SOY OIL

PROCESSING
INDUSTRY

PRESENTED BY:
MALAYSIA BOLEH
RESEARCH &
CONSULTANCY

MALAYSIA BOLEH
RESEARCH &
CONSULTANCY

MALAYSIA BOLEH
RESEARCH & CONSULTANCY
1. MR. MOHD HILMI MOHD IDRIS
2. MS. ADLINA SNAWI
3. MR. MUHAMMAD SUFFIAN AHMAD
4. MR. ABDUL MAJID IBRAHIM
5. MR. SHAHRUDDIN KASSIM
6. MR. ZAKARIA ABU HASAN
7. MR. FAZIL MAT ZAIN
8. MS. ZURAIDAH KORNAIN
9. MS. ZAUYAH TARMIZZI
10. MR. MARZUKI ZAINAL ABIDIN

PROCESS FLOW
DIAGRAM

Process Flow Diagram

Testing

SEED UNLOADING &

CLEANING SECTION

Yard
Big Silos
Day Silo
screener
De-Stoner

PREPARATORY
SECTION

Cracker
Cooker
Flakers

SOLVENT EXTRACTION
PLANT

Dryer
Extractor
Economiser

WET DOC
cyclone

DT-DC
Screener
Oversized lump

Evaporator

Lump-crusher
Mixing & Packing

Stripper Cum Dryer

Storage
Tanks

CRUDE OIL

Storage
Tanks

DOC

SEED UNLOADING &

CLEANING SECTION

Testing

Yard

Big Silos

Day Silo

screener

De-Stoner

Cracker

Cooker

Flakers

Dryer

PREPARATORY
SECTION

SOLVENT EXTRACTION PLANT

Extractor

WET
DOC

DT-DC

cyclone
Economiser

Screener
Oversized
lump

Evaporator

Lump-crusher

Mixing &
Packing

Stripper Cum
Dryer

Storage
Tanks

CRUDE OIL

Storage
Tanks

DOC

MATERIAL FLOW
DIAGRAM (Hexane)

Material Flow Diagram

SOLVENT EXTRACTION
PLANT

(Miscella+Hexane)

(Jet + Chiller)

Extractor

DT-DC

Economiser

Cyclone

Evaporator

Stripper Cum Dryer

Condenser

Loss
Water-Solvent
Separator

MISCELLA

DOC

MAJOR WASTE
STREAMS/AREAS OF
LOSSES

MAJOR WASTE STREAMS/AREAS OF LOSSES

PROCESS
1
2

WASTE/LOSS

Conveyor & Bucket

Seed
Elevator
Transportation
Husk
Big Silo to Day Silo Stone

PLACES/AREAS

Preparatory
Section

Day Silo to
Screener

Cracked Seed
Dust
Husk

De-Stoner

Mud Balls
Stone

Mechanical
Cracker

NIL

Condensed
the soy seed

Cooker

Steam
Water

Flaking

Flakers

Soy Seed

Drying

Dryer

NIL

MAJOR WASTE STREAMS/AREAS OF LOSSES

PROCESS

PLACES/AREAS

WASTE/LOSS

Rotary Type
Extractor (RTE)

Hexane

10

Distillation

Hexane

Stripper

Hexane

Condenser

Hexane

11
12

Solvent
Extraction
(Crude Oil
Production)

Water/Solvent
Separator

13

14

Waste Water
Hexane
Hexane
Moisture
Heat

Desolvent
DT-DC
(De-Oiled Cake
Production)

Moisture
Heat

15

Cooling

16

Seaving

NIL

17

Packaging

NIL

FISHBONE DIAGRAM

FISHBONE DIAGRAM
Economiser

Leakage
Hexane supply
system

Evaporator

MACHINE

Chiller
condenser

Hexane/water
seperator
Stripper
(Dryer)

ENVIRONMENT
RTE

Jetcon

Poor air
quality

Inefficient
machine

Process control
not effective

RTE

Poor soy
seed quality

Poor hexane
quality

Poor equipment
calibration
METHOD

Hexane
recovery
system

DT-DC

High
humidity

No standard
operating
procedure

Hexane
Loss

MATERIAL

Human
error

Lack of
training
Lack of
motivation

Poor steam
quality
MAN

PROPOSED
GP OPTIONS

GP OPTIONS

GP OPTION

DESCRIPTION

Up to date & efficient machine

1 NEW EQUIPMENT Upgrade
Total Preventive Maintenance

NEW MATERIAL/
CHEMICAL

Replace Hexane (hexane is

hazardous to health,
substitute
with more environmental
friendly chemical)
Better quality of soy seed

ALTERNATIVE
SUPPLIER

To supply better quality of soy

seed

4 METHODOLOGY

Develop Standard Operating

Procedures (SOP)
Implement EMS (ISO 14001)
Equipment calibration

GP OBJECTIVES
& TARGETS

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAM

SOY BEAN OIL REFINING PROCESS
1
OBJECTIVE

2
TARGET

3
PROGRAM

1.1
Minimise
Hexane
Usage

2.1
Reduce
consumption
by 10%
within one (1)
year

3.1.1
Maintenance (Total
Productivity Maintenance
TPM)
Condition-based Maintenance
- CBM

3.1.2
Improve Calibration of
equipment

5
ACTION
RESPONSIBLE
PERSONS
4.1.1
5.1
Implement TPM & 5.1.1
CBM
Head of Dept
5.1.2
Maintenance Mgr
5.1.3
Maintenance
Technicians
5.1.4
Contractors
4.1.2
5.1.2
Scheduled
Approved Calibration
calibration
Agency or Company

6
TIME
FRAME
6.1.1
Start
Immediately
& monitor
within one (1)
year.
Annual
review.

6.1.2
Continuousbased on
equipment
validity
3.1.3
4.1.3
5.1.3
6.1.3
Replace old and unreliable
Reliablity Trending Maintenance Manager Continuousequipment
and Analysis
based on
equipment
condition and
technoeconomics
3.1.4
4.1.4
5.1.4
6.1.4
Improve Hexane Quality from Testing of raw
Testing
One (1) year.
Supplier
material
engineer/technician
Annual
review.

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAM

SOY BEAN OIL REFINING PROCESS
1

OBJECTI
VE

TARGET

PROGRAM

ACTION

RESPONSIBLE
PERSONS

TIME
FRAME

1.2
Reduce
moisture
content
in seed

2.2
Reduce
moisture
to
minimum
acceptabl
e limits

3.2
Incoming
seed
testing

4.2.1
Enforce
Contract
Specifica
tions
4.2.2
Test for
moisture
at
Incoming
Goods

5.2
5.2.1
Head of Dept
5.2.2
Testing Mgr
5.2.3
Testing
engineer/technici
an
5.2.4
Contractors

6.2
Start
Immedia
tely &
monitor
within
one (1)
year.
Annual
review.

1.3
Reduce
husk
content
in seed

2.3
Reduce
husk to
minimum
acceptabl
e limits

3.3
Incoming
seed
testing

4.3.1
Enforce
Contract
Specifica
tions
4.3.2
Test for
husk at
Incoming
Goods

5.3
5.3.1
Head of Dept
Contract &
Operations Sect
5.3.2
Testing Mgr
5.3.3
Testing
engineer/technici
an
5.3.4
Contractors

6.3
Start
Immedia
tely &
monitor
within
one (1)
year.
Annual
review.

GP CONSULTANCY REPORT BY MALAYSIA BOLEH TEAM

SOY BEAN OIL REFINING PROCESS

OBJECTI
VE

TARGET

PROGRAM

ACTION

RESPONSIBLE
PERSONS

TIME
FRAME

1.4
Optimise
flake
thicknes
s in
Flaker

2.4
Optimis
e flake
to
accepta
ble
limits

3.4
3.4.1
Implement
TPM & CBM
3.4.2
Measure
flake
thickness
3.4.3
Ensure
reliability
of
equipment

4.4.1
Use TPM
4.4.2
Testing
for flake
thicknes
s using
specialis
ed tools.
4.4.3
Use
good
quality
equipme
nt

5.4
5.4.1
Head of Dept
Contract &
Operations Sect
5.4.2
Testing Mgr
5.4.3
Testing
engineer/technicia
n
5.4.4
Contractors

6.4
Start
Immediat
ely &
monitor
within
one (1)
year.
Annual
review.

GP POLICY

GP : POLICY
We are committed to :
1. Answer the societal demands for
higher productivity in a sustainable
manner with preserving the
environment.
2. Ensure the natural environment on
which society depends is not
degraded and polluted.
3. Make a better and cost-effective
approach in implementing efficient and
innovative GP solution.
4. Assist other companies in gaining
their competitive advantages and costeffective reduction of waste and
emissions.