How to ensure minimal downtime in high-volume palm oil processing at Kilang Sawit Bukit Bandi

In the specialist world of processing crude palm oil, one of the key metrics is the Oil Extraction Rate (OER) – how much oil you can get out of any given batch or harvest. The actual equipment is only part of the profitability equation.

DATE 2018-09-27
Kilang Sawit Bukit Bandi,

This is one of the reasons why the Kilang Sawit Bukit Bandi palm oil processing mill in Malaysia (part of the Ladang Rakyat Trengganu Sdn Bhd group of companies) has prioritized the multiple benefits available from Alfa Laval Performance Agreements.

Intelligent, pro-active service and maintenance can be just as vital a parameter as performance. For Kilang Sawit Bukit Bandi, for example, the entire operation would grind to a halt if the production-critical Alfa Laval decanter centrifuge at the heart of the D3 PRO separation process were to break down. As mill manager/chief engineer Mr Haji Matan Ibrahim points out, “we had only one decanter centrifuge, so we really need it to be in tip-top condition and to keep running all the time.”

 

8 years of successful reliability

This is why the mill has also made sure to benefit from the performance and revenue optimization provided by Alfa Laval Performance Agreements that have extended uninterrupted for over 8 years – to date.

As Mr Haji Matan Ibrahim reports, there has hardly been any downtime associated with the Alfa Laval installations since they were first brought on line in 2008. “We have no problems, even though our process is running 24 hours a day, non-stop. For us, the Performance Agreement means hardly any breakdowns – and immediate, prioritized action should they arise,” he explains. Prevention better than cure Key measures of the Alfa Laval Performance Agreements include the exclusive use of OEM parts, strict adherence to a proactive maintenance schedule, privileged discounts on parts and a renter floating unit programme to help keep the customer’s production running while any service work takes place.

 

Prevention better than cure

Key measures of the Alfa Laval Performance Agreements include the exclusive use of OEM parts, strict adherence to a proactive maintenance schedule, privileged discounts on parts and a renter floating unit programme to help keep the customer’s production running while any service work takes place.

 

Spare parts availability

The effective pre-planning pivotal in Alfa Laval Performance Agreements, also factors in the effective service lives of key parts so that these are made available even before the item needs to be replaced. This contributes still further to the Kilang Sawit Bukit Bandi goal of zero downtime.

 

No-surprises advantage, peace-of-mind benefits

For Kilang Sawit Bukit Bandi, this focus on prevention and performance brings significant benefits.

  • Easy availability of OEM spare parts that boost performance and extend equipment service life
  • Enhanced service life for downstream equipment
  • Earlier detection of technical problems keeps repairs to a minimum
  • Minimizing wear and tear reduces operating costs
  • Pre-agreed annual maintenance costs makes budgeting easier
  • Planned schedule of service visits minimizes production interruptions

By reducing or eliminating risk of costly downtime and processing interruptions, Alfa Laval Performance Agreements provide operators with considerably greater peace of mind.

Alfa Laval Performance Agreements provide the company with other profit-boosting and know-how-building benefits, too. These include special training sessions – both on-site and in the classroom – focused on trouble-shooting and maintenance to give mill personnel professional training. There are also quarterly inspections in which mill personnel take on a hands-on role in assessing the current state of the palm oil processing equipment, alongside Alfa Laval engineers.

Mill manager

Mill Manager/Chief Engineer of Kilang Sawit Bukit Bandi, Mr Haji Matan Ibrahim:

The normal oil loss rate in palm oil processing is 0.8–1.0%, but here at Bukit Bandi we’ve been able to achieve an average oil loss rate of 0.25–0.5%. This is 50% less than the norm, which gives us a big commercial advantage.
We have no problems, even though our process is running 24 hours a day, non-stop. For us, the Performance Agreement means hardly any breakdowns – and immediate, prioritized action should they arise.

Chief Executive of Ladang Rakyat Trengganu Sdn Bhd, Mr Che Ku Hafeez:

Alfa Laval experts really know what to do, how to repair things and how to deal with the problems. We insist on always going back to Alfa Laval for after-sales service … because we’ve proved that it’s cheaper in the long run.

Palm Oil Processing

Alfa Laval solutions are well-proven for palm oil installations with capacities of up to 3000 tons per day. The ability to achieve consistent uptime levels as well as exceptional processing results helps provide you with considerable peace of mind.

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