1. 1
Contents
Chapter One...................................................................................................................................4
1.0 CAMEROON DEVELOPMENT CORPORATION – GENERAL INTRODUCTION......................................4
1.1 CDC MAJOR CROPS..................................................................................................................5
1.2 ORGANISATIONAL STRUCTURE OF CDC.......................................................................................5
Chapter Two.....................................................................................................................................11
2.0 IDENAU INDUSTRIAL MILL........................................................................................................11
2.1 Palm Oil Process line................................................................................................................11
2.1.1 The SecurityPost/Gate......................................................................................................11
2.1.2 The Weigh Bridge..............................................................................................................11
2.1.3 The Ramp .........................................................................................................................12
2.1.4 Sterilization of Bunches.....................................................................................................12
2.1.5 Camp stand/Hoist .............................................................................................................13
2.1.6 Bunch Thresher.................................................................................................................13
2.1.7 Digestion of the Fruits.......................................................................................................13
2.1.8 At the Press ......................................................................................................................13
2.2 Clarification.............................................................................................................................14
2.2.1 Desanding tank.................................................................................................................14
2.2.2 Vibrating Screen................................................................................................................14
2.2.3 Pre heater tank.................................................................................................................14
2.2.4 Continuous Settling Tank...................................................................................................14
2.2.5 Sludge tank.......................................................................................................................14
2.2.6 Sludge separator...............................................................................................................14
2.2.7 Clean oil tank....................................................................................................................15
2.2.8 Purifiers............................................................................................................................15
2.2.9 Buffer tank .......................................................................................................................15
2.2.10 Vacuum dryer.................................................................................................................15
2.3 Storage...................................................................................................................................15
2.3.1 Storage and sales tank.......................................................................................................15
2.3.2 Bottling............................................................................................................................15
2.4 Palm Kernel Processing............................................................................................................15
2.4.1Press cake breaker conveyor..............................................................................................15

2. 2
2.4.2 De-pericapper...................................................................................................................16
2.4.3 Polishing drum..................................................................................................................16
2.4.4 Nut conditioner.................................................................................................................16
2.4.5 Cracker.............................................................................................................................16
2.4.6 Kernel silo.........................................................................................................................17
2.4.7 Bagging station.................................................................................................................17
2.4.8 Kernel store......................................................................................................................17
Chapter Three ..................................................................................................................................19
3.0 The Boiler...............................................................................................................................19
3.1 Water Softener Plant...............................................................................................................19
3.1.1 Regeneration of Resins......................................................................................................19
3.2 Boiler Operations ....................................................................................................................20
Chapter Four....................................................................................................................................21
4.0 Quality control/the laboratory - Brief Introduction....................................................................21
4.1 Hardness Test.........................................................................................................................21
4.2 Chemical Test..........................................................................................................................22
4.2.1 Test for moisture content..................................................................................................22
4.2.2 DIRT CONTENT..................................................................................................................22
4.2.3 Test for FFA..........................................................................................................................23
4.3 EVALUATION OF OIL LOSSES AT VARIOUS STATIONS..................................................................23
4.3.1 CHEMICAL EXTRACTION.....................................................................................................23
4.3.2 PRESS CAKE ANALYSIS .......................................................................................................24
4.4 KERNEL ANALYSIS....................................................................................................................24
4.4.1. Kernel losses....................................................................................................................24
4.4.2. Kernel losses in dry shell...................................................................................................24
4.4.3. Palm Kernel quality control...............................................................................................24
4.4.4. BROKEN PHASE................................................................................................................25
4.4.5. COLORATION...................................................................................................................25
4.4.6. FFA AND MOISTURE CONTENT OF KERNEL OIL...................................................................25
CHAPTER Five...................................................................................................................................26
5.0 Conclusion and Recommendation ............................................................................................26
5.1 Recommendations ..................................................................................................................26
5.1.1 At the processline ............................................................................................................26

3. 3
5.1.2 At the Laboratory..............................................................................................................27
5.1.3 General Recommendation.................................................................................................27
REFERENCES AND ABBBREVIATIONS........................................................................................................28

4. 4
Chapter One
1.0 CAMEROON DEVELOPMENT CORPORATION – GENERAL INTRODUCTION
It isa publicestablishmentincorporatedin1947 toacquire,developandoperate extensive plantationsof
tropical crops namely rubber, oil, palm kernel and banana in the littoral and south west regions. From
these crops,itproducessemi-finishedrubber,palmoil,palmkernelandtopgrade ediblebananaforlocal
and export market.
The CDC employs close to 22000 people making it the second largest employer in Cameroon after the
state. In line with government policy, the corporation creates jobs, rural development and plays a vital
role in nation building.
The corporationissuedshare capitalis 35.7billionFCFA.TheCDCissolelyownedbythestate of Cameroon
under the technical supervision of the Ministry of Agriculture and Rural Development and the financial
tutelage of the ministry of finance.
The CDC carries out activities which go beyond her scope in a bid to employ, their familiesand their
communities at large.
Some publicutilityservicesthatthe corporationprovidesincludesportable water,bore holesinMatouke
rubberprojectandBoa plains,free electricity,recreational andtoiletfacilitiesalso make upthispackage.
Road maintenance is a duty par excellence of the technical service department through-out
the corporation.
Educationwise,theCDChasputinplace awell-coordinatedstrategy, toensurethe educationof kidsliving
in and around her plantation. Children and dependence of CDC workers on one hand and on the other
hand benefit from savoir-faire of teachers employed by the CDC. As well the construction by the
engineering and technicians of the corporation.
To further empower the population, the CDC has put in place a small holder scheme which is
operatedinthe palmoil andrubbersector.Itis awin-winpartnershipthroughwhich hundreds of farmers
produce and sell to CDC at the prize that prevails at the time of the transaction.The scheme empowers
farmers financially by educating them on how to obtain high quality yields, improve productivity and
maximize their income or a sustainable basis.
The CDCimplementsahuge scale of activitiesto achievecontinuousimprovementof healthcare of
her employees with two hospitals, a clinic and 68 health post spread across the twenty estates of the
corporation, medical services are provided to workers, their dependence and the general public.

5. 5
1.1 CDC MAJOR CROPS
As mentionedabove,the CDChas 3 main crops whichare rubber, oil palm and banana. These crops are
divided into groups, departments with-in the corporation.
A. GROUP RUBBER DEPARTMENT
The group is headed by the group rubber manager (GRM). There are ten estatesand one project in this
sector as follows; MUKONJE, TOMBEL, KOMPINA, MISELLELE, MEANJA, MATOUKE rubber projects.
B. OIL PALM GROUP
There are three mainoilmillsatMondoni,IlloaniandIdenauwhere crops(FFB) are processedintofinished
products for the local market.
C. BANANA GROUP
The banana group is headed by a group banana manager (GBN). The group comprises of 5 states,
Mafounja, Mondoni, Benoe, Nddongo, Moquo estate by other services such as engineering, human
resources,medical,marketing,logistic.Researchandaccountingservice,the objective of the groupis to
produce quality banana for local and external marketing.
1.2 ORGANISATIONAL STRUCTURE OF CDC
BOARD OF DIRECTORS
The board of directorsof the companyconsistof membersfromthe civil service orfromthe government.
The objective istoscrutinize,approveandadoptpoliciesleddownbytopmanagement.The boardisalso
responsible of making proposals in appointing the general manager and also to evaluate and appraise
him/her when necessary.
ADMINISTRATION
Administrationaffairsare managedat the headoffice at Bota, Limbe.The head office setpoliciesof the
corporation and coordinates all activities. The unit under the head office includes;
- General Manager office
- Human resource department
- Finance department
- Information system department
- Marketing and sales services
- Inspection and control department

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- Technical services department
THE GENERAL MANAGER’S OFFICE
The GM’s office coordinatesthe managementof the corporation.Thisofficeissupportedbythe secretary
and the support staff or offices that assist the GMin his duties. They include;
- Attaches and technical advisers to GM
- Head office management control
- Plan, environmental, research and quality
- Communication and public relations services
- Security services
HEAD OFFICE MANAGEMENT COTROLLER
The main objective of the department is the production of the annual budget of the corporation,
monitoring actual cost against estimates and ensuring that the corporation objective as defined if the
budget plans are realized.
PLAN, ENVIRONMENTAL, RESEARCH, QUALITY
The plan and development department set and followedup the implementation of the corporationten
years strategic plan; initiated, coordinated and monitored the realization of projects and plantation
development in the corporation. The department had addition responsibilities in the development and
expansion of plantation such as the Donga Matung, and Manyu projects and in providing technical
assistance to existing palm oil, small holders and in sensitizing more farmers to join the small holders’
scheme.
THE COMMUNICATION/ PUBLIC RELATIONS SERVICES
This service is responsible for public relation to provide information about CDC to management,
employee, and to the society. It is also in charge of all CDC publication and publicities.
HUMAN RESOURCES DEPARTMENT
This department is in charge of formulating and coordinating all related issues and activities within the
corporation. It has a training service which carries out continuous training and retraining of CDC
personnel. Its main functions are selection, recruitment, and appraisal of worker

7. 7
FINANCE DEPARTMENT
Thisdepartmentisincharge of all the financial transactionof the corporation.Italsokeepsrecordsof all
financial transactions and prepares all accounts of the corporation. It is responsible for the payment of
wages and salaries to workers.
INFORMATION SYSTEM DEPARTMENT
This department provides computer services to the corporation and also carries out installation and
maintenance of hardware.The ISD designs and developsapplicationsto meet the requirementof users
department.
INSPECTION AND CONTROL
This department is responsible for all internal auditing for the corporation. This provides guidelines for
the proper functioning and monitoring of all operations by carrying out routine auditing assignment.
SECURITY SERVICES
The service coordinates all aspects of security and protection to the corporation.
MARKETING AND SALES SERVICES
It comprises of rubber sales, palm oil sales, banana marketing and support department.
a. Rubber sales deals with the marketing of rubber to foreign customers
b. Palm oil sales offers three products mainly; palm kernel, loose palm oil and palm kernel to the
local consumers.
c. The banana marketing sales banana to the local and export market. CDC banana is marketed
underthe followbrandnames/range:MAKOSSA BANANA,SAWA BANANA, andTIKOBANANA.Theyalso
had local banana for the sub regional and local market.
d. The supplies department primary function to obtain for the corporation everything it needs to
carry outits activities.The departmentpurchasedcapital assetssuchasplant,machinery,motorvehicle,
office equipment, tools and appliances of every kind, consumables, lubricants and more.

8. 8
MEDICAL AND HEALTH SERVICES
The mission of the MHS is to maintain healthy work force and environment. The department has two
hospitals,17 clinics,68aidpoints,anintergradedhealthcenteranda cercie d’orfor familyplanning.CDC
also out sources some medical services notably OPHTHALMOLOGY, CARDIOLOGY and Dental surgery.
Patience are equallyreferredtogeneral hospital Doualaand Lanquintini;andexceptional casesworkers
are evacuated to Europe for proper medical care.
TECHNICAL SERVICES
It isresponsible forprovidingengineeringservicestothe cropgroupsanddepartmentof the corporation.
It is made of the following engineering units;
CIVIL/ WATER WORK SERVICES
It is responsible for;
- Construction and maintenance of buildings, roads and bridges
- Production of office furniture
- Construction and maintenance of water intakes and treatment stations
- Construction and management of water distribution network.
ELECTRICAL AND ELECTRONIC SERVICES
The service is responsible for;
- Area electrification and maintenance of electrical networks and electronic components.
- Management of CDC communication units and base stations.
- Monitoring of electrical and telephone consumption.
- Maintenance and service of weigh bridge
MECHANICAL ENGINEERING WORKSHOP
Itisresponsibleforallmechanical worksinthe corporation.Italsotakescare of the fabricationof machine
parts, maintenance of cars-tractors and heavy equipment.

9. 9
PLANT MAINTENANCE SERVICE
It is responsible for service management and repairs the generator sets and water pumps in the
corporation
SOCIAL AMENITIES
- Provision of houses to workers
- Provision of recreational facilities (clubs)
- Provision of portable water
- Electrification of houses
- Provision and maintenance of road networks
- Medical and health care
- Provisionof teachersandsome formof assistance tosome governmentwithinCDCenvironment
- Creation of a solidarity funds for HIV/AIDS patients
- Encourage workers to save in credit union by deduction at source.
In conclusion, the mission of CDC is to;
- Purchase, create, administer, operate and develop all undertakings in the field of husbandry for
production and processing of its products.
- To sell agriculturalproductsintheirraw statesorafter industrial processing,gradingandpacking.
- To assistsmall holdersor groupengagedinthe cultivationof cropssimilartothose cultivatedby
CDC.

10. 10
Fig 1: CDC General Organigram

11. 11
Chapter Two
2.0 IDENAU INDUSTRIAL MILL
Brief Introduction of the industrial Unit
The IdenauIndistrial unitstartedoperationsin1985. It islocatedin the SouthWest Regionof Cameroon
in the Fako divisionprecisely in the Idenausubdivision. It is one of three palm oil processing mills in the
Corporationanddealsessentialwiththe productionof low FreeFatty Acid(FFA) PalmOilaswellas kernel
nuts, which are sold mostly to companiesthat further process palm oil into other finished products like
cookingoil.The IIUoperatesona 21% extractionrate at peak season(February toJune) butcango down
to 17% at low peak seasons. The IIU has a labor force of about 160 workers.
The IIU processesthe Teneraspecie of palmfruitsbecause it producesmore oil and small kernel.Based
on my internship path I concentrated on the process line and the Laboratory
2.1 Palm Oil Process line
2.1.1 The Security Post/Gate
All FFB from the estates or local farm suppliers come into the IIU through the gate. The securitypeople
are in charge of the security of the IU as well as keeping records on anything leaving and entering the
compound.
2.1.2 The Weigh Bridge
The weigh bridge is a platform that automatically determines weight. It has a maximum capacity of 60
tons.
At the weigh bridge, the weight of FFB is determined so as to predict the amount of oil that would be
produced from the FFB entering into the IU. The weigh bridge is also used for the sales of palm oil and
kernel nuts.
To determine the weight of FFB the operator guides the truck through the following processes;
- The truck containing FFB mounts the platform and the gross weight is determined.
- The truck thengoes to the ramp and offloadsitscontentandreturnsto the platformemptyand
its tare weight is determined.
- The operatorthensubtracts the gross weightfromthe tare weighttodetermine the net weight
Net weight = Gross Weight – Tare Weight
The netweightgottenat thislevel will determine the total amount of oil that will be producedfromthe
FFB which on average will be 21% of the net weight.
For sales of palm oil and kernel nuts, the process is reversed.
- First an empty truck climbs on the platform and its tare weight is determined
- The truck thengoesto the storage tank and loadspalmoil or kernel nutsand thenclimbsonthe
platform and its tare weight is determined
- The operator then subtracts the gross weight from the tare weight to have the net weight.
Here the net weight is used to determine a selling price.

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2.1.3 The Ramp
The ramp at IIU isan openlandthat can containabout2000 tonsof FFB.The ramp isthe offloadingpoint
of FFB at the IIU. At the ramp, a laboratory technician carries out 6 quality control test on FFB which
include,
- Green Bunches: Produces more of sludge than oil because the process of oil formation in the
mesorcap is incomplete.
- Rotten Bunches: Produce more of sludge as well and also has a high content of FFA due to
enzymatic action.
- Empty Bunches: They absorb oil during sterilization
- Long stalk: They also absorb oil during sterilization and hence must be cut into a V-Shape
- ForeignBodies:Theyinvolvestones,sticksandotherbodiesthatare not neededandwhichmay
damage the machines
- Loose Fruits
The IIU usedtolevypenaltieson5of thisparameters excludingloosfruits.However,throughtheduration
of my internship the IU did not levy penalties on FFB.
The FFB are later transported unto the loading bay which are 4 in number. The loading bay each have
hydraulicdoorswhichcanopenandfillthe cageswhich cancontain2.5tonsof FFB.The forklifttransports
the cages onto the bulky wheel which transports the cages on rails into the sterilizer.
*** It is important to note that handling off FFB at the ramp greatly determines the final FFA content in
palm oil. Research shows that bruising causes an increase in FFA up to 60% in the bruised area
(http://www.fao.org/docrep/005/y4355e/y4355e04.htm). Also delay in sterilization would also increase
enzyme action and hence FFA in palm oil. So in essence operation at the ramp determines the quality of
oil produced to a greater extend.
2.1.4 Sterilization of Bunches
At the IIU there are two sterilizer that can contain a maximum of 10 cages each (each cage can contain
2.5 tons of FFB). However during the internship onlyone sterilizer was working and was taking 6 cages
averagely.
Sterilization is cooking the FFB and at the IIU it is done with wet steam from the boiler at high
temperatures at about 2.5 bars. Sterilization serves the following purposes:
- The hightemperature destroysoil-splitting enzymes and arrests hydrolysis and auto-oxidation
- The wet heatweakensthe fruit stems and makes it easier for it to be removed by the thresher
- Heat helps to solidify proteins in which the oil-bearing cells are microscopically dispersed.The
protein solidification (coagulation) allows the oil-bearing cells to come together and flow more
easily on application of pressure.
- The heat weakens the pulp structure making the removal of fibre easy. The heat also burst oil
containing cells in the mesocarp making it easy for oil to flow readily
- The increase and reduction of pressure causesthe moisture in the nuts to expand and contract
causing the detachment of the kernels within their shells.
The IIU uses the triple peak system of sterilization which is as follows:

13. 13
- Venting:This is the periodical openingof valvestoallow the release of steamat the pressure of
1bar and 1.5 bar. Ventingisavery crucial stepinsterilizationasithelpsto ameliorate the process
of sterilizationbyremovingwaterpresentinthe FFB,anddirt.Ventingisusuallydone for45mins.
- The holding period: This period follows after venting at 1.5 bar. The condensate valves and the
steamvalvesare closeduntil a pressure of 2.5 bar. This occurs at a temperature of 140O
C forthe
remaining 45 minutes.
- Blow down stage: This is always carried out at the end of the sterilization process after all the
majorvalveshave beenopenedtoallow the exitof steamandaconsequentdropof the pressure
to zero bar, thereby facilitating the release of the sterilized FFB prior to threshing.
It is importantto note that sterilizationisaveryimportantstage as itinfluencesthe successof the other
stages.Howeverithassome badeffectssuchasdiscolourationof palmkernels,reductionof proteinvalue
at the press cake and low bleaching ability of extracted oil.
2.1.5 Camp stand/Hoist
The cages are pulledoutfromthe sterilizerandassembled atthe camp stand by a Fork liftCaterpillar.A
mobile crane at the top of the building hoists the cages and tips them into the thresher drum.
2.1.6 Bunch Thresher
The bunch thresher is a rotating drum that vibrates and separates the fruits from the husk. The husk is
transported on a belt conveyor into a truck or on the floor, where it is carriedto a disposal ground.The
fruits meanwhile are carried by a bucket elevator conveyor from the bottom of the drum into a screw
conveyorthatcarriesthe fruitsintothe digester.If the digestersare full,the fruitscome outatthe endof
the screw conveyor into another conveyor beneath that transports the fruits back into the threshing
drum.
2.1.7 Digestion of the Fruits
Digestion is the removal of palm oil from the fruits by rupturing the oil containing cells. The IIU has 3
digesters(only2were functionalduring the internship).They consistsof asteam-heatedcylindricalvessel
fitted with a central rotating shaft carryinga number of beater (stirring) arms that destroys the exocarp
and oil containgcellsaswell asreducesthe viscosityof the oil. The process takes 20-30 mins at 95-98O
C.
2.1.8 At the Press
The purpose of mashingisto separate the pulpand nut and crush the palm pulp.At the same time,the
steamis used to cook the palm fruitand broke the cell of pulp.Because of cooking,sterilizing,threshing
and mashing,the pulp becomessoftand the cell structure weakensandthe oil containing cell isbroken.
Hot water is passes in the press to carry the oil and reduce its viscosity. After pressing, oil palm fruit is
dividedintotwoparts: the mixture of oil,water and solidimpurities,andthe presscake (fiberand nut).
The presscake fallsbygravityintothe screwconveyorintothe presscake breakerwhilethe oilandsludge
goes into the “desanding tank”.
The IIU has 3 presses.2havinga 10 toncapacity and one witha capacity of 15 ton.Duringthe internship
just one 10 ton and the 15 ton press was working making production to be at 25tonnes/hr. The
temperature ismaintainedat90-95%. In case the waterbecomes toohot the cold watervalve isopened
to lower the temperature.

14. 14
2.2 Clarification
The mainpointof clarificationprocessisseparatingthe oil fromitsentrainedimpurities.There are three
main functions of clarification process which to control the quality of oil, minimize oil loss in sludge or
water phase and essential for effective oil separation. This unit consist parts; the de-sanding tank, the
vibrating screen, crude oil tank ,preheater, continuous settling tank, the sludge tank, the clean oil tank,
the purifiers, vacuum dryer and sludge separators.
2.2.1 Desanding tank
The crude palmoil (CPO) fromthe pressesconsistsof amixture of palm oil (35%- 45%), water(45%-55%)
and fibrous materials in varying proportions. This tank is responsible for the removal of sand after it
accumulates at the bottom.It has steamcoils that helpstomaintain the temperature between60-80O
C,
to reduce the oil density and thus facilitates oil separation from sand, fibres and dirt particles which
percolate to the bottomwhile the oil floatsat the top. The bottom of the tank is openedfora 2hours to
completely remove the sand, fibers and dirt particles in the oil to avoid abrasion of the other units.
2.2.2 Vibrating Screen
It is a circularstructure whichpossessesasieve of about1mm in diameterspacingpoweredbya pump.
As the screenvibratesthe meshretainsthe largerparticlessuch asdirt particles,fiberspresentinthe oil,
fall into the screw conveyorby gravityto be recycled.Due to this vibration,the oil drainsinto the crude
oil tank and is pumped to the preheater tank.
2.2.3 Pre heater tank
It contains steamcoils that carry steamand it separatesoil fromother componentsbydensity.The oil is
heatedinthistanktoa temperature of 98-1000
C toprepare the oil forseparation.Itisatthisstage where
moisture startsbeingsentoff.The tankhas an openingatthe topfor moisture loss.The heatedcrude oil
enters into the continuous settling tank by gravity.
2.2.4 Continuous Settling Tank
The heatedcrude oil entersintothe tank,wherethe crude oil isseparatedfromnon-oilymatter.Cleanoil
floatsand siphons intothe cleanoil tank, while the dense non-oilypartsettlesatthe bottom,flowsinto
the sludge tank.Thisis knownasthe oilysludge .The oilysludge isthenpassedintorotarybrushstrainer
to remove remaining fibers, debris and calyx before it enters the sludge separator.
2.2.5 Sludge tank
This tank is made up of two compartments. Oil leaving the continuous settling tank enters through the
top of the tank and falls by gravity to the bottom. The sludge is then pumped intothe desanding hydro
cyclone situated at the top of the sludge tank, where the remaining sand in the oil is removed and falls
into the second compartment. Besides, the first compartment is a rotary strainer through which the oil
goesintothe sludge separator.The rotatory strainerhelpstoremove fibersinthe oil beforeitentersthe
sludge separator.
2.2.6 Sludge separator
Oil from the rotary strainer enters into the “alpha-laval” (centrifuge), for separation. This centrifugal
processhelpstoreduce oillosses.Itseparatestheoil fromthe sludge.Before thesludgeentersthe sludge
separator,hotwaterisadded toittofacilitate separation.Also,the temperatureusedmustbe maintained

15. 15
between70-70
Cforefficientseparation.The minimumquantityof oilinthe sludge mustnotbe more than
17%.The waste after separation flows to the sludge pit.
2.2.7 Clean oil tank
It holdsthe oil priortopurification.Itisalwaysopenatthe toptopermitmoisture loss.The temperature
inthe tankis maintainedat98-1000
C, so that substancesinthe waterevaporate.The oil now goestothe
oil heaters for evaporation.
- Oil Heaters: Temperature of the oil is raised to 1000
C to enhance evaporation.
2.2.8 Purifiers
It receivesoil fromthe clean oil.Impurities suchas dirt,moisture andnon-oilysubstances are removed.
2.2.9 Buffer tank
This tank has an opening at the top, to ease the escape of some of the moisture before it goes to the
vacuum dryer.
2.2.10 Vacuum dryer
The unithelpstodrythe oil sothatalmostall the moisture inthe oil isremovedandshelflifeisincreased.
Drying is done at low pressure and high temperature .The oil is dried at a temperature of 120O
C and a
pressure of 0.8bars for efficient drying of the oil.
2.3 Storage
2.3.1 Storage and sales tank
The oil isthenpumpedintothe storage tankorsalestank,whenneed arises.The oilstaysinthe salestank
for 14-18 days to settle before it is bottled.
2.3.2 Bottling
The oil is filled in the bottling tank and allowed to settle for 14-18 days. The organoleptic properties,
chemical analysisandphysical parametersare evaluatedtoensure thatthe qualityof oil isuptostandard
before bottling. The colour of the oil must be bright red and odorless, while the FFA content must not
exceed3.5%.The dirtandmoisturecontentmustnotexceed0.02and0.2% respectively.The oilis filledin
plastic containers have a capacity of 5 and 20 liters.
After bottling, the packaged oil is kept in the store prior to transportation and distribution.
2.4 Palm Kernel Processing
2.4.1Press cake breaker conveyor
This conveyor has propeller knivesto stir and loosen the press cake.It conveysthe press cake from the
pressto the nut-fiberseparator. Thisconveyorhassteaminjectors(jackets) throughwhichsteampasses
to dry the press cake, and also detaches the fibers from the nut, enabling the fiber cyclone to easily
aspirate the fiber.Thisis because the moisture of fibersreducestoa certainminimummoisture content
that can easily be sucked by the suction fan.

16. 16
2.4.2 De-pericapper
Thisseparatesthe nutsfromthe fiberthroughawinnowingsystemin acolumn.The lighterparticlessuch
as the fibersandverysmall particlesof kernelsandshellsare alsoabsorbedto the fibercyclone through
the suction fan. This fan has a precise air velocity and a flow rate to be able to absorb only the lighter
particles into the fiber cyclone. The fiber collected goes to the boiler to serve as fuel.
At this point,the weightof the fiber is critical because,if the weightis higherthan expected, much of the
fiber will fall by gravity into the polishing drum.
The tubesthroughwhichthe fibersare suckedintothe fibercyclone have holesonthemwhichaffect the
absorption process.
2.4.3 Polishing drum
The nuts are polished and sent to the nut silos for drying then cracking. Here, stones sticks and large
fibersfromEFBbunchesfall atthe endof the drum.Thisdrum alsohasperforationsforseparationof the
mature and immature nuts.The mature ones go to the nut siloforconditioning,while the immatureare
collected and used at the boiler as a source of fuel.
The separation is because the immature nuts produce low kernel oil.
- Wet Nut elevator: conveys the nuts from the polishing drum to the nut silo.
2.4.4 Nut conditioner
Thisis a silothatusesdry steam to heatthe nutsand equallycoolsthe nutsbefore cracking.The silohas
steaminjectorsthroughwhich the dry steampassesto heat the nuts while the fancirculatesthe hot air
toall partsof the silo priortocracking.Hence,leading tohighnutcrackingefficiency.The nutsare retained
only for a period of time. The temperature of the silo is about 60-700C.
- Dry Nutelevator: It hasa magnetto attract ferrousmaterials.It conveysnutsfromthe discharge
screws under the silo to the cracker.
2.4.5 Cracker
There are two typesof crackers used here:the Ripple mill and the Supreme nut cracker. The ripple mill
is mostly used now. It has rods and ripple plate. The distance between these two parts needs to be
adjustedall the timesaccordingtothe sizesof nuts.The crackedmixturemade upof kernels,looseshells,
and partly cracked nuts goes to the winnowing column through the cracked mixture conveyor.
The ripple mill usedisable tocrack both the mature and immature teneranuts.Hence,the perforations
forthe immature nutsatthe polishingdrumhavebeenreducedtopermitboththe mature andimmature
nuts to be cracked. The kernel contains loose shells and broken kernels.
The mechanism is as follows:
- Winnowing column: This involves separation of kernels from the shells and other dirt materials.
This operates on the same principle as the nut fiber separator, whereby, suction fan absorbs
lighter particles such as shells and broken kernels, while the heavier kernel falls into the kernel
rotor lockby gravity.The kernel rotorlockrationalizesthe quantityof kernelstobe blownbythe
kernel transporter (blower) into the kernel silo.
The shellsabsorbedare sentto the boilertoserve as biomassfuel throughthe shell cyclone.Laboratory
analysis are done to know the quantity of palm kernel loss to the dry shells. The weight of the kernel is
very critical.

17. 17
The tubesthroughwhichthe shellsare suckedinto the fibercyclone have holesonthemwhichaffectthe
absorption process.
2.4.6 Kernel silo
Thisworkson the same principle asthe nutsilo.The temperature here mustbe inthe range 60-700
C.The
kernel isallowedtodry for a periodof time before it is bagged.It also has heatingcoilsand a fan which
helpsto dry the kernelspriorto bagging.The heatingcoilspermitsteamto flow throughthem while the
fan circulates hot air to all the corners of the silo.
2.4.7 Bagging station
The kernelsare filled into40kg bagsand keptinthe kernel store.The kernels deteriorate wheninthe silo
and evenafterbagging.Whenthe kernelsare placedinbags,the bagsbecome wetand warmdue to the
high moisture content of the kernels. The presence of moisture also favours the growth of molds and
increases enzyme action.
The screwconveyorbelowthekernelsilo, conveysthekernels to thebagging station areworn outand are
non-functional.Hence,during bagging thedischargescrewsareopened and thekernelsfalldirectly to the
ground beforeit is bagged.This leads to the contamination of kernelsby dust,stones,sand found on the
floor.
2.4.8 Kernel store
This is an open area where the bags are kept prior to transportation to Mondoni or sold to potential
buyers such as Azur. The bags are in direct contact with the floor which leads to further increase in
moisture content of the kernels. The bags are kept at room temperature of 20-250C.
Unit Operation Purposes
Fruit fermentation To loosen fruit base from spikelet and to allow
ripening processes to abate
Bunch chopping To facilitate manual removal of fruit
Fruit sorting To remove and sort fruit from spikelet
Fruit boiling To sterilize and stop enzymatic spoilage,
coagulate protein and expose microscopic oil
cells
Fruit digestion To rupture oil-bearing cells to allow oil flow
during extraction while separating fibre from
nuts
Mash pressing To release fluid palm oil using applied pressure
on ruptured cellular contents
Fibre-nut separation To separate de-oiled fibre from palm nuts.

18. 18
Second Pressing To recover residual oil for use as soap stock
Nut drying To sun dry nuts for later cracking
Centrifugation Separates oil from sludge
Fig: Palm Oil Processing Flow Diagram

19. 19
Chapter Three
3.0 The Boiler
Atthe IIUboileristhe mainsource of power.Itproducessteamthatisusedtoturnthe turbine togenerate
electricity,italso produces steamthatissuppliedtothe sterilizerandheatingcoilsof the operatingunits
in the factory.
The boiler at the IIU is a Water tube boiler. Water flows inside tubes and the tubes are heated by hot
gases of combustion. The fuel used at the heat source is fibres as well as kernel shells.
3.1 Water Softener Plant
Water entering the boiler should be soft water. The softener plant is made up of two cylinders working
independently.Theyactlike ionexchangers.The cylinders containnegativelychargedresins.Hardwater
(containingMg2+
and Ca2+
) fromthe filtrationunitenters the cylinderthroughpipes.NaClsolutionfroma
drum is injectedintothe cylindercountercurrently.The resinattract the Na ionswhile the chloride ions
reactwithwaterandflowoutlike weakhypochlorousacid.The resinshave ahigheraffinityforCaandMg
ion and hence release the Na ions that go into solution and pass out of the cylinder intothe boiler feed
tank. When the resins become saturated with Ca and Mg ions, the cylinder becomes hard. This is
determinedbyalaboratorytestthatwe will seelater.The saturatedcylinder isswitchedoff andthe other
cylinder takes over.
3.1.1 Regeneration of Resins
When one of the cylinders become saturated with Ca and Mg ions, we say it is “hard” at the IIU. So in
orderto de-saturate the cylinder, we have to “regenerate the resins”. It takes place in four processes;
- Backwash: To eliminate mud particles from the resins. Water stored in the cylinder is
allowed to flow with pressure removing all the mud particles in the cylinder.
- 100 kgon NaCl solutionisinjectedintothe cylinder.NaionsishigherthanMg andCa ion
in the cationic series and hence will displace Ca and Mg ions.
- Slow rinse: This is to eliminate chloride ions
- Fast rinse: This is process also removes chloride ions but at a higher pressure
*** It isimportanttonote thatNa ionsjustlike MgandCa ionsare harmful tothe boiler.Howeverthe Na
ionswill reactwithCO2 toformSodiumCarbonate whichwillnotbreakdownonheatingatthe boilerbut
will settle beneath the tanks.
Na + CO2 NaCO3(S)
NaCO3 no reaction
However, when Ca and Mg ions react with CO2 to form their carbonates, this carbonates further
breakdown at the boiler to produce oxides that will corrode the tubes of the boiler.
So Na ions is the better of both evil.
Ca + CO2 CaCO3(s)
CaCO3 CaO(s) + CO2(g)

20. 20
3.2 Boiler Operations
Water from the boiler feed tank enters the boiler unit through the dilator that further removes O2 to
prevent corrosion in the boiler. An oxygen scavenger (DIA-PROSIM™ 830).The alkalizing agent( CIP-2) is
usedto increase alkalinityinthe boilertohelpavoidcorrosionbymakingthe wallsof the boilerslippery.
If the total alkalinity in the boiler surpasses 120ppm, blow down valves are used to reduce alkalinity
The IIU boiler has about 578 pipes according to the operator. Water enters the boiler unit into the top
drum.The water isheatedatabout250O
C. Hence,the drumcontains55% waterand45% of steam.Since
water is denser it settles down and goes through a pipe to a lower drum. From the lower drum water
enter the 578 pipes and are heated by gas from the heat source.
The steamfrom the boilerissentto the powerhouse where itturns a turbinestogenerate electricityas
well as into the factory where it heats the coils of the different units.
The Boiler has about 5 main fans
- Induced Draught Fan: It helps to send out the waste gases through the chimney.
- Force Draught Fan: It controls the ignition burning in the burners.
- Secondary air fan: It alsoignites burningbutitisrunnedonlywhenwetmaterial is used as fuel.
- Fuel Feeder Fan or Suction Farm: It aspirates fibres and shells into the burner.
Steam from the boiler goes to the accumulator in the power house. It is from the accumulator that it is
redistributed steam throughout the factory. Steam leaving the boiler is at 21bars when it enters the
accumulator. The temperature at the boiler is at 250O
C.
The Boilerhas3 soothe blowersthatblow outsoothe fromthe wallsof the pipesintothe chimneywhere
it is sent out as a waste gas.
Fig: Water tube boiler at the IIU

21. 21
Chapter Four
4.0 Quality control/the laboratory - Brief Introduction
The Laboratory is incharge of qualitycontrol and helpsto ensure the overall qualityof palmoil that has
beenextracted,monitorthe receptionof FFBat the ramp and check the efficiencyof the operatingunits
in the factory. The lab also checks oil losses in the process line.
Qualitycontrol testare carriedout on palmoil and kernel nutsbytakingsamplesatvariouspointsinthe
process line as well as on the final extracted oil.
There are six parameters used to determine the quality of palm oil. It has three physical and three
chemical test to determine oil quality;
Physical test
 The colour must be bright red
 The taste should be good
 It must be odourless except for its characteristic palm oil scent
Chemical test
 Moisture content
 Dirt content
 FFA content
The lab also conduct hardness test
4.1 Hardness Test
Procedure
- A petri dish was weigh
- 5g of palm oil was placed in the petri dish
- 50ml of ethanol was added
- The petri dish and its content was heated for the first bubbles this is in order to facilitate
extraction
- 3-5 drops of phenolphthaleinindicatoraddedandtitratedwith 0.1N sodiumhydroxide until the
end point
Observation/ Conclusion
The norms of FFA is 3.35%. A higherpercentage showsthat there is a higherlevel of FFA whichcouldbe
as a result of rotten fruits, contamination with water and air, no good or poor storage conditions.
If the colour is pink= Hardwater
If the colour is dark-blue= Softwater

22. 22
Fig: Diagram showing Soft water (left) and Hard water (right)
4.2 Chemical Test
4.2.1 Test for moisture content
Procedure
 Weight of empty dish was gotten
 10g of the sample was placed in the dish
 The dish was then placed in the oven for 2hours 30minutes
 It was then removed and placed in a desiccator for cooling
 The weight of the dry sample was then collected
Observation/Conclusion
WEIGHT OF SAMPLE= (wet sample + dish) - (dry sample + dish)
Moisture content= weight of wet sample – weight of the dry sample
%moisture content= Moisture Content/10 * 100
The norm of moisture content is 0.2
4.2.2 DIRT CONTENT
Procedure
 Micro filter paper was placed in a perforated crucible and weighed using a sensitive balance
 Hexane is later added unto the oil sample to reduce its viscosity
 The Oil is the poured into the perforated crucible. The filter paper traps dirt particles.
 The filter paper is dried in the oven and then weighed in a crucible.
Observation/Conclusion
Dirt content= Final weight of perforated crucible (containing dirt content) - Initial weight of perforated
crucible
%dirt content = dirt content/10 * 100

23. 23
4.2.3 Test for FFA
Procedure
 5g of palm oil was weighed and poured into a conical flask
 50ml of ethanol is added to the conical flask and heated at 80O
C until the first bubble appears.
 3-5 dropsof phenolphthaleinindicatorwasaddedintothe conical flask andtitratedagainst0.1N
sodium hydroxide until the appearance of a permanent orange colour.
 The end point here is noted and it corresponds to the volume of NaOH
Observation/Conclusion
The norms of FFA is 3.35%. A higherpercentage showsthatthere isa higherlevel of FFA whichcouldbe
as a result of rotten fruits, contamination with water and air, no good or poor storage conditions.
FFA = [Volume of NaOH * Normality (0.1N)* Molar Mass of Acid (25.6g)]/ Weight of Sample
4.3 EVALUATION OF OIL LOSSES AT VARIOUS STATIONS
4.3.1 CHEMICAL EXTRACTION
This evaluation seeks to ensure that the oil loss at each station respects the norms.
Samples were collected from the various stations for evaluation;
 10g was collected from fibres from the press and cyclone fibres respectively
 20g of nuts from the presses
 20g of bunch stalk
 50g of sludge (waste water)
Procedure
- The weightof the emptydisheswasnotedandthe disheswere thenfilledupwiththe sampleand
dried for 4 hours in the oven at a temperature of 103O
C except for the nuts that are dried for 2
hours. This is to eliminate moisture
- Afterovendriedsampleswereremovedandputinsidethe desiccatortocool andlaterreweighed
- The samples were later filled into thimbles and properly closedwith cotton wool and fitted into
extractors and attached in to a weighed flask. Hexane is used as an extraction fluid.
- The extractorwere then mountedonthe condenserfor4 hoursexceptfor the nutswhich takes
two hours. Water constantly passes through the condenser for cooling.
- After4hours,the hexane musthave extractedall the oil.The hexane isnowremovedleavingonly
the oil inthe flask.Once the oil isweighedwiththe flask,the oil will representthe oil lossonwet
basiswhichwill laterbe expressedasoil lossondrybasis.The oil losson drybasisrepresentsthe
oil loss.
The norms after extraction supposed to be as follows;
FOR FIBERS THE OIL LOSS MUST NOT EXCEED 7.5% WHILE THAT OF SLUDGE SHOULD NOT EXCEED 17%
*** The idea to control these lossesis to ensure that the industrial unitoperates with in the extraction
rate and it also helps to improve the efficiency of the machineries.

24. 24
4.3.2 PRESS CAKE ANALYSIS
This test is carried out to determine the quality of nuts pressed against fibres. Samples were collected
from the presses and quartered, later 500g of the sample is weighed from the 500g. The nuts are
separatedfrom the fibres, weighed and expressed in percentages. The nuts are expressed as follows;
- Whole nut press
- Partly cracked
- Free kernel shell
- Free shell
One hundred minus the total percentages of these nuts will give the percentage of nuts and fibers in a
press cake.
4.4 KERNEL ANALYSIS
4.4.1. Kernel losses
Kernel losses in the cyclone fibers are kernels that go the boiler with the fibers
500g of sample was collected from fiber cyclone
Free kernels were separated from the sample, weighed and expressed in percentage
%kernel loss = the free kernels/500g sample X 100
The norms of kernel losses in the fiber cyclone is 1.5
4.4.2. Kernel losses in dry shell
Kernel from shell cyclone was used
250g of sample was collected from the shell cyclone
Shells were separated from the sample, weighed and expressed in percentage
Kernel loss in dry shell = dry shell/250g Sample X 100
The norm of kernel losses in dry shell is 3
4.4.3. Palm Kernel quality control
This is done in order to determine the efficiency of the cracker in separating the nuts from the shells.
During cracking,250g of sample was collected,all the dirt and shell removedandweighedusinga triple
beam balance (it is called a triple bean balance because it weighs in hundreds, tens and units.
Dirt in silo = dirt/sample size X 100
The norm of dirt to silo is 2.40%.
DIRT EX SILO
A sample of 250g was collected from the kernels in bags. Dirt’s were removed and weighed
Dirt ex silo = dirt/sample Size X 100

25. 25
4.4.4. BROKEN PHASE
From the sample of dirt ex silo, broken nuts were separated from full nuts, weighed and expressed in
percentage
Broken = broken kernels/sample size (250) X 100
The norm of broken phase is 10.0%
4.4.5. COLORATION
25 whole kernel were randomly selected and split into two equal halves using a knife
They were then separated into white, brown and dark kernel, weighed and expressed in percentage.
Brown kernel = brown kernel/sample size X 100
White kernel = white kernel/ sample size (25g) X 100
Dark kernel = dark kernel/ Sample size (25g) X 100
4.4.6. FFA AND MOISTURE CONTENT OF KERNEL OIL
i. Moisturecontent
- Some whole and broken kernels were collected and smutched
- 10g of the smutchedsample wascollectedandplacedinanovenat103°Cfor1hour. Afteranhour
it was then placed in a desiccator for cooling for 15minutes.
Moisture content = (weight of sample + dish) weight of dry sample
Moisture = weight of moisture/ weight of wet sample X 100
The norm is 7.50%
ii. FFA of kernel
- The same sample for moisture content was then placed in a thimble and mounted on an
extraction heater to extract the oil. Palm kernel is made up of lauric acid.
- After extraction, the weight of the oil was gotten
- 50ml of ethanol was added to it
- It was the heated for the first bubbles in order to facilitate titration
- 3-5drops of phenolphthaleinindicatorwasadded and titratedwith0.1N sodiumhydroxide until
the endpoint.
% FFA = [volume of NaOHusedX the normality(0.1N) X the molarmass of lauricacid (20.0g)]/Weightof
oil
The norm is 1%.

26. 26
CHAPTER Five
5.0 Conclusion and Recommendation
My internship at the IIU lasted for a month and it was focused on the process line and the laboratory. I
learnta lotconcerningdiscipline because Ihadtotravel a distance of 41 kmfrom Limbe toIdenau,5days
a week.
As an engineeringstudentIalso came to the understandingthat,the operatorswithlittle educationand
whomactuallyoperate the variousunitseverydaycanbe the bestteachersbecause theyhave mastered
the units they operate and know many details that the engineers and the more educated people in the
factory will not know.
IthinkIwasblessed tobe atthe IIUbecauseImetalotof dynamicanintelligentpeople aswellasstudents
from other universities. Together we learnt from each other and I developed interpersonal skill whichI
must say, is the most important skill to have as a worker.
I leave the IIU with the knowledge of Palm oil processing in its details, as well as the quality control
techniques that are put in place to check the quality of the oil produced.
I thinkwiththisknowledge Ihave receivedIwill use ittoempowerlocal farmersthatprocesspalmfruits
intopalm oil,and alsoI have a betterpicture of some of the unitoperationlike the production of steam
at the boilerwhichwillhelpme betterunderstandmore unitoperationinthe future because I nowhave
a practical understanding of their operation
Nevertheless the IIU has a lot of setbacks which I will name the “most essential”
5.1 Recommendations
5.1.1 At the process line
 The IIU shouldbe able toincrease the numberof loadingbaysatthe ramp. Directdumpingof FFB
onthe floor,aswell asthe use of caterpillarstotransportFFBintothe loadingbaycausesbruising
which increase enzymaticactivityatthe bruisedregion.There isnodrainage systemonthe floor
andhence the FFBare usuallyinwaterespeciallyduringtherainy season.Thisprovidesconditions
that stimulate and catalyze rapid fermentation. I also think that below the loading bays there
should be a drainage system, so as to avoid stagnant water that increase humidity and hence
bacterial action which will increase the level of FFA in extracted palm oil.
 The IIU should increase the number of sterilizers. One of the major reasons why there is a high
level of FFA inextractedoil isbecauseittakesalongtime before FFBatthe ramp is sterilizedand
hence fermentationoccurswithinalongperiodof time andthusincreasingFFA levels.Increasing
the numberof sterilizerswillpreservethe FFBlongerevenif theremill hasproblemsandwill need
to delay the processing of FFB
 At the boiler,due to the use of kernel nutsas a fuel source,at timesthe chimney producesa lot
of soothe in the form of waste gas which is pumped out into the air. This will further affect the
environmentandincrease greenhouse gases.Itisimportantforthe IIUtobuy acatalyticconverter
for the chimney and avoid pollution of the atmosphere.

27. 27
5.1.2 At the Laboratory
As far as I am concerned the IIU has an outdated laboratory.
- It usually lacks material to carry out basic test and has a poor ventilation system.
- The human risk is high, as basic laboratory rules are not followed to the core.
- There isno separate store where chemicals are kept and hence are left lying around in the lab.
My recommendations are as follows
 First of all the Lab is small and a bigger lab is needed,or a total rearrangement of the lab could
solve the problem of overcrowding and packing of samples, equipment, chemicals, process
reports, as well as working space
 It will be important to have a separate store where chemicals are stored, so as to avoid any
accidents in the lab.
 There shouldbe a reception centerforfreshlytakensamplesaswell asanother centerforalreay
tested samples to avoid confusion.
 There shouldbe ventilationsystemsatareas where testare carriedout to evacuate the smell of
the organicchemicalsusedduringthe test.Thiswillavoidhealthriskassociatedwithinhalingthis
compounds.
 Most especiallythe IIUshouldcheckthat fundamentallaboratoryruleslikeavoidingeatinginthe
lab, and wearing laboratory overalls should be respected
5.1.3 General Recommendation
The IIU lacks a good communication system. An intranet should be installed to facilitate the sharing of
information within personnel’s as well as sharing of tasks down the professional ladder.
Phones should be installed or walky-talky should be given to personnel so as to avoid unnecessary
movement around the IU as well as for rapid intervention in case of emergencies
The stairsinthe factory are alwaysslipperyand dilapidated. Hence, canleadto a majoraccidents.Asper
my observation the factorystepsare alwaysslippery because of oil leakages atvariouspointsinthe units
as well as a high level of untidiness in the factory.
Most especiallystudentsoninternshiphave little ornowork to do.The IIU shouldprovide studentswith
workinggearsand try to motivate studentstodo some of the operationsinthe mill so that we can have
a 100% practical experience.

28. 28
REFERENCES AND ABBBREVIATIONS
IIU - Idenao Industrial Unit
IU - Industrial unit
FFA – Free Fatty Acids
FFB – Fresh Fruit Bunches
I used the following websites for my research on palm oil processing
http://www.malaysianpalmoil.com/oil-palm-process.html
http://www.fao.org/docrep/005/y4355e/y4355e04.htm
http://www.palmoilmills.org/products/palm-oil-mill-plant/palm-oil-mill-machine.html