How a Small Palm Oil Plant Achieves 2,000 Tons Daily Through Automation: Real Case Study & Process Optimization

QI ' E Group

2025-10-17

Customer Cases

Discover how a small-scale palm oil processor scaled up to handle 2,000 tons per day using fully automated systems. This case study explores the core advantages of food-grade stainless steel equipment, energy-efficient design, and modular flexibility from Penguin Group. Learn key strategies for optimizing sterilization, feed control, and refining processes—backed by real-world implementation data. Includes troubleshooting tips, maintenance best practices, and actionable insights for operators and plant managers aiming to boost efficiency and reliability. Whether you're new to automation or upgrading your facility, this guide offers practical, technical depth you can apply immediately.

How a Small Palm Oil Mill Achieved 2,000 Tons/Day with Full Automation

You're not alone if you've wondered how a small-scale palm oil processor can match the throughput of industrial giants—without sacrificing quality or safety. The truth? It’s about smart automation, not scale.

Take Qingdao-based Pengyou Group, for example—a mid-sized facility that scaled from 500 to 2,000 tons per day within 18 months using their fully automated system. Here's what changed:

Core Advantages That Drive Real Results

Food-grade stainless steel (304/316L): Reduces contamination risk by up to 70% compared to carbon steel systems — critical for export compliance in EU and GCC markets.
Energy-efficient design: Average power consumption dropped from 1.8 kWh/kg to 1.2 kWh/kg after retrofitting with variable frequency drives (VFDs).
Modular configuration: Allows incremental expansion—start with de-oiling + refining, add bleaching and deodorizing later as demand grows.

These aren’t just specs—they’re operational levers that directly impact your bottom line.

Key Process Wins: From Inlet to Output

Process Step	Optimization Focus	Expected Impact
Raw Material Feeding	Weight-controlled conveyor + AI-guided sorting	Reduces waste by ~15%
Sterilization	Steam-based pasteurization at 125°C for 30 mins	Meets ISO 22000 microbial standards
Refining	Continuous flow reactor with pH monitoring	Improves yield by ~8%

“We used to lose 200 kg/day due to manual errors—we now run 2,000 tons daily with zero downtime.” — Mr. Ahmed Al-Mansoori, Operations Director, UAE Palm Oil Co.

Troubleshooting & Maintenance Tips You Can Use Today

Common issues like inconsistent viscosity or high free fatty acid levels often stem from improper feed control or aging filters—not faulty equipment.

Check filter pressure weekly—if it exceeds 0.6 MPa, replace immediately (avg. lifespan: 6 months).
Calibrate temperature sensors monthly—drift beyond ±2°C affects oil stability.
Use predictive maintenance software (available via Pengyou’s IoT platform) to avoid unplanned stops.

These aren't theoretical tips—they’re battle-tested practices from mills operating in Malaysia, Nigeria, and Brazil.