the decanter is fed to separators where the oil is removed and
subsequently
Oil Polishing
The water phase from the separators is fed to the evaporators where it is
concentrated before being blended with the presscake during the drying stage.
22
23
Drying
The water in the press cake, sludge and concentrate is removed by rapid hot air
drying after which the fishmeal is cooled, milled and stored.
The differences between one process and another process in a lot of fish
oil production is the oil polishing process. The oil polishing process consists of
carbon treatments, degumming, alkali refining or neutraliztion, water washing,
drying, bleaching, winterization, and deodorization. There are some technologies
to be used in some process.
2.1.1 Degumming Process

There are two kinds of gums, first is hydratable gums that easily removed,
and the second one is non-hydratable gums that hard to remove from oil. Some of
non-hydratable phosphatides removed with water degumming, but it requires the
use of acid to convert to hydratable for complete removal. In degumming
process, there are three kinds of process based on the degumming agent. There
are water degumming, enzyme degumming, and acid degumming.
a. Water Degumming
Water degumming is most commonly used. The gums removed with this
process are normally dried to form lecithin, which is a valuable by-product. If
preferred, the gums can instead be returned to the meal in the extraction plant.
Water degumming has an important additional advantage that also makes it
attractive in many other contexts. Using this relatively simple, cheap process to
remove as much gum as possible in the initial stages, less material needs to be
removed later on using neutralization. This also means there is less soap stock for
treatment of disposal.
b. Enzyme Degumming
Any gums present in the oil can also remove by using enzymes. Enzymes
are biological catalysts that react specifically with target substrates with the added
advantage that they yield few by-products. Phospholipase is the enzyme that
reacts specifically with the phospholipids in oil. It converts gums into distinct
fractions that are soluble in oil and water, respectively. The phospholipases most
commonly used in oil degumming are phospholipase A (PLA) and phospholipase
24
C (PLC). Phospholipids are emulsifiers that cause losses of oil during the
traditional water degumming process. Phosphatidylcholine (PC) is the most
hydratable phospholipid and has the highest emulsification strength. The PLC
enzyme reacts with PC and phophatidylethanolamine (PE), forming
diacylglycerols and a water-soluble phosphate-bearing ester fragment, thus
reducing the final emulsion. This results in cleaner separation during
centrifugation, and also reduces losses of the neutral oil. In addition, the
diacylglycerols produced by PLC degumming provide a bonus oil yield that is
retained thoughout the refining process. Since PE is a non-hydratable gum, the oil
usually has a lower gum contetnt after PLC degumming compare with the water
degumming process. This means less material that requires removal in subsequent
processes.
c. Acid Degumming
In this degumming process, after heating the oil, small amount of a
suitable acid and caustic soda will be added at carefully controlled temperature.
The hydratable and non-hydratable gums from selected oil can be separated, right
down to a level where these oils have a quality that is acceptable for further
processing. The gums that are removed at this stage are very sticky. This makes
centrifugation with disc stack will work very well. With this acid degumming, the
oil losses will be reduced, or increasing the oil yield, and the operating cost will
be reduced.
2.1.2 Bleaching Process

a. Dry Bleaching
Dry bleaching is the method traditionally used for fats and oils. Before it is
mixed with bleaching earth, the oil is heated. If the process requires it, a citric acid
solution is mixed with the hot oil to bind trace metals and decompose any residual
soaps. After this treatment, the oil is mixed with bleaching earth, activated carbon,
or a mixture of these two. This is done under vacuum to prevent oxidation, and in
the presence of sparging steam. This process is called dry bleaching, because the
bleaching reactor operates at a vacuum of about 70 torr, which greatly reduces the
humidity in the oil. The advantage of this process are:
25
1. Lower initial investment compared with other types of bleaching

2. The use of plate heat exchangers for heating and cooling means lower
consumption of utilities compared with shell and tube solutions. This
results in lower operating costs
3. Easy, straightforward control and operation
4. Only a minimum space is requires for installation
5. Minimal energy consumption.
b. Wet Bleaching
Wet bleaching is a bleaching process in which water is added to the oil
while it is in contact with the bleaching agent in the bleaching reactor. The
presence of small amounts of water results in more efficient use of the relatively
expensive bleaching earth. This greater efficiency results in lower earth
consumption as well as reduction of total oil losses. But the investment costs are
slightly higher. The water present during wet bleaching is introduced in the form
of a citric acid solution, or by taking wet oil from separation line. Adjustment is
carried out by careful control of the operating vacuum in the bleaching reactor to
determine how much of the water subsequently evaporates. Even tiny amounts of
water remaining in the mixture after this will cause filtration problem later on.
The oil therefore has to be dried before filtration. In terms of the equipment used,
the basic different between wet and dry bleaching installations is therefore
whether or not a dryer is located between the bleaching reactor and the filtration
system. The advantage of wet bleaching are more efficient use of the bleaching
earth, easy to combine with a silica treatment process highly flexible, low
consumption of bleaching earth, and reduced oil loss during filtration.
2.2 Proses Selection

2.2.1 Degumming
The table 2.1 below show the scoring for selection process based on the
comparison of water,enzym, and acid uses :
26
Table 2. 1 Parameter of Scoring for Selection Degumming Process
Reaction Time Results

Score (Hydration Temperature Effecivity
Phosphorus Losses
mixing time)
High because
Reaction time The operation Contain in Oil losses
no need next
3 occurs for 0-20 temperature is fish oil < 30 in process
step
minutes < 60C ppm < 10 %
purification
The operation Medium Contain in

Reaction time Oil losses
temperature is because need fish oil
2 occurs for 20-40 in process
about 60-100 some next step between 30-
minutes < 10-20 %
C purification 50 ppm
Low because
Reaction time The operation Oil losses
need complex Contain in
1 occurs for 40-60 temperature is in process
purifications fish oil <30
minutes > 100 C > 20 %
step
(Source: Groups Personal Data)
For purpose of concept selection, the weight factor of the criteria were
determined subjectively by our team from our rational intent. The total weight
factor has to be 100% and it is normally used to assign the weight factor value of
each criteria. Design concepts are rated through a comparison to the reference
design concept. Representative ratings or ranks are valued from 1 to 3, indicating
much worse to much better designs that the reference, this would be explained
hereafter. Once all the concepts are rated, a total score for each design concept is
calculated. The calculation show in table 2.2 below:
Table 2. 2 Scoring Result of Degumming Selection
Type of Degumming
% Enzyme
Criteria Water Degumming Acid Degumming
weight Degumming
rank weight score rank weight score rank weight score
Reaction time
(Hydration Time) 5 2 0.1 2 0.1 1 0.05
Temperature 10 2 0.2 2 0.2 3 0.3
Effectivity 35 2 0.7 2 0.7 2 0.7
Phosphorus 45 1 0.45 2 0.9 3 1.35
Losses 5 1 0.05 2 0.1 1 0.05
Total 100 1.5 2 2.45
(Source: Groups Personal Data)
27
The table shows that each degumming process has advantage and
disadvantage, such as water degumming has an advantage with a good efectivity
but the product still contain phosporus and has a losses. Enzym degumming has
an advantage with a good reaction time, temperature operation, efectivity and
losses in oil not to many. Acid Degumming Entrained bed has advantage in high
conversion but temperature of gasification is too high, fluidized bed has advantage
in feedstock (coal rank) because all variant of coal capable become feed, and
entrained bed has advantage in high purity of product. From scoring in the table
2.5, we choose gasifier that will be used is Entrained Bed Reactor. This type of
gasifier is choosen because high purity of product.
2.3 Process Description

2.3.1 Homogenization
Large fish are hashed while smaller fish for example those less than 40 cm
long are fed directly at a constant rate by the feeding machine to the indirect steam
cooker. Large fish have to be hashed into smaller pieces before being passed by
the feeder into the cooker. This is to ensure uniform processing and equal
temperature in the cooked material. Also, the feeder ensures a steady rate of
presentation to the cooker.
2.3.2 Cooking
The purpose of heating process is to liberate the oil from the fat depots of
the fish, and to condition the material for the subsequent treatment in the various
processing units of the plant. The optimum conditions for a particular type of raw
material must largely be established through practical experience. The cooking
system is using a steam cooker, through which the fish conveyed continuously.
Heats is generally transferred indirectly from a surrounding jacket and a heated
rotary screw conveyor. In indirect cookers provision is also made for the
admission of live steam directly into the mass as this may sometimes be
advantageous.
Cooking is an exacting operation in production and is sometimes difficult
to control. Production of cooked material which can be readily pressed is
28
dependent on the quality of the raw material and on the process conditions. The
most common practice of cooking good raw material, however, is to heat to 95-
100 C within 15 to 20 min. Most manufacturers operate cookers to ensure rapid
heating of the mass to a temperature of about 95 C. The proof of good cooking is
good pressability of the mass which leads to proper removal of press liquor and,
in particular for fatty fish species, efficient recovery of oil, giving a meal with low
fat content which is a criterion of quality. The process must be controlled to
ensure sufficient cooking, but overcooking must be avoided as this results in
problems with pressing and the presence of large amounts of suspended particles
in the stick water, which makes evaporation difficult.
The capacity is influenced by the resistance to heat transfer largely caused
by the existence of films and coatings on the heating surfaces. An important way
of reducing the tendency to scaling, caused by coagulation of protein on the hot
walls, is to use moderate steam temperatures, especially in the early stages of
heating. Another measure is, of course, to introduce and enforce good routines for
effective cleaning at regular intervals.
2.3.3 Dryer Pressing

The purpose of the press is to squeeze out as much liquid as possible from
the solid phase. This is important to reduce the moisture content of the press cake
as far as possible, thereby reducing the fuel consumption of the dryers and
increasing their capacity. The performance ot the press is largely determined by
the profile and the compression ratio of the screw, that is, the ratio between the
flight volumes of the inlet and outlet flights.
The performance of the press may be regulated in two ways: one may
adjust the level of cooked material in the hopper above the press, a high level
resulting in higher pressure and consequently a more complete filling of the inlet
screw flight; the other factor is the rate of revolution of the screws; increased
speed means greater thoughput and a shorter pressing time. How to adjust these
two factors, to obtain optimum performance is largely a matter of experience and
skill.
29
Good performance of the press depends upon relatively tight fitting of the
screw flights to the surrounding strainer plates. If the distance between the flight
tops and the screens becomes too wide, for instance after long wear and tear, both
the efficiency and the capacity will suffer; rebuilding and readjustment of the
screw flights are then necessary. Another factor that needs continuous
surveillance is the performance of the strainer plates. Regular inspection and
cleaning is necessary to ensure that the holes are open and allow free escape of
liquid. As pointed out earlier, temperature is a factor of great importance for the
whole cooking and pressing operation. Basic information today indicates that
moderate temperatures are preferable from the standpoint of release of oil and
denaturation of protein. On the other side, high temperatures reduce the viscosity
of the oil and tend to facilitate the flow from the solid phase. With the equipment
we just have described, we must again rely on experimental data to establish
optimum conditions for a particular raw material.
Processing problems may be encountered under two entirely different
conditions. One relates to completely fresh fish that tends to retain more oil and
water than desirable. For the time being, there is no solution to this problem
except by resorting to one of the two equally deplorable measures; either by
reducing the speed of the press and thereby the capacity of the whole plant or by
storing the fish for a day or two before processing, thus leading to deterioration of
quality. The other situation occurs with soft and autolyzed fish. The answer to this
problem is to bleed off in the pre-strainer more liquid and fines to be handled by
the decanters. Some processors will often resort to the use of coagulating agents
like formaldehyde, which help to solidify the material and improve the
performance of the press. This, practice, however, should be restricted as far as
possible because formaldehyde reacts with the essential amino acid lysine, and
thereby reduces the nutritional quality of the protein. Calcium chloride (CaCl2)
has also been used as a hardener, but this practice was abandoned because it raised
the chloride content of the meal to unacceptable levels, particularly in cases where
stick water is incorporated and whole meal produced.
30
2.3.4 Separation
The liquor coming from the press and the pre-strainer consists of water and
varying amounts of oil and dry matter. The oil content is related to the proportion
of oil in the fish. The content of dry matter, occurring both in dissolved and
suspended (finely dispersed) forms, varies with the size and quality of the fish and
with the extent of mechanical handling prior to processing.
The quantity of press liquor will also vary with the nature and quality of
the raw material, and increases particularly with advancing autolysis of the fish.
Under average conditions one may estimate the volume of press liquor at about
70% of the raw material while the remaining 30% makes up the press cake.
The separation of the three fractions of the press liquor, sludge, oil and
water, is based on their different specific gravities. If press liquor is left for some
time in a tank, it will settle out in three layers: sludge at the bottom, water in
between and oil at the top. In the early days of fish oil production, this method of
settling under the influence of gravity alone was standard procedure. It had many
drawbacks such as poor yield, impure fractions and, above all, it was extremely
slow. With centrifugation we get several thousand times greater forces at our
disposal, and the separation process may now be accomplished in seconds when
compared with the hours required for the settling method.
An important prerequisite for efficient separation is high temperature,
implying that the press liquor should be reheated to 90-95C before entering the
centrifuges. This applies to sludge removal as well as to separation of oil and
water.
The suspended solids are first to be removed. This is done in a horizontal
centrifuge, a so- called decanter or desludger. It consists of a partly cylindrical and
partly conical rotor drum (bowl) and, inside this, a screw conveyor of the same
shape. The press liquor is fed into the rotor where, by centrifugal force, it is
thrown toward the bowl's periphery. The denser solids are rapidly precipitated
along the inside rotor surface. The screw conveyor rotates with the bowl, but at a
rate some 30 to 50 rpm faster than the speed of rotation of the drum; the deposited
solids are thus scraped off continuously. Before being discharged, they are lifted
out of the liquid phase and pass through a drying or dewatering zone.
31
The performance of the decanter may be controlled in two ways. It is

possible to adjust the thickness of the liquid layer (a thick layer represents a
longer zone and allows more time for clarification of the liquid) and, associated
with this, there will be a correspondingly shorter zone of. sludge and less time for
dewatering the solids. The reverse will, of course, be the case with a thin liquid
layer. The other regulating parameter is the speed of the screw conveyor relative
to that of the bowl. The higher the content of solids in the liquid the faster the
conveyor should rotate in relation to the bowl in order to remove the precipitate.
In addition to these parameters one may naturally influence performance by
regulating the feed. Optimum conditions are dependent both on quantity and
nature, specially particle size, of the solids in the liquid. Decanters are available in
various sizes.
Separation of stick water from oil takes place in vertical disc centrifuges,
either of the nozzle type, which discharge the stick water and remaining sludge
continuously, or of the self cleaning type, which is often preferred. In the latter,
the stick water is continuously discharged, whereas the sludge is collected in the
bowl and periodically ejected according to a timed programme which depends on
the quantity and the nature of the sludge. The stick water with a dry matter content
of 6-9% is concentrated in evaporators. The sludge in most cases can be pumped
to the press cake.
The main component of the bowl is a stack of conical discs lying on top of
each other at distances of 0.5 to 2 mm apart. The discs have a number of
distribution holes to provide passages for the liquid from the bottom of the disc
stack. The decanter liquid is fed from a control tube. The oil moves along the
discs toward the centre and discharges through the holes in the nut. The stick
water moves toward the periphery and discharges behind the separating plate
through the regulation ring . This is inter-changeable to adjust the separation. The
sludge separates along the bowl periphery and is discharged through the bowl slot
into the frame chute at regular intervals.
32
2.3.5 Polishing
2.3.5.1 Carbon Treatment
Carbon treatments are used on the initial crude oil to remove dioxins,
furans, and polyaromatic hydrocarbons (PAH), which are toxic. The European
Union recommends the reduction of dioxins, furans, and PCBs in feed and food. It
sets out action levels for certain food sources, including farmed fish, to encourage
member states to proactively reduce dioxin levels. When these contaminants
occur in wild-caught fish, the reason is environmental pollution rather than a point
source; therefore, no action levels have been set for wild-caught fish. Generally,
carbon treatment is necessary for farmed fish and fish caught near industrial areas.
The process of this treatment consist of two adsorption processes. First of
all, there is an adsorption process using a silica gel, to remove some of meal fines.
After that, there is an adsorption using activation carbon to remove dioxin and
PCB. The adsorption time using silica gel takes 15 minutes at 50oC. And the
activated carbon treatment helds in 30 minutes at 60oC and less than 100 bar.
Figure 2. 1 Carbon Treatment Process
(Source : www.Alvalaval.com)
2.3.5.2 Degumming
Purposes of degumming are prevent crude oil settling during storage or
transport, prevent acidual of gums, physical refining, and reduction in
neutralization losses. From the process selection, we choose to use deep
degumming. This deep degumming, has a lot of advantages such as the process
will reduce the oil losses and increase the purity of the oil. With deep degumming,
33
it can remove hydratable phosphatides and also non-hydratable phosphatides. The

crude oil from carbon treatment, is hydrated, heated to 60C, and treated with
phosphoric acid (0.05-0.2%) to separate the phospholipids, resins, proteins,
minerals, and other materials intrinsic. And after that there will be a alkali refining
before the gums from degumming is separated. The main reason for the removal
of phospholipids is that some of the compounds, particularly the calcium and
magnesium salt of phosphatidic and lysophatidic acids, are strong emulsifiers. If
these compounds remain in the oil during the alkali refining/neutralization step,
they may inhibit the separation of the soaps. Phospholipids (also called
phosphotides) will react with water to form insoluble sediments.
2.3.5.3 Alkali Refining

Due to the length of time between harvesting the fish and sitting in holding
tanks, the oils triglycerides break down, through hydrolytic rancidity, into free
fatty acids, creating a rancid smell/taste, and the oil begins to turn brown.
Purposes of alkali refining are removing phospholipids (gums), colour bodies
(pigments), metal ions, free fattu acids. Phospholipids have a properties that cause
emulsions, darken oil with heat, and interfere with crystallization. Pigments are
removed because it have some nutritional value, and it can be not heat stable. The
chemical reaction in alkali refining is :
Figure 2. 2 Alkali Refining Process
(Source : www.Alvalaval.com)
Other mechanisms are colour bodies adsorbed onto soap, phosphatides

hydrated by water in lye, and chelated metal ions removed in soal. The process of
alkali refining are crude oil afer degumming process, is injected with NaOH, after
that there will be a mixing time. After that there will be a heating, and also
separation using disc stack centrifuge, with the help of water. This process
34
produces soaps that must be removed with water or steam washing, followed by
centrifuging.
2.3.5.4 Water Washing

Water washing remove the soaps created by the alkali, oxidation products,
and other trace metals. After being injected with water, there will be a separation
using disc stack centrifuge that will remove soapstock and also gums
(phospholipids) from the oil.
2.3.5.5 Bleaching
The major objective of bleaching is to return the oil to an acceptable pale
color using clays treated with mineral acids, in this process, we choose to use
natural bleaching earth. Depending on how long the oil has been sitting, up to 2%
bleaching earth may be used. The natural bleaching earths used with only limited
colour-reducing effect but are particularly useful in treating animal fats. Bleaching
makes it possible to remove certain pigments such as carotinoids and pigments
such as carotinoids and chlorophyll, decompose and partially remove oxidation
products, remove contaminants such as soaps and trace metals. In this processing,
we choose to use dry bleaching. Dry bleaching is the method that traditionally
used for fats and oil. Before oil is mixed with bleaching earth, the oil is heated.
After that, the oil is mixed with bleaching earth, activated carbon, or mixture of
these two. This is done under vacuum to prevent oxidation, and in the presence of
sparging steam. The process is named dry bleaching because the bleaching reactor
operates at a vacuum of about 70 torr, which greatly reduces the humidity in the
oil. After this, the bleaching agents is normally removed using pressure leaf
filters. Naturally, the filter cake that accumulates here still contains oil. Much of
this can be recovered by steam blowing the contents of these filters. Filtered oil
collects in the buffer tank, which operates under the same vacuum as the
bleaching reactor. From there, oil goes via one of the polishing filters to the next
process.
35
2.3.5.6 Winterization
Winterization concentrates the omega fatty acids. This is addition by
subtraction. The oil is cooled to sub-zero temperature, causing crystallization and
reduction in the amount of saturated fatty acids. Triglycerides and waxes are also
removed. Removing the saturated fats and triglycerides further destabilizes the oil,
as the remaining polyunsaturated fats, in the form of omega-3 fatty acids, are very
fragile and oxidize easily. The human body does not require concentrated levels
of essential fatty acids, especially in an isolated form. Denaturing the oil creates
an imbalance that severely weakens its effectiveness.
2.3.5.7 Deodorization
To remove additional free fatty acids, mono- and di-glycerides, hydro
peroxides, aldehydes, ketones, chlorinated hydrocarbons, volatile compounds
(rancid fishy smells and taste), and pigments formed during the previous
processing steps, deodorization is necessary. During this process, the oil can be
heated up to 190 C (374 F) or higher as live steam passes through the oil at low
pressure. This step may lead to the formation of trans fats (trans isomers) of EPA
and DHA. Trans fats were found in up to 4.5% of the total EPA and up to 5.9% of
the DHA. In this process, we use molecular distillation. Molecular distillation
removes most of the remaining pesticides and organic pollutants, which include
dioxins, lindane, DDT, as well as bromated compounds (flame retardants) and
reduces all such environmental pollutants to lower levels. Molecular distillation is
also responsible for a tremendous loss of vitamins A and D naturally occurring in
cod liver oil and the creation of trans fats due to high heat.
2.3.6 Fish Meal

The purpose of the drying process is to convert the wet and unstable
mixture of press cake, decanter sludge and concentration into a dry and stable fish
meal. In practice, this means drying to a moisture content below 12%, which
generally may be considered low enough to check microbial activity. This drying
is done by heating the material to a temperature where the rate of evaporation of
the water is considered satisfactory. Increasing the temperature will speed up the
36
drying process. There are, however, certain critical limits observe in order to
avoid reduction of quality, especially of the protein.
With the equipment and conditions normally used in the fishmeal industry,
the temperature of the drying material should not exceed 90C in order not to
impair nutritional value.
A prerequisite for optimum drying conditions is that the material should be
divided into relatively small pieces or particles so as to facilitate the escape of
water vapor from below the surface into the air. The press cake is, therefore,
passed through a wet mill where it is disintegrated by fast moving hammer heads
mounted on a rotor. The press cake is beaten against a screen in the bottom
provided with sharp edged, square holes.
To avoid sticking and lump formation during one stage drying of press
cake to which stick water concentrate is added, thorough mixing is necessary.
This may be achieved by heating the concentrate to a high temperature (about
100C) before mixing. Such heating also serves to destroy bacteria, including
Salmonella, if present. Mixing is generally performed in the screw conveyors, the
concentrate preferably being added before disintegration of the press cake in the
wet mill. In two stage drying the concentrate is added to the press cake between
the dryers.
2.4 Waste Treatment For Fish Oil Plant

2.4.1 Scrubber
Water scrubbing leads to a marked reduction in odor by removal of water
soluble constituents. A simple scrubbing tower in which effluent air is passed up
through a tower while water cascades down through the tower is normally
adequate. The principle is to ensure good air/water contact and the tower is
sometimes fitted with ceramic rings or with sprays so as to achieve this. Sea water
is perfectly suitable if available. An indirect system where the warm moist
effluent air passes over a series of cooled coils is preferred but not required. In the
indirect system the condensed water from the air will remove some of the water
soluble compounds and the water in the coils can then be recooled in a cooling
tower and recycled.
37
2.4.2 Gases Treatment

Effluent gases may be dispersed through the use of high stacks, in which
case the odor laden air is released at a sufficient height above the ground so that a
natural mixing with the atmosphere reduces the concentration of odorants to
below the detection threshold limit by the time it reaches ground level.
2.4.3 Water Treatment

Water from scrubber process will be gathered with water that contain a
solid waste. In the majority of cases the removal of solids is adequate treatment to
protect the receiving environment as this will prevent the build up of sludge
around the effluent outfall with its consequent effect on dissolved oxygen. While
there is some flexibility in the type of odor control employed, all fish meal plants
must adhere to the following requirements:
1. When fish waste is flumed to the fish reduction plant from the fish
processing plant, the discharge water should be treated to pass screening
with openings of 5mm maximum.
2. A clean up area must be available for fish waste delivery trucks with
wastewater solids removal equivalent to 0.71 mm screening or finer. The
same screening requirement applies to general plant wash up water.
Following screening these effluents must be discharged through an outfall which
allows sufficient tidal flushing action to dilute the remaining effluent and thus
minimize pollution problems. All solids collected by the screens must be
incorporated back into the process or disposed of along with any excess or
deteriorated offal either on a gurry ground (if a permit for dumping is obtained) or
buried at an approved waste disposal site. And all of the water from screener, will
be collected in collecting pit, before going to the sea.
38
2.5 Block Flow Diagram
Figure 2. 3 Block Flow Diagram of Fish Oil Plant
39
2.6 Process Flow Diagram
Figure 2. 4 Process Flow Diagram of Fish Oil Plant
40
Figure 2. 4 Process Flow Diagram of Fish Oil Plant (continued)
41
42
CHAPTER III
MASS & ENERGY BALANCE
From the process in chapter II, we can calculate mass and energy balance
of the plant. Mass balance will be evaluated each equipment. From this chapter,
we will know how much fish needed to produce fish oil with our designated
capacity which converts 17, 056 ton fish oil 341,12 kg per day. Then, we will
know the energy needed to generate the process from the beginning until fish oil
as main product and fish meal as by product produced. In this chapter, mass and
energy balance will be calculated each unit and then each operation unit.
3.1 Mass Balance for Each Operation Unit

Firstly, we calculate the mass balance for each operation unit, as follows:
Table 3. 1 Mass Balance Unit Pressing
Operation Unit: Pressing

Mass Balance (kg/day)
Component Output to Output (Fish
Input
Decanter Meal)
Palmitic Acid 2988.86 2988.86 0
Oleic 1644.28 1644.28 0
Stearic 1084.95 1084.95 0
Palmitoleic 988.27 988.27 0
Miristic Acid 624.97 624.97 0
Eicosapentaenoic 132.37 132.37
0
acid (EPA)
Docosahexaenoic 114.94 114.94
0
acid (DHA)
Linolenic 93.81 93.81 0
Lysine 1570.86 0 1570.86
Methionine 1210.98 0 1210.98
PCB 69.93 69.93 0
43
44
Table 3. 1 Mass Balance Unit Pressing (continued)
Operation Unit: Pressing

Component Output to Output (Fish
Input
Decanter Meal)
Dioxine 95.51 95.51 0
Phospholipid 221.73 221.73 0
Pigment 85.28 85.28 0
Triglycerides 65.69 65.69 0
Wax 39.23 39.23 0
Hydrogen 18.76 18.76
0
Peroxide
Ketone 37.86 37.86 0
Lindane 15.18 15.18 0
Water 5952.54 5952.54 0
TOTAL 17,056 14,274.17 2,781.83
TOTAL 17,056 17,056
Table 3. 2 Mass Balance Unit Decanting
Operation Unit: Decanting

Input Output Output to
Component
(Stickwater) Carbon
Treatment
Palmitic Acid 2988.86 19.43 2969.43
Oleic 1644.28 8.88 1635.40
Stearic 1084.95 7.70 1077.25
Palmitoleic 988.27 6.72 981.55
Miristic Acid 624.97 2.25 622.72
0
acid (EPA)
45
Table 3. 2 Mass Balance Unit Decanting (continued)
Operation Unit: Decanting

Input Output Output to
Component
(Stickwater) Carbon
Treatment
0
acid (DHA)
Linolenic 93.81 0 93.81
PCB 69.93 0 69.93
Dioxine 95.51 0 95.51
Phospholipid 221.73 0 221.73
Pigment 85.28 0 85.28
Triglycerides 65.69 0 65.69
Wax 39.23 0 39.23
0
Peroxide
Ketone 37.86 0 37.86
Lindane 15.18 0 15.18
Water 5952.54 5952.54 0
TOTAL 14274.17 5997.52 8276.64
TOTAL 14274.17 14274.17
Table 3. 3 Mass Balance Unit Carbon Treatment
Operation Unit: Carbon Treatment

Component Input Output to Output to Waste
Degumming
Palmitic Acid 2969.43 2969.43 0
Oleic 1635.40 1635.40 0
Stearic 1077.25 1077.25 0
46
Table 3. 3Mass Balance Unit Carbon Treatment (continued)

Degumming
Eicosapentaenoic
132.37 132.37 0
acid (EPA)
Docosahexaenoic
114.94 114.94 0
acid (DHA)
Linolenic 93.81 93.81 0
PCB 69.93 0 69.93
Dioxine 95.51 26.74 68.77
Phospholipid 221.73 221.73 0
Pigment 85.28 85.28 0
Wax 39.23 39.23 0
Hydrogen
18.76 18.76 0
Peroxide
Ketone 37.86 37.86 0
Lindane 15.18 15.18 0
TOTAL 8,276.64 8,137.94 138.70
TOTAL 8,276.64 8,276.64
Table 3. 4 Mass Balance Unit Acid Degumming
Operation Unit: Acid Degumming

Component Input Output to Alkali Output to Waste
Refining
Palmitic Acid 2969.43 2969.43 0
47
Table 3. 4 Mass Balance Unit Acid Degumming (continued)
Operation Unit: Acid Degumming

Component Input Output to Alkali Output to Waste
Refining
Oleic 1635.40 1635.40 0
Stearic 1077.25 1077.25 0
Eicosapentaenoic 132.37 132.37 0
acid (EPA)
Docosahexaenoic 114.94 114.94 0
acid (DHA)
Linolenic 93.81 93.81 0
Dioxine 26.74 26.74 0
Phospholipid 221.73 0 221.73
Pigment 85.28 85.28 0
Wax 39.23 39.23 0
Hydrogen 18.76 18.76 0
Peroxide
Ketone 37.86 37.86 0
Lindane 15.18 15.18 0
TOTAL 8,137.94 7,916.22 221.73
TOTAL 8,137.94 8,137.94
48
Table 3. 5 Mass Balance Unit Alkali Refining
Operation Unit: Alkali Refining

Mass Balance
Component Input Output to Water Output to Waste
Washing
Palmitic Acid 2,969.43 2,969.43 0
Oleic 1,635.40 1,635.40 0
Stearic 1,077.25 1,077.25 0
Eicosapentaenoic acid 132.37 132.37
0
(EPA)
Docosahexaenoic acid 114.94 114.94
0
(DHA)
Linolenic 93.81 93.81 0
Dioxine 26.74 26.74 0
Pigment 85.28 85.28 0
Wax 39.23 39.23 0
Hydrogen Peroxide 18.76 18.76 0
Ketone 37.86 37.86 0
Lindane 15.18 15.18 0
Sodium Hydroxide 5500.00 0 5,500
TOTAL 13,416.22 7,916.22 5,500
TOTAL 13,416.22 13,416.22
Transeterification/ Saponification Reaction that occurs in Water Washing stages:

Triglycerides (Esther and Fatty Acids) + 3 NaOH ---> Glycerol + 3 Soap
49
Table 3. 6 Mass Balance Unit Water Washing
Operation Unit: Water Washing

Mass Balance
Bleaching
Palmitic Acid 2,969.43 0 0
Oleic 1,635.40 0 0
Stearic 1,077.25 0 0
Palmitoleic 981.55 0 0
Miristic Acid 622.72 0 0
Soaps 0 0 3,213.01
Glycerol 0 0 9,631.15
0
acid (EPA)
0
acid (DHA)
Linolenic 93.81 93.81 0
Dioxine 26.74 26.74 0
Pigment 85.28 85.28 0
Wax 39.23 39.23 0
0
Peroxide
Ketone 37.86 37.86 0
Lindane 15.18 15.18 0
Water 2,500 0.00 2,500
TOTAL 10,416.22 572.06 9,844.15
TOTAL 10,416.22 10,416.22
50
Table 3. 7 Mass Balance Unit Bleaching
Operation Unit: Bleaching

Mass Balance
Winterization
Eicosapentaenoic 132.37 132.37 0
acid (EPA)
Docosahexaenoic 114.94 114.94 0
acid (DHA)
Linolenic 93.81 93.81 0
Dioxine 26.74 26.74 0
Bleaching Earth 127.92 0 127.92
Pigment 85.28 0 85.28
Wax 39.23 39.23 0
Hydrogen 18.76 18.76 0
Peroxide
Ketone 37.86 37.86 0
Lindane 15.18 15.18
699.98 486.78
TOTAL
699.98 699.98
TOTAL
Table 3. 8 Mass Balance Unit Winterization
Operation Unit: Winterization

Mass Balance
Component Input Output to Output to
Evaporation Waste
Eicosapentaenoic acid 132.37 132.37
0
(EPA)
Docosahexaenoic acid 114.94 114.94

0
(DHA)
51
Table 3. 8 Mass Balance Unit Winterization (continued)

Mass Balance
Evaporation Waste
Linolenic 93.81 93.81 0
Dioxine 26.74 26.74 0
Triglycerides 7.88 0 7.88
Wax 39.23 0 39.23
Hydrogen Peroxide 18.76 18.76 0
Ketone 37.86 37.86 0
Lindane 15.18 15.18 0
TOTAL 486.78 439.67 47.11
486.78 486.78
TOTAL
Table 3. 9 Mass Balance Unit Evaporation
Operation Unit: Evaporation

Mass Balance
Packaging Waste
Eicosapentaenoic acid (EPA) 132.37 132.37 0
Docosahexaenoic acid (DHA) 114.94 114.94 0
Linolenic 93.81 93.81 0
Dioxine 26.74 0 26.74
Hydrogen Peroxide 18.76 0 18.76
Ketone 37.86 0 37.86
Lindane 15.18 0 15.18
TOTAL 439.67 341.12 98.55
TOTAL 439.67 439.67
52
3.2 Overall Mass Balance

After the mass balance of each operation unit has been calculated, we also
calculate th overall mass balance, as follows:
Table 3. 10 Overall Mass Balance
Mass In
Mass Out (kg/day)
(kg/day)
Component
Feed Fish Oil Fish Meal Waste
Palmitic Acid 2988.86 0 343.72 4187.15

Oleic 1644.28 0 151.93 2680.30
Stearic 1084.95 0 100.90 1375.12
Palmitoleic 988.27 0 121.56 1229.85
Miristic Acid 624.97 0 75.62 871.82
Eicosapentaenoic acid 132.37
132.37 0 0
(EPA)
Docosahexaenoic acid 114.94
114.94 0 0
(DHA)
Linolenic 93.81 93.81 0 0
Lysine 1570.86 0 1570.86 0
Methionine 1210.98 0 1210.98 0
PCB 69.93 0 0 187.62
Dioxine 95.51 0 0 443.46
Phospholipid 221.73 0 221.73 0
Pigment 85.28 0 0 85.28
Triglycerides 65.69 0 0 472.45
Wax 39.23 0 0 209.79
Hydrogen Peroxide 18.76 0 0 187.62
Ketone 37.86 0 0 208.08
53
Table 3. 10 Overall Mass Balance (continued)
Mass In
Mass Out (kg/day)
(kg/day)
Component
Feed Fish Oil Fish Meal Waste
Lindane 15.18 0 0 151.8

Water 5952.54 0 0 2804
TOTAL (kg/day) 17056.00 341.12 3797.29 12917.59
TOTAL (kg/day) 17,056 17,056
After the mass balance is calculated, mass efficiency of the process should
also be calculated. We calculate the mass efficiency of fish oil production with the
following formula:
Mass efficiency of main product (fish oil):
341.12
% = 100% = 100% = 2%
17,056
Mass efficiency of by product (fish meal)

3797.29
% = 100% = 100%
17,056
= 22,26%
Hence, the overall mass efficiency of products is 24,26%

% = 24,26%
3.3 Energy Required per Operation Unit

The energy balance is determined for the system that have temperature
change, because it is where the energy flows to the system. The energy balance
for each operation unit will be listed as follows:
54
Table 3. 11 Energy Balance Unit Cooking
Operation Unit: Cooking

Cp
Component m (kg) Tin (oC) Tout (oC) Q (kJ)
(kJ/kg.oC)
Palmitic Acid 0.463 2988.86 15.5 90 103096.2
Oleic 2.884 1644.28 15.5 90 353286.7
Stearic 2.359 1084.95 15.5 90 190675.1
Palmitoleic 2.72 988.27 15.5 90 200263
Miristic Acid 0.432 624.97 15.5 90 20114.03
Eicosapentaenoic
0.75 132.37 15.5 90 7396.174
acid (EPA)
Docosahexaenoic
0.87 114.94 15.5 90 7449.836
acid (DHA)
Linolenic 1.916 93.81 15.5 90 13390.63
Lysine 1.668 1570.86 15.5 90 195204.2
Methionine 1.823 1210.98 15.5 90 164466.9
PCB 0.396 69.93 15.5 90 2063.063
Dioxine 0.98 95.51 15.5 90 6973.448
Phospholipid 2.87 221.73 15.5 90 47408.77
Pigment 0.53 85.28 15.5 90 3367.281
Triglycerides 2.23 65.69 15.5 90 10912.85
Wax 3.43 39.23 15.5 90 10024.33
Hydrogen
2.629 18.76 15.5 90 3674.656
Peroxide
Ketone 2.297 37.86 15.5 90 6479.589
Lindane 0.73 15.18 15.5 90 825.5556
Water 5.861 5952.54 15.5 90 2599146
QTotal (kJ) 3,946,218
55
Table 3. 12 Energy Balance Unit Drying
Operation Unit: Drying

Cp
(kJ/kg.oC)
Palmitic Acid 0.463 2988.86 60 90 103096.2
Oleic 2.884 1644.28 60 90 353286.7
Stearic 2.359 1084.95 60 90 190675.1
Palmitoleic 2.72 988.27 60 90 200263
Miristic Acid 0.432 624.97 60 90 20114.03
Lysine 1.668 1570.86 60 90 78605.71
Methionine 1.823 1210.98 60 90 66228.28
60 90 1046636
Water
5.861 5952.54
QTotal (kJ) 1,193,631
Table 3. 13 Energy Balance Unit Carbon Treatment

Cp
Component o
m (kg) Tin (oC) Tout (oC) Q (kJ)
(kJ/kg. C)
Palmitic Acid 0.463 2969.43 60 90 13748.47
Oleic 2.884 1635.40 60 90 47164.96
Stearic 2.359 1077.25 60 90 25412.25
Palmitoleic 2.720 981.55 60 90 26698.15
Miristic Acid 0.432 622.72 60 90 2690.15
Eicosapentaenoic 60 90
acid (EPA) 0.750 132.37 992.78
Docosahexaenoic 60 90
acid (DHA) 0.870 114.94 999.98
Linolenic 1.916 93.81 60 90 1797.40
56
Table 3. 13 Energy Balance Unit Carbon Treatment (continued)

Cp
(kJ/kg.oC)
PCB 0.396 69.93 60 90 276.92
Dioxine 0.980 95.51 60 90 936.03
Phospholipid 2.870 221.73 60 90 6363.59
Pigment 0.530 85.28 60 90 451.98
Triglycerides 2.230 65.69 60 90 1464.81
Wax 3.430 39.23 60 90 1345.55
Hydrogen 60 90
Peroxide 2.629 18.76 493.24
Ketone 2.297 37.86 60 90 869.74
Lindane 0.730 15.18 60 90 110.81
QTotal (kJ) 131,816.84
Table 3. 14 Energy Balance Unit Bleaching
Operation Unit: Heating (Bleaching Stage)

Cp
Component o
(kJ/kg. C)
Eicosapentaenoic
acid (EPA) 0.75 132.37 90 105 1489.16
Docosahexaenoic 90 105
acid (DHA) 0.87 114.94 1499.97
Linolenic 1.92 93.81 90 105 2696.10
Dioxine 0.98 26.74 90 105 393.13
Bleaching Earth 0.37 127.92 90 105 709.96
Pigment 0.53 85.28 90 105 677.98
Triglycerides 2.23 7.88 90 105 263.67
Wax 3.43 39.23 90 105 2018.32
57
Table 3. 14 Energy Balance Unit Bleaching (continued)
Operation Unit: Heating (Bleaching Stage)

Cp
(kJ/kg.oC)
Hydrogen 90 105
Peroxide 2.63 18.76 739.86
Ketone 2.30 37.86 90 105 1304.62
Lindane 0.73 15.18 90 105 166.22
QTotal (kJ) 11,958.98
Table 3. 15 Energy Balance Unit Centrifugation
Operation Unit: Centrifugation

Cp Tout (oC) - Tin (oC)
Component m (kg) Q (kJ)
(kJ/kg.oC)
Soaps 0.56 1838.01 10 28.65
Glycerol 1.63 5506.15 10 89750.17
Eicosapentaenoic 10
acid (EPA) 0.75 132.37 992.78

Docosahexaenoic 10
acid (DHA) 0.87 114.94 999.98
Linolenic 1.92 93.81 10 1797.40
Dioxine 0.98 26.74 10 262.09
Pigment 0.53 85.28 10 451.98
Triglycerides 2.23 65.69 10 1464.81
Wax 3.43 39.23 10 1345.55
Hydrogen Peroxide 2.63 18.76 10 493.24
Ketone 2.30 37.86 10 869.74
Lindane 0.73 15.18 10 110.81
Water 5.86 2500.00 10 146525.00
QTotal (kJ) 245,092.2
58
Table 3. 16 Energy Balance Unit Distillation
Operation Unit: Evaporation

(kJ/kg.oC)
Eicosapentaenoic
acid (EPA) 0.75 132.37 200 19855.50
Docosahexaenoic 200
acid (DHA) 0.87 114.94 19999.56
200
Linolenic
1.92 93.81 35947.99
26.74 200
Dioxine
0.98 5241.79
Hydrogen 200
Peroxide 2.63 18.76 9864.85
Ketone 2.30 37.86 200 17394.87
Lindane 0.73 15.18 200 2216.26
QTotal (kJ) 110,520.8
Table 3. 17 Energy Balance Unit Winterization

(kJ/kg.oC)
Eicosapentaenoic
acid (EPA) 0.75 132.37 105 10424.14
Docosahexaenoic 105
acid (DHA) 0.87 114.94 10499.77
105
Linolenic
1.916 93.81 18872.7
Dioxine 0.98 26.74 105 2751.938
Triglycerides 2.23 7.88 105 1845.663
59
Table 3. 18 Energy Balance Unit Winterization (continued)

(kJ/kg.oC)
Wax 3.43 39.23 105 14128.25
Hydrogen 105
Peroxide 2.629 18.76 5179.046
Ketone 2.297 37.86 105 9132.306
Lindane 0.73 15.18 105 1163.535
QTotal (kJ) 73,997.34
Table 3. 19 Energy Balance Unit Alkali Refining
Operation Unit: Alkali Refining
In Mass (kg) Cp (kJ/kg.oC) Q (kJ)

65.69
Triglyceride
2.23 1464.812
NaOH 5500 0.3471 19090.5
Sum 58.736.31
Out Mass (kg) Cp (kJ/kg.oC) Q (kJ)
Glycerol 5506.145 1.63 89750.17
Soaps 1838.009 0.56 10292.85
Sum 120628.7
Total (Out-In) 61,892.41
60
3.4 Energy Required for Component Stream
Table 3. 20 Energy Balance Component

Components Energy
Cp
Component o
(kJ/kg. C)
Palmitic Acid 0.463 2988.86 15.5 90 and 105 121466.75
Oleic 2.884 1644.28 15.5 90 and 105 417845.71
Stearic 2.359 1084.95 15.5 90 and 105 225495.68
Palmitoleic 2.72 988.27 15.5 90 and 105 235624.91
Miristic Acid 0.432 624.97 15.5 90 and 105 23673.81
Eicosapentaenoic 0.75 132.37 15.5 200
acid (EPA) 18316.70
Docosahexaenoic 0.87 114.94 15.5 200
acid (DHA) 18449.59
Linolenic 1.916 93.81 15.5 200 33162.02
Lysine 1.668 1570.86 15.5 90 195204.19
Methionine 1.823 1210.98 15.5 90 164466.89
PCB 0.396 69.93 15.5 70 1509.22
Dioxine 0.98 95.51 15.5 70 5101.38
Phospholipid 2.87 221.73 15.5 90 47408.77
Pigment 0.53 85.28 15.5 105 4045.26
Triglycerides 2.23 65.69 15.5 200 27025.78
Wax 3.43 39.23 15.5 200 24825.36
Hydrogen 15.5 200
Peroxide 2.629 18.76 9100.32
Ketone 2.297 37.86 15.5 200 16046.77
Table 3. 19 Energy Balance Component (continued)

Components Energy
Component Cp (kJ/kg.oC) m (kg) Tin (oC) Tout (oC) Q (kJ)
Lindane 0.73 15.18 15.5 200 2044.50
61
Water 5.861 5952.54 15.5 100 2948024.20

QTotal (kJ) 5,770,025.19
3.5 Overall Energy Balance

After calculating the energy required from the component stream and also
energy derived from each operation unit, we have to calculate the overall energy
balance to know whether the energy required by all component streams can be
fulfilled by energy within overall operation unit or not. The calculation can be
seen as follows:

= +
Energy Balance Q (kJ)
Operation Units Energy
(A) 5,775,127.10
Component Streams
Energy (B) 5,770,025.19
Total (A-B) 5,101.90
62
BAB VI
CONCLUSION
After the explanation in the chapters before, we can conclude some points
below:
Considering supply and demand of fish oil in Indonesian we decided to have

5% market share from fish oil market.
Type of fish that we used to produce fish oil is long jawed mackerel, our
consideration to choose this fish because omega-3 contain in long jawed
mackerel is highest than other common fish that used to produce fish oil.
Regarding the process selection, we chose to have 5 main stages before the
final product would be packaged and distributed, which included cooking,
pressing, decanting, polishing and drying.
Polishing process consist of carbon treatment, degumming, alkali refining,
water washing, bleaching, winterization, and deodorization.
Mass efficiency of our main product is 2%, by product is 22.26%, so overall
mass efficiency of our fish oil production is 24,26%.
Overall energy required to produce fish oil is 1,236,289.28 kJ.
63
REFERENCES
Douglas, J.M., 1998, Conceptual Design of Chemical Processes, McGraw Hill.

Kirk-Othmer, 1991, Enyclopedia of Chemical Technology, 3rd edition, McGraw
Hill.
Walas, Stanley M. 1990, Chemical Process Equipment : Selection and Design,
Buther Worths.
Seider W.D., Seader J.D., Lewin D.R., 2004, Product and Process Design
Principles. Synthesis, Analysis and Evaluation, Wiley and Sons Inc.
Sinnott RK, 2005, Chemical Engineering Design, Coulson and Richardsons
Chemical Engineering Vol 6, 4th ed., Elsevier
https://examine.com/supplements/fish-oil/
http://spo.nmfs.noaa.gov/Circulars/CIRC276.pdf
http://www.iffo.net/system/files/Chemical%20composition%20and%20stability%
20of%20fish%20oil%201992-1_1.pdf
http://www.fao.org/docrep/x5738e/x5738e05.htm
https://www.bps.go.id/linkTabelStatis/view/id/1019
https://www.researchgate.net/publication/228086444_Extraction_Processing_and
_Stabilization_of_Health-Promoting_Fish_Oils

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UNIVERSITAS INDONESIA

FISH OIL PLANT

CHEMICAL ENGINEERING DEPARTMENT

EXECUTIVE SUMMARY ................................................................................... ii

Figure 1. 1 Chemical Bonds of EPA and DHA.................................................... 11

Table 1. 1 Nutrient in long jawed mackerel per 100 g ......................................... 12

1.2 Literature Review

1.2.1 Fish Oil Content and Sources

1.2.2 Structures and Properties

Figure 1. 1 Chemical Bonds of EPA and DHA

1.2.3 Supplemental sources of Omega-3 fatty acids

although this is somewhat comparable to phospholipid formation, the two have

Table 1. 1 Nutrient in long jawed mackerel per 100 g

Nutrient Amount Recommend (%)

Table 1. 1 Nutrient in long jawed mackerel per 100 g (continued)

Energy 205 Kcal 21

Total fat 13.89g

Pantotenat Acid 0.399 mg 22

Riboflavin 0.312 mg 163

1.3 Market and Capacity Analysis

1.3.1 Demand of Fish Oil

Year Population (million)

Table 1. 3 Consumption of Fish Oil in Indonesia

Year Consumption (ton)

1.3.2 Supply of Fish Oil

Table 1. 4 Supply of Fish Oil per Year

Year Demand of fish oil (tonnes)

Figure 1. 2 Graph of Demand and Supply of Fish Oil in Indonesia

(Source : Groups Personal Data)

1.3.3 Capacity Analysis

1.4 Raw Material Analysis

Characteristic of Rastrelliger Sp. (Kembung Fish / Long Jawed Mackerel)

Figure 1. 3 Rastrelliger Sp. (Kembung Fish / Long Jawed Mackerel)

Habitat and distribution of Rastrelliger Sp. (Kembung Fish / Long Jawed

Figure 1. 4 Distribution of Long Jawed Mackerel in the world (FAO)

Distribution in Indonesia is widely available in the side between Java

(2015) 938,991 tonnes

1.5 Plant Location Analysis

1.5.1 Proximity to the Raw Material Source Location

1.5.2 Proximity to Market Location Products Company

performance in various aspects of the economy. So, East Java it is a potential

Table 1. 5 Number of Unemployment People in East Java

Registered Job Vacancies Fulfillment

2014 295,495 247,180 185,801 109,694

Figure 1. 5 Plant Location

(Source : Google Maps)

2.1 Alternative Process

2.1.1 Degumming Process

2.1.2 Bleaching Process

1. Lower initial investment compared with other types of bleaching

2.2 Proses Selection

Table 2. 1 Parameter of Scoring for Selection Degumming Process

Reaction Time Results

The operation Medium Contain in

Table 2. 2 Scoring Result of Degumming Selection

2.3 Process Description

2.3.3 Dryer Pressing

The performance of the decanter may be controlled in two ways. It is

Figure 2. 1 Carbon Treatment Process

it can remove hydratable phosphatides and also non-hydratable phosphatides. The

2.3.5.3 Alkali Refining

Figure 2. 2 Alkali Refining Process

Other mechanisms are colour bodies adsorbed onto soap, phosphatides

2.3.5.4 Water Washing