Model Tertutup Sistem Produksi Mandiri Energi pada Industri Pengolahan Kakao.
A CLOSED MODEL OF PRODUCTION SYSTEM FOR
ENERGY INDEPENDENT IN CACAO PROCESSING
INDUSTRY
MOHAMMAD RIYAN PRATAMA
DEPARTMENT OF AGROINDUSTRIAL TECHNOLOGY
FACULTY OF AGRICULTURAL TECHNOLOGY
BOGOR AGRICULTURAL UNIVERSITY
BOGOR
2015
STATEMENT OF ORIGINALITY, INFORMATION SOURCE
AND COPYRIGHT TRANSFER
I hereby declare this skripsi entitled A Closed Model of Production System
for Energy Independent in Cacao Processing Industry is actually my work with
referrals from supervising committee and has not been submitted in any form to any
college. I have not submitted this skripsi either in whole or part for a degree at this
and any other institution. Source of information or quoted from works published or
not published from other authors mentioned in the text and listed in the reference at
the end of this skripsi. Hereby, I state that the copyright of this paper is transferred
to Bogor Agricultural University.
Bogor, August 2015
Moh Riyan Pratama
NIM F34110072
ABSTRACT
MOH RIYAN PRATAMA. A Closed Model of Production System for Energy
Independent in Cacao Processing Industry. Supervised by TAJUDDIN
BANTACUT.
Cacao processing industry produces cocoa butter, cocoa powder, and
generates by-product in the forms of pod husk and bean shells which can be utilized
as an energy source. The objectives of this research was to develop an energy
independent model of a closed system production process for cocoa butter and
cocoa powder. This closed system model was developed by analyzing mass balance,
assessing the potential energy of by-products, and building a closed system cacao
processing industry. To improve it comprehensiveness, this study reviewed
secondary data from relevant literatures. Results from this study showed that the
achievable yield of cocoa butter and cocoa powder was 32% and 50%. Respectively
cacao industry with a capacity of 4,500 kg of cacao per day has the potential energy
of 14,561,293.2 kCal per day derived from the pod husk and bean shells. This
potential energy is able to meet the energy requirements for the production process.
This study explained that the cacao industry is potentially be an energy independent
industry by optimize the utilization of by-products.
Keywords: closed system, cacao processing industry, energy independent
ABSTRAK
MOH RIYAN PRATAMA. Model Tertutup Sistem Produksi Mandiri Energi pada
Industri Pengolahan Kakao. Dibimbing oleh TAJUDDIN BANTACUT.
Industri pengolahan kakao menghasilkan produk lemak kokoa dan bubuk
kokoa serta hasil samping berupa cangkang dan kulit biji kakao yang dapat
dimanfaatkan sebagai sumber energi. Penelitian ini bertujuan untuk
mengembangkan model sistem tertutup proses produksi lemak kokoa dan bubuk
kokoa yang mandiri energi. Pengembangan model sistem tertutup ini berdasarkan
analisis kesetimbangan massa, perhitungan potensi energi dari hasil samping, dan
membangun rancangan sistem tertutup industri pengolahan kakao. Dalam
membangun model yang komprehensif, penelitian ini menggunakan kajian data
sekunder dari literatur yang relevan. Hasil dari studi ini menunjukkan bahwa
rendemen lemak kokoa dan bubuk kokoa yang dapat dicapai adalah 32% dan 50 %.
Industri kakao dengan kapasitas 4,500 kg buah kakao per hari memiliki potensi
energi 14,561,293.2 kKal per hari yang berasal dari cangkang buah dan kulit biji
kakao. Potensi energi ini dapat memenuhi kebutuhan energi untuk proses produksi.
Studi ini menjelaskan bahwa industri kakao dapat menjadi industri yang mandiri
energi dengan memanfaatkan secara optimal hasil samping.
Kata kunci: industri pengolahan kakao, mandiri energi, sistem tertutup
A CLOSED MODEL OF PRODUCTION SYSTEM FOR
ENERGY INDEPENDENT IN CACAO PROCESSING
INDUSTRY
MOHAMMAD RIYAN PRATAMA
Skripsi
as partial fulfilment of the requirements for the degree of
Bachelor (Honour) of Agricultural Technology
at
Department of Agroindustrial Technology
DEPARTMENT OF AGROINDUSTRIAL TECHNOLOGY
FACULTY OF AGRICULTURAL TECHNOLOGY
BOGOR AGRICULTURAL UNIVERSITY
BOGOR
2015
Title of The Skripsi
Name
NIM
: A Closed Model of Production System for Energy
0Independent in Cacao Processing Industry
: Mohammad Riyan Pratama
: F34110072
Approved by
Dr Ir Tajuddin Bantacut, MSc
Supervisor
Acknowledged by
Prof Dr Ir Nastiti Siswi Indrasti
Head of Department of Agroindustrial Technology
Date of Graduation
:
PREFACE
The authors say their praise and gratitude to Allah subhanahu wa ta’ala for
all the grace so this skripsi has been completed successfully. This research was
conducted since February 2015 with theme is closed system of production and the
title of A Closed Model of Production System for Energy Independent in Cacao
Processing Industry.
The authors conveys his thanks to Dr Tajuddin Bantacut as the supervisor
who gave the orders and helped, ranging from research to writing the script of the
skripsi. In addition, the authors convey thanks to Novitasari Destiara, STP who gave
helped the calculation of the model. Expression of thanks is also given to father,
mother, families, and Yurisqi Mukdisari for all the prayers and affection. Thanks to
the friends of Agroindustrial Technology batch 48 over the spirit of cooperation
that has been given for the author attended. This skripsi may be beneficial in the
field of education and industry.
Bogor, August 2015
Moh Riyan Pratama
TABLE OF CONTENTS
LIST OF TABLES ............................................................................................... viii
LIST OF FIGURES ............................................................................................. viii
LIST OF APPENDICES ...................................................................................... viii
INTRODUCTION .................................................................................................. 1
Background .................................................................................................... 1
Research Objectives....................................................................................... 2
Scope of The Research .................................................................................. 2
METHOD................................................................................................................ 2
Data Collection .............................................................................................. 2
System Boundary ........................................................................................... 3
Model Description ......................................................................................... 3
Mass Balance ................................................................................................. 3
Energy Content of By-Product ...................................................................... 4
Process Flow of Self-Sufficient Energy ........................................................ 4
MASS BALANCE MODEL OF CACAO PROCESSING .................................... 5
Mass Balance Model Level I ......................................................................... 5
Mass Balance Model Level II ........................................................................ 6
Mass Balance Model Level III ...................................................................... 9
RESULT AND DISCUSSION ............................................................................. 12
Mass Balance Model Output ....................................................................... 12
Energy Self-Sufficient in Cacao Processing Industry ................................. 14
Closed System Production of Cacao processing Industry ........................... 18
CONCLUSIONS AND SUGGESTIONS ............................................................. 19
Conclusions ................................................................................................. 19
Recommendations........................................................................................ 19
REFERENCES...................................................................................................... 20
APPENDICES ...................................................................................................... 23
LIST OF TABLES
1 The cacao processing industry process specsificationsa ....................................... 5
2 Symbol description of mass balance models level II ........................................... 7
3 Mass balance model efficiency coefficient level II .............................................. 8
4 Description of mass balance models symbol level III ........................................ 10
5 Mass balance model efficiency coefficient level III ........................................... 12
6 Comparison of mass balance models yield level I, II, III, and actual factorya ... 13
7 Cacao processing industry energy needsb ........................................................... 15
8 The calculation of conversion biomass into electrical energy............................ 16
LIST OF FIGURES
1 Mass balance model level I .................................................................................. 6
2 Mass balance model level II (symbol description in Table 2) .............................. 6
3 Mass balance model level III (symbol description in Table 4) ............................ 9
4 Mass balance model level III (symbol description in Table 4) .......................... 13
5 Self-sufficient energy production process model of cacao processing industry
(4,500 kg/day) .................................................................................................... 17
6 Closed system production of cacao processing industry .................................... 18
LIST OF APPENDICES
1 The mass balance model calculations of level II ................................................ 23
2 The mass balance model calculations of level III............................................... 24
INTRODUCTION
Background
The cacao processing industry produces intermediate products which are
cocoa butter and cocoa powder. This production processes consume electrical
energy amounting to 50 GJ/t cacao (BC 2013; Ntiamoah and Afrane 2008). In
current practice, the energy is powered by the state electricity company (PLN) that
in general derived from the power plants of fossil fuel combustion.
The availability of fossil fuels has been declining due to an excessive
exploitation to meet the very massive and fast growing demand. The annual
availability of fossil fuels such as oil and gas declines to 4% and 8% (BPS 2015).
This conditions will continue and will end up in energy crisis of industrial
production in near future, so industry requires a source of renewable energy.
Development of a production system has the aspect of saving the usage of raw
materials and energy from nature, so as to reduce and prevent the incidence of
problems of energy and environment (Robert et al. 2002). Utilization of biomass in
by-product to produce energy can be an alternative to reduce or even replace the
consumption of fossil fuel.
The cacao processing industry produces a by-product containing lot of energy
(Prasertsan et al. 2002). The results of the by-product have more percentage
compared with the main product. Fresh cacao fruit will produce 6.7% cacao dried
bean (Effendi 1995) and over 80% by-product in the form of pod husk, pulp,
placenta, and bean shells (Patabang 2011; Uwagboe et al. 2010). The processing of
cacao fruits generates a large amount of cacao pod husk discarded as by product
represents between 70 to 75% of the whole cacao fruits weight (Alemawor et al.
2009; Cruz et al. 2012) and 8–11% cacao beans shells of the whole wet cacao beans
weight (Olubamiwa et al. 2006). By-product is a potential alternative energy source
because it contains many energy and abundant for its availability.
by-product which can be used as an alternative energy source is the pod husk
and bean shells. The energy contained within the cacao pod husk is 4,063 kcal/kg
(Syamsiro et al. 2012) and within bean shells is 4,116 kcal/kg (Pabisa 2013;
Spilacek 2014). The energy needs of the cacao processing industry are expected to
be fulfilled from the by-product. That large amount of energy can be reutilized as
alternative energy source with direct combustion and steam turbine system.
Biomass combustion such as burning cacao pod husk is to provide heat and power
linked in the renewable energy to provide sustainable service in the form of heat,
power, and electricity (Madguni and Singh 2013).
The moisture content of pod husk is 10–14% wb (Daud et al. 2013; Hamzat
and Adeola 2011) and in cacao beans shell is 4.9–11.2% wb (Domfeh 1972), that it
can burn directly in a boiler to produce steam and drive a turbine that produces
electricity (Diji 2013). The energy produced can be used as an energy input for
processing cacao to form a closed system. Other benefits of the application of a
closed system is that it is directly reducing the amount of waste produced by cacao
processing industry so it can reduce costs for handling the waste.
Development of closed systems for cacao processing industry is needed to
improve the efficiency of the production process and by-product that can be
2
generated. Analysis of alternative energy sources derived from biomass is needed
to find out the potential of the independent energy of cacao processing industry.
The mass balance model developed is expected to form a closed system for cacao
processing industry.
Research Objectives
This research’s objective was to develop independent energy production
system design in the cacao processing industry, with a minimum input and optimum
output. These objectives were achieved by:
1. Calculating mass flow in the process and constructing the mas balance model
of the production of cocoa butter and cocoa powder.
2. Calculating the energy needs of optimum production process and energy yield
content of the by-product.
3. Designing the flow of a process independent of the energy production system,
with a minimum input and optimum output.
Scope of The Research
The scope of this research was on cacao processing industry that produces
cocoa butter and cocoa powder product with an energy source from pod husk and
bean shells. Analysis to establish the model performed on the mass transfer flow of
materials during the production process (mass balance equilibrium), losses during
the production process, the use of energy for the production process, and the
analysis of the potential energy of by-product. The results of each model is in
comparison to analyze the level of consistency models and compared to the actual
factory data to analyze the level of accuracy of the model. Actual data based on the
cacao processing industry factory with a capacity of 5,000 kg of cacao fruit per day.
The closed system of mass flow and energy in cacao processing industry was
analyzed and established.
METHOD
Data Collection
The data used in the research data were secondary and primary data. The
secondary data used were journals, research papers, thesis, dissertations, and books
that included mass balance process and resource requirements. Most secondary data
were taken from data of production of dried cacao beans, cocoa powder and cocoa
butter that implemented the independent energy system. Meanwhile, the primary
data were the actual mass balance based on the cacao processing industry in
Lampung.
3
System Boundary
Cacao processing industry has a complex production system because it
involves many factors that are interconnected with each other. The factors are
material and energy (input) required in the production process as well as the byproduct (output) generated from the production process, which is interconnected.
These factors require a comprehensive approach to find the optimal solution of
energy used. Therefore, the systems approach used to analyze the flow of mass,
energy needs, including energy potential by-product of the production process of
cocoa butter and cocoa powder.
Cacao processing process consists of two main processes, namely the process
of upstream and downstream processes. Upstream process is converting raw
materials of cacao fruits and becoming dry beans, while the downstream processes
is to convert raw dried cacao beans into cocoa butter and cocoa powder. In building
this model between the upstream and downstream process needs to be integrated.
In this research, the primary processes were divided into four compartment such as
upstream processes, liquoring process, fat or butter separation process, and flouring
process. The main input material was cacao fruit with a capacity of 4,500 kg per
day and an additional ingredient (potassium carbonate) in the downstream
processes (Dyer 2003). The output is cocoa butter, cocoa powder, and by-product
such as pod husk, pulp, placenta, water vapour, and bean shells.
Model Description
Mass balance model was developed based on the process of flow of
compartment that can describe the actual production process. The model was
developed to obtain independent variables as input and dependent variables as
output. The model was built by using the ratio (coefficient of efficiency) of the
independent and dependent variables based on the principles of linear equations by
using a calculation tool namely Microsoft Excel.
Results of the model calculations were compared with actual production
process of cacao processing industry in Lampung. The results were used to identify
and calculate the amount energy potential of by-products as a source of energy to
meet the requires of the production process. This model has a high degree of
accuracy and in accordance with the actual production process forming the basis of
analysis of potential energy of by-products to develop more energy namely
independent production process.
Mass Balance
Mass balance model was created by identifying compartments that can
describe the production process. Later, the model was built by creating a mass
balance equation that connects the input (cacao and supporting materials) and
output (cocoa butter, cocoa powder, and by-products). The mass balance model was
developed from a simple model to an increasingly complex one. The simple model
was formed from the assumption that the single compartment system without
spesific flow of input and output.
4
Mass balance equations was solved by building a matrix based on the
efficiency factor (the ratio of the variable value) from secondary data on the mass
flow of cacao processing industry. After identifying tha mass balance and efficiency
factor, then the value of the efficiency equations and mass balance can be
determined.
Energy Content of By-Product
Based on a mass balance model that describes the actual condition of the
cocoa processing industry, the potential energy of by-product can be calculated with
the equation:
Potential Energy kCal = Mass kg × Caloric Value kCal/kg
Which, the mass of by-product was obtained from the calculation model, while the
caloric values were obtained from the literature.
Calculation assumptions used were derived from the caloric values of pod
husk of 4,063 kCal/kg (Syamsiro et al. 2012) and bean shells of 4,116 (Pabisa 2013;
Spilacek 2014). In this research it was used assumption of efficiensy boiler of
76.8% (Bora and Nakkeeran 2014) and turbine efficiency of 43.5% (Wolowicz et
al. 2012).
Process Flow of Self-Sufficient Energy
The by-product of cacao processing was examined in its utility as the main
energy source for the energy needs of the cacao processing industry. Analysis of
the energy usage begins with the calculation of the equilibrium of the mass balance
through observations of the input-output system of the mass of the material. The
resulting by-product and the potential conversion of mass into energy by-product.
Energy needs was analyzed from a classification tool (machines) used in the
production process, the calculation of the amount of energy used for the production,
and the sources of energy available.
The cacao processing industry used electrical energy in the production
process. However, the energy needs of the cacao processing industry differ from
one another, depending on the applied process technology. Electrical energy on the
cacao processing industry in Lampung used in the drying process, the liquor process,
milling process, pressing process, and the separation process. Specifications of the
engine used in the cacao processing industry with a capacity of 5,000 kg of cacao
fruit per day is presented in Table 1.
5
Table 1 The cacao processing industry process specsificationsa
Engine Spesification
Energy
Total of
Process
Capacity
Consumption Machines
(kg/h)
(kW)
Drying process I
60
20.92
2
Drying process II
80
10.18
1
Liquor process
50
19.15
1
Pressing process
18
669.4
2
Milling process
8
45.44
3
Separation process
30
45.3
1
a
Source: Prepared from Hamdani (2009)
The potential energy of by-product in the cacao processing industry can
determine the level of sufficient energy by way of comparison with the consumption
of the energy it uses. If the energy is greater or equal than the energy needs of the
plant, the plant could potentially be self-sufficient in energy. However, if the energy
obtained is smaller than the needs, the plant still requires energy from outside the
production system and the plant is not independent of energy.
MASS BALANCE MODEL OF CACAO PROCESSING
Modeling of the process of cacao processing is made into a model of level I,
II, and III. In making mass balance model, the first thing to do is identify the
compartments. Each compartment in the model of equations of mass balance was
made to determine input and output generated per compartment. The general
equations of the mass balance were the same as the input and the output. These
equations were identified with secondary data about the mass flow of cacao
processing to determine the value of the element of efficiency and balance of
masses.
The resulting output of each compartment as the product and the by-product
was to be reutilized so it has a higher value than if it was only processed into waste.
By-products that still have potential energy are reused as input in the process of
energy production. The by-product mass were obtained from the mass balance
model calculations and the heat value derived from literary sources. The potential
of the energy produced will be reduced by the energy need in the production process
to determine the level of energy self-sufficiency in the cacao processing industry.
Mass Balance Model Level I
Model level I was formed from the assumption that the system is the one
compartment thoroughly without specific flow linking inputs (I), products (P), and
by-product (W) (Figure 1). This model was developed based on the input and output
6
of the industry of dried cacao beans, cocoa butter and cocoa powder. The mass
balance equation for level I:
Figure 1 Mass balance model level I
I=P+W
Efficiency a =
P
I
The Mass Balance Model of the Level I has 1 compartment process with raw
materials input of 4,500 kg of cacao fruit per day and additional material of
potassium bicarbonate (Dyer 2003). The amount of raw materials used as model
inputs was in accordance with the yield observations.
Mass Balance Model Level II
Model level II was developed by building four compartments based on the
main process in the cacao processing industry so that each compartment can be
identified in greater detail. The compartment are the upstream processes (I), the
liquor process (II), the process of fat separation (III), and the flouring process (IV)
(Figure 2).
Figure 2 Mass balance model level II (symbol description in Table 2)
7
Table 2 Symbol description of mass balance models level II
Symbol
Explanation
I
Process of cacao fruits into dry beans
II
Process of dry cacao beans into cocoa liquor
III
Process of cocoa liquor into cocoa butter
IV
Process of cocoa cake into cocoa powder
I11
Cacao
I41
Potassium carbonate
X11
Dry cacao beans
X21
Cocoa liquor
X31
Cocoa cake
W11
Pod husk
W12
Water vapour
W13
Pulp and placenta
W21
Bean shell
P31
Cocoa butter
P41
Cocoa powder (fine)
Mass balance equations:
I
:I −X −W −W −W =
…………… (2.1)
II
:I −X −X −W =
…………………… (2.2)
III
: X − X − P = …………………………… (2.3)
IV
: X − P = …………………………………… (2.4)
Efficiency coefficient equation
The production of dried cacao beans (a1)
a =
X
=
I
dried cacao beans
cacao fruits
……………………………… (2.5)
The processes of 446 g cacao fruits produced 31.58 g of dried cacao beans (Maulina
2013). The percentage of dry beans was 7.08% of the cacao fruits (Maulina 2013)
or 7.5% of the cacao fruits (Adzimah 2010), then a1 was about 0.07.
The production of cacao pod husk (a2)
a =
I
=
………………………………… (2.6)
The cacao pod husk generated from processing the fruit into cacao beans was 70.4%
of cacao processed fruits (Adzimah 2010) but according to Nguyen (2014), cacao
fruits contained 70.15% of pod husk. Based on the data, a2 used for the model was
0.70.
8
The production of pulp and placenta (a3)
=
a =
………………………… (2.7)
Percentage of separable pulp and the placenta was 2.38% of the dried cacao beans
produced (Adzimah 2010; Pusporini 2013), then a3 was 0.02.
The production of cocoa liquor (a4)
a =
=
………………………… (2.8)
Cocoa liquor generated from processing dried cacao beans is 7.80 kg cocoa liquor
from 9.77 kg of dried beans (Elisabeth et al. 2007). According to Akinnuli et al.
(2014), researched that a total of 15733.46 kg cocoa liquor was obtained from
19987.73 kg of dried cacao beans. The percentage of cocoa liquor was 78.72%
(Akinnuli et al. 2014) and 79.83% (Elisabeth et al. 2007) of the cacao beans dried,
than a4 is 0.79.
The production of cocoa butter (a5)
a =
P
=
………………………………… (2.9)
Cocoa butter resulted from the processing of cocoa liquor into cocoa butter is about
35.87% (Akinnuli et al 2014) and 39% (Indarti 2007; Sudibyo 2006). The chosen
percentage used for a5 was 0.39 which was the greatest percentage that can be
generated.
Based on equation of efficiency coefficient factor, the summary of efficiency
coefficient can be seen in Table 3. The calculation of the value of the coefficient of
efficiency required to complete the matrix in building model level II, the full matrix
can be seen in Appendices 1.
Table 3 Mass balance model efficiency coefficient level II
The Value of
Symbol
Reference
Coefficient of Efficiency
a1
0.07
Adzimmah (2010); Maulina (2013)
a2
0.70
Adzimmah (2010); Nguyen 2014)
a3
0.02
Adzimmah (2010); Pusporini 2013)
a4
0.79
Akinnuli et al. (2014); Elisabeth et al. 2007)
a5
0.39
Indarti (2007); Sudibyo (2006)
9
Mass Balance Model Level III
Model level III was the development of a model of level II with detailing the
compartment into the process unit that has independent input and dependent
variables as the output of a process (Figure 3). The yield value of Mass Balance
Models Level III was better because it details the compartment into 9
compartments. The compartment was arranged by any processing that occurs in the
cacao processing industry.
A Mass Balance Model Level III model has 9 unit process with 2 independent
variables (I11 and I81) and 16 dependent variables (X11 to X91; W11 to W51; P71 and
P91). On dependent variables X61 can be ignored because it was only as a process
identifiers and wasa direct flow, therefore it has no flow coming out of the system.
The more specific a modeling was made the better results will be shown. A more
detailed calculation will produce a model with better results and will be able to
describe the actual conditions that actually occur in the cacao processing industry.
Figure 3 Mass balance model level III (symbol description in Table 4)
10
Table 4 Description of mass balance models symbol level III
Symbol
Explanation
1
The cracking process of cacao fruits
2
The fermentation process of cacao beans
3
The drying process of cacao beans
4
The roasting process of cacao beans
5
The separation process of beans (nib)
6
The grinding process of nib
7
The pressing process of cocoa liquor
8
The grinding process of cocoa cake
9
The separation process of cocoa powder
I11
Cacao fruits
I81
Potassium carbonate
X11
Cacao beans with pulp and placenta
X21
Wet cacao bean
X31
Dried cacao bean
X41
Roasted cacao bean
X51
Nib
X61
Cocoa liquor
X71
Cocoa cake
X81
Cocoa powder (fine and coarse)
X91
Cocoa powder (coarse)
W11
Pod husk
W21
Pulp and placenta
W31 and W41 Water vapour
W51
Beans shells
P71
Cocoa butter
P91
Cocoa powder (fine)
Mass balance equation:
1
:I −X −W
2
:X −X −W
3
:X −X −W
4
:X −X −W
5
:X −X −W
6
:X −X =
7
:X −X −P
8
:I +X +X
9
:X −X −P
=
………………………………………… (3.1)
=
………………………………………… (3.2)
=
………………………………………… (3.3)
=
………………………………………… (3.4)
=
………………………………………… (3.5)
………………………………………………… (3.6)
= …………………………………………… (3.7)
−X =
…………………………………… (3.8)
= …………………………………………… (3.9)
Efficiency coefficient equation
The production of cacao beans with pulp and placenta (a1)
a =
I
=
w
……………………… (3.10)
11
Cacao beans produced from the process of cracking the fruit has a percentage
amounting to 21.7% (Adzimah 2010; Nguyen et al. 2001; Velayutham et al. 2013),
then a1 was 0.22.
The production of wet cacao beans (a2)
a =
=
…………………… (3.11)
w
Percentage of separable pulp and the placenta was 2.38% generated from cacao
beans with pulp and placenta (Adzimah 2010; Pusporini 2013), then a2 was 0.02.
The production of dried cacao beans (a3)
=
a =
……………………………………… (3.12)
w
As much as 25 kg of wet beans with moisture content of 60% (wet basis) wasdried
to moisture content of 6.45-7% (Guehi et al. 2010; Napitupulu et al. 2012).
Percentage dried bean up to 43% of the wet beans, then the a3 was 0.43.
The production of roasted cacao bean (a4)
a =
=
…………………………………… (3.13)
Roasted cacao beans resulted from roasting process was 9.77 kg with input (dried
cacao beans) 10.13 kg (Elisabeth et al. 2007). Based on the research of Akinnuli et
al. (2014), a total of 20,957.3 kg of roasted cacao beans produced from the dried
cacao beans was 21,500 kg. Percentage of roasted beans resulted from roasting
process were 96.54% (Elisabeth et al.2007) and 97.48% (Akinnuli et al. 2014), then
a4 is 0.97.
The production of nib (a5)
=
a =
………………………………… (3.14)
Percentage of the nib that can be produced from the separation of the nib with shells
amounting to 82% of the roasted cacao beans produced (Azizah 2005; Pusporini
2013), the a5 was 0.82.
The production of cocoa butter (a6)
a =
P
=
w
………………………………………… (3.15)
Cocoa butter resulted from the processing of cocoa liquor into cocoa butter has a
percentage of 39% (Indarti 2007; Sudibyo 2006), then a6 was 0.39.
12
The production of cocoa powder (fine) (a7)
a =
P
=
w
w
………………………… (3.16)
Cocoa powder (fine) resulted from the grinding process and separation process was
4.77 kg with the input of the cacao beans (coarse and fine) 5 kg (Elisabeth et al.
2007). Percentage of cocoa powder produced from the milling process and
separation process was 95.4% (Elisabeth et al. 2007; Joel et al. 2013), then a7 is
0.95.
Based on equation of efficiency coefficient, the summary of factor efficiency
coefficient can be seen in Table 5. The value of the coefficient of efficiency of
model level III used to supplement matrix in building a model of level III
(Appendices 2).
Symbol
a1
a2
a3
a4
a5
a6
a7
Table 5 Mass balance model efficiency coefficient level III
The Value of Coefficient
Reference
of Efficiency
Adzimmah (2010); Nguyen et al. (2001);
0.22
Velayutham et al. (2013)
0.02
Adzimmah (2010); Pusporini (2013)
Guehi et al. (2010); Napitupulu et al.
0.43
(2012)
Akinnuli et al. (2014); Elisabeth et al.
0.97
(2007)
0.82
Azizah (2005); Pusporini (2013)
0.39
Indarti (2007); Sudibyo (2006)
0.95
Elisabeth et al. (2007); Joel et al. (2013)
RESULT AND DISCUSSION
Mass Balance Model Output
Based on the Mass Balance Model Level I, II, and III had consistent results
of cocoa butter and cocoa powder per dried cacao beans, presented in Table 6. The
consistency of the results of each mass balance models proved that the calculated
model has consistent results. The Mass Balance Model Level I was the basic
calculation that becomes a comparison for Mass Balance Models for Level II and
III.
13
Table 6 Comparison of mass balance models yield level I, II, III, and actual
factorya
Model of
Model of Model of
Factory
Materials
Level I
Level II
Level III Actual Data
Cocoa butter (%)
30.86
30.8
32
32.8
Cocoa powder (%)
47.86
48.2
50
42.5
a
per amount of dried cacao beans
The Mass Balance Model Level II has a ratio value greater than the Mass
Balance Model Level I and there was an increased level of efficiency system that
became 100%. The Mass Balance Model Level II entire mass flow can be identified
so that no loss occurs in Mass Balance Model Level I.
Mass Balance Model Level III had the greatest value of the cocoa butter and
cocoa powder than the Mass Balance Model Level II. This model has a
compartment that development was more complex than the Mass Balance Model
Level II that the resulting product ratio was better. The efficiency of the system on
a Mass Balance Model Level III was the same with the Mass Balance Model Level
II can also identify all of its flow. The model has compartment and increasingly
detailed, will resulting in the better product ratio and can describe the actual
condition of the production process.
Result obtained from Mass Balance Model Level III of cocoa butter was equal
with factory’s actual data, while a higher result obtained in cocoa powder than
factory’s actual data. The difference was due to the actual data on the factory that
still incurred loss of 5–8% on the liquor processing and pressing process. The
production system in factory also does not re-mill (cycle) cocoa powder that were
still coarse that the final yield of cocoa powder (fine) was lower compared to every
model because the factory was focus more on cocoa butter, but the cocoa powder
only becoming additional product.
Figure 4 Mass balance model level III (symbol description in Table 4)
14
Cocoa butter and cocoa powder yield can be increased if the machine works
in optimal conditions and also applying the cycle system for cocoa powder that is
still rough. Comparison between products on a model level III with factory’s actual
data will show the potential of production improvement. Potential yield
improvements can be increased on the cocoa powder product to 7.5% that can be
seen in Table 6.
Increasing cocoa powder yield can be done by not washing the cacao beans
after fermentation. Washing will remove the bean shells thereby reducing the yield
of cocoa cake and cocoa powder yield will be reduced. Moisture content of cacao
beans also affect the yield of cocoa powder produced. The shrinkage and volume
change were associated with the cacao beans moisture contents, which can reduce
the cacao mass (Asiedu 1989; Gereke and Niemz 2010). The increase rate of 4% of
moisture content will increase the linear dimensions of 3%, sperichity values of 2%,
and deformation linearly of 57% (Plange et al. 2012).
Energy Self-Sufficient in Cacao Processing Industry
The cocoa processing industry produces semi-finished products namely
cocoa butter and cocoa powder. The cocoa butter and cocoa powder made from
cocoa liquor through the several processing stages with the initial input is the dried
cacao beans. In addition to producing the aforementioned products, cacao
processing industry also produces by-product in the form of beans shell. Cacao
beans shell contains small amounts of energy that can be used as an energy source.
But the energy produced from the shell of the cacao beans are not enough to meet
the energy needs of the production sector.
The fulfillment of energy for production can be met from a by-product
produced in the process of the upstream of the cacao processing. The upstream
process cacao produces more than 75% by-product in the form of pod husk, pulp,
placenta and water vapour that is still not used (Patabang 2011). The number of byproduct is more compared to the resulted product. Whereas the by-product still
contains considerable amounts of energy to meet the energy needs of the production
sector. The by-product in the form of pod husk contains energy amounting to
4,063.1 kcal/kg (Syamsiro et al. 2012) and bean shells of 4,116 kcal/kg (Pabisa
2013; Spilacek 2014).
The cacao processing industry requires electrical energy to do the production
process. The main processing applied by the cacao processing industry is the
upstream process, liquor process, pressing process (separation of cocoa butter), and
the milling process. In each major process there are some machines that use
electrical energy, as in Table 1. Based on Table 1 industry with the capacity of 4,500
kg per day needs electric energy sources amounted 14,436 kWh, complete
calculation is in Table 7.
15
Table 7 Cacao processing industry energy needsb
Engine
Operation
Input
Total of
Spesification
time
Process
Machine
(kg) (kg/h) (kW)
(hours)
Drying I
970.2
60
20.92
2
8.1
Drying II
417.2
80
10.18
1
5.2
Separation I
404.7
80
20.74
1
5.1
Grinding
331.8
50
19.15
1
6.6
Pressing
331.8
18 669.40
2
9.2
Milling
202.4
8
45.44
3
8.4
Separation II 213.0
30
45.30
1
7.1
Total of Energy Consumed
Energy
Consumed
(kWh)
338.3
53.1
104.9
127.1
12,340.7
1,149.7
321.7
14,436.0
b
Source: Prepared from Hamdani (2009)
A closed system model of the cacao processing industry (Figure 5) is an
energy independent production model that is able to meet the needs of energy
without input from the outside of production systems beside the input of raw
materials and supplementary materials. The potential energy at the pod husk and
the beans shell is calculated based on the value of heat (heating value) multiplied
by the sum of the mass of the model level III.
The amount of energy obtained from the by-product of production processes
is reutilized to meet the needs of electric energy during the production process. Byproduct was converted into heat energy by steam turbine system. Pod husk and
beans shell were burned directly to produce steam used in the turbine to produce
electrical energy. In the theoretical calculations, the electrical energy generated
from the potential energy of the pod husk and beans shell is the 27,555.2 kWh per
day. The conversion of biomass into electrical energy calculations are presented in
Table 8 and the model (Figure 5) explains that energy needs for production process
can be self-sufficient in energy and still have a surplus as much as 91%.
16
Table 8 The calculation of conversion biomass into electrical energy
PARAMETER
Plant capacity
Avalability of pod husk
Avalability of bean shells
UNIT
kg cacao/day
kg/day
kg/day
AMOUNT
4,500.0
3,510.0
72.8
Energy Content
Pod husk
Bean shells
kCal/kg
kCal/kg
Total Energy of Biomass
Pod husk
kCal
Bean shells
kCal
Total Steam
Heat required to produce steam (derived from
kCal/kg
the steam table for saturated conditions 30 bar)
Boiler efficiency
%
Steam from pod husk
kg/day
Steam from bean shells
kg/day
Total generated steam per day
kg/day
Total generated steam per second
kg/s
Total Electrical Energy
Conversion of steam in the turbine
kg/s
Turbine efficiency
%
The power from turbine
kWh
Electrical energy generated
kWh/day
The plant's energy needs
kWh/day
Electrical Energy Can be Met
Source: c Syamsiro et al. 2012
4,063.1c
4,116d.0
14,261,481.0
299,812.2
669.9
76.8e
16,355.6
343.8
16699.4
0.5
61f.0
43.5 f
833,000 f.0
27,555.2
14,436.0
191%
d
Pabisa 2013; Spilacek 2014
Bora and Nakkeeran 2014
f
Wolowicz et al. 2012
e
The use of cacao pod husk and bean shells as the fuel of power plant for the
production process can replace the electrical energy obtained from coal power
plants of PLN. A total of 8.1 tons of coal can generate electricity amounting to
24,000 kWh (Sulistyono 2012). In meeting the demand for electricity in the
production process as much as 14,436 kWh, PLN needs as much as 0.6 tons of coal.
The uses of cacao pod husk and bean shells as fuels of power plants can save the
use of coal as much as 4.8 tons per day. Cacao pod husk and bean shell of 1 tons
can save the coal consumption as much as 1.3 tons.
Emissions from cacao shells combustion have very small levels of SO2
around of 90 mg/m3, but the level of NO are mostly between 1,000-1,400 mg/m3
(Spilacek 2014). Biomass such as cacao pod husk and bean shells remains will
decompose that it will still release pollution of C, H, N, O, and S which contained
the by-product.
17
Figure 5 Self-sufficient energy production process model of cacao processing industry (4,500
kg/day)
18
Closed System Production of Cacao processing Industry
In forming a closed system production, by-product that has the potential to be
reutilized or processed into additional products need to be built into the system. A
production system produces a by-product in the form of water vapour, pulp and
placenta, cacao pod husks and bean shells. The by-product which still contains
amount of energy such as pod husks and bean shells are reutilized as energy inputs,
but not all by-products can be reutilized as energy input due to the high level of
moisture content, such as water vapour, pulp and placenta.
The water vapour produced from the drying process and the roasting process
reutilized by condenser to produce a water, that can utilized for irrigation in the
cocoa groves or industrial activity. The pulp and placenta resulted from the
fermentation process can be reutilized as bio-herbicide. Pulp and placenta results of
the fermentation of cocoa beans containing and produce acetic acid which can
damage the weeds with a dose of 500 L/ha (Pujisiswanto 2011). A closed system
production of cacao processing industry shown in Figure 6, which all of output from
cacao production systems can be reutilized.
Figure 6 Closed system production of cacao processing industry
19
CONCLUSIONS AND SUGGESTIONS
Conclusions
The cacao processing industry is an industry that can be self-sufficient in
energy by performing processing from upstream processing (cacao fruit). The
upstream process produces a by-product that contains more energy than with
downstream process. The resulted by-product can not be used to generate all the
energy (electricity) due to high moisture content. Utilization of pulp and placenta
can be used as bio-herbicide for the cacao plant. The resulted water vapour can be
reutilized as a source of water for irrigation in the cocoa groves or industrial activity.
The generated potential energy comes from the cacao pod husk and beans shells.
On the cacao processing industry with a capacity of 4,500 kg of fruit per day,
produces cacao pod husk is 3,510 kg and cacao beans shell is 72.8 kg. The byproduct such as pod husk and bean shells can generate electrical energy by as much
as 27,555.2 kWh per day with the production of electricity for energy needs as much
as 14,436 kWh so the cacao processing industry can be said to be energy
independent and still surplus of electricity as much as 91%. Cacao pod husk and
bean shell of 1 tons can save the coal consumption as much as 1.3 tons. In addition
to independent energy cacao processing industry can also produce bio-herbicide
and water. Energy independent production model on this research can be developed
into a cacao processing industry production system that is independent of energy.
The cacao processing industry can be developed into a closed system production of
industry.
Recommendations
Further research in applying this system needs to be done to adjust energy
needs. This adjustment needs to be done because every industry has a long operation
and engine specifications of different machines that their energy needs will be
different.
20
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22
Robert KH, Schmidt-Bleek B, Aloisi LJ, Basile G, Jansen JL, Kuehr R, Price
ENERGY INDEPENDENT IN CACAO PROCESSING
INDUSTRY
MOHAMMAD RIYAN PRATAMA
DEPARTMENT OF AGROINDUSTRIAL TECHNOLOGY
FACULTY OF AGRICULTURAL TECHNOLOGY
BOGOR AGRICULTURAL UNIVERSITY
BOGOR
2015
STATEMENT OF ORIGINALITY, INFORMATION SOURCE
AND COPYRIGHT TRANSFER
I hereby declare this skripsi entitled A Closed Model of Production System
for Energy Independent in Cacao Processing Industry is actually my work with
referrals from supervising committee and has not been submitted in any form to any
college. I have not submitted this skripsi either in whole or part for a degree at this
and any other institution. Source of information or quoted from works published or
not published from other authors mentioned in the text and listed in the reference at
the end of this skripsi. Hereby, I state that the copyright of this paper is transferred
to Bogor Agricultural University.
Bogor, August 2015
Moh Riyan Pratama
NIM F34110072
ABSTRACT
MOH RIYAN PRATAMA. A Closed Model of Production System for Energy
Independent in Cacao Processing Industry. Supervised by TAJUDDIN
BANTACUT.
Cacao processing industry produces cocoa butter, cocoa powder, and
generates by-product in the forms of pod husk and bean shells which can be utilized
as an energy source. The objectives of this research was to develop an energy
independent model of a closed system production process for cocoa butter and
cocoa powder. This closed system model was developed by analyzing mass balance,
assessing the potential energy of by-products, and building a closed system cacao
processing industry. To improve it comprehensiveness, this study reviewed
secondary data from relevant literatures. Results from this study showed that the
achievable yield of cocoa butter and cocoa powder was 32% and 50%. Respectively
cacao industry with a capacity of 4,500 kg of cacao per day has the potential energy
of 14,561,293.2 kCal per day derived from the pod husk and bean shells. This
potential energy is able to meet the energy requirements for the production process.
This study explained that the cacao industry is potentially be an energy independent
industry by optimize the utilization of by-products.
Keywords: closed system, cacao processing industry, energy independent
ABSTRAK
MOH RIYAN PRATAMA. Model Tertutup Sistem Produksi Mandiri Energi pada
Industri Pengolahan Kakao. Dibimbing oleh TAJUDDIN BANTACUT.
Industri pengolahan kakao menghasilkan produk lemak kokoa dan bubuk
kokoa serta hasil samping berupa cangkang dan kulit biji kakao yang dapat
dimanfaatkan sebagai sumber energi. Penelitian ini bertujuan untuk
mengembangkan model sistem tertutup proses produksi lemak kokoa dan bubuk
kokoa yang mandiri energi. Pengembangan model sistem tertutup ini berdasarkan
analisis kesetimbangan massa, perhitungan potensi energi dari hasil samping, dan
membangun rancangan sistem tertutup industri pengolahan kakao. Dalam
membangun model yang komprehensif, penelitian ini menggunakan kajian data
sekunder dari literatur yang relevan. Hasil dari studi ini menunjukkan bahwa
rendemen lemak kokoa dan bubuk kokoa yang dapat dicapai adalah 32% dan 50 %.
Industri kakao dengan kapasitas 4,500 kg buah kakao per hari memiliki potensi
energi 14,561,293.2 kKal per hari yang berasal dari cangkang buah dan kulit biji
kakao. Potensi energi ini dapat memenuhi kebutuhan energi untuk proses produksi.
Studi ini menjelaskan bahwa industri kakao dapat menjadi industri yang mandiri
energi dengan memanfaatkan secara optimal hasil samping.
Kata kunci: industri pengolahan kakao, mandiri energi, sistem tertutup
A CLOSED MODEL OF PRODUCTION SYSTEM FOR
ENERGY INDEPENDENT IN CACAO PROCESSING
INDUSTRY
MOHAMMAD RIYAN PRATAMA
Skripsi
as partial fulfilment of the requirements for the degree of
Bachelor (Honour) of Agricultural Technology
at
Department of Agroindustrial Technology
DEPARTMENT OF AGROINDUSTRIAL TECHNOLOGY
FACULTY OF AGRICULTURAL TECHNOLOGY
BOGOR AGRICULTURAL UNIVERSITY
BOGOR
2015
Title of The Skripsi
Name
NIM
: A Closed Model of Production System for Energy
0Independent in Cacao Processing Industry
: Mohammad Riyan Pratama
: F34110072
Approved by
Dr Ir Tajuddin Bantacut, MSc
Supervisor
Acknowledged by
Prof Dr Ir Nastiti Siswi Indrasti
Head of Department of Agroindustrial Technology
Date of Graduation
:
PREFACE
The authors say their praise and gratitude to Allah subhanahu wa ta’ala for
all the grace so this skripsi has been completed successfully. This research was
conducted since February 2015 with theme is closed system of production and the
title of A Closed Model of Production System for Energy Independent in Cacao
Processing Industry.
The authors conveys his thanks to Dr Tajuddin Bantacut as the supervisor
who gave the orders and helped, ranging from research to writing the script of the
skripsi. In addition, the authors convey thanks to Novitasari Destiara, STP who gave
helped the calculation of the model. Expression of thanks is also given to father,
mother, families, and Yurisqi Mukdisari for all the prayers and affection. Thanks to
the friends of Agroindustrial Technology batch 48 over the spirit of cooperation
that has been given for the author attended. This skripsi may be beneficial in the
field of education and industry.
Bogor, August 2015
Moh Riyan Pratama
TABLE OF CONTENTS
LIST OF TABLES ............................................................................................... viii
LIST OF FIGURES ............................................................................................. viii
LIST OF APPENDICES ...................................................................................... viii
INTRODUCTION .................................................................................................. 1
Background .................................................................................................... 1
Research Objectives....................................................................................... 2
Scope of The Research .................................................................................. 2
METHOD................................................................................................................ 2
Data Collection .............................................................................................. 2
System Boundary ........................................................................................... 3
Model Description ......................................................................................... 3
Mass Balance ................................................................................................. 3
Energy Content of By-Product ...................................................................... 4
Process Flow of Self-Sufficient Energy ........................................................ 4
MASS BALANCE MODEL OF CACAO PROCESSING .................................... 5
Mass Balance Model Level I ......................................................................... 5
Mass Balance Model Level II ........................................................................ 6
Mass Balance Model Level III ...................................................................... 9
RESULT AND DISCUSSION ............................................................................. 12
Mass Balance Model Output ....................................................................... 12
Energy Self-Sufficient in Cacao Processing Industry ................................. 14
Closed System Production of Cacao processing Industry ........................... 18
CONCLUSIONS AND SUGGESTIONS ............................................................. 19
Conclusions ................................................................................................. 19
Recommendations........................................................................................ 19
REFERENCES...................................................................................................... 20
APPENDICES ...................................................................................................... 23
LIST OF TABLES
1 The cacao processing industry process specsificationsa ....................................... 5
2 Symbol description of mass balance models level II ........................................... 7
3 Mass balance model efficiency coefficient level II .............................................. 8
4 Description of mass balance models symbol level III ........................................ 10
5 Mass balance model efficiency coefficient level III ........................................... 12
6 Comparison of mass balance models yield level I, II, III, and actual factorya ... 13
7 Cacao processing industry energy needsb ........................................................... 15
8 The calculation of conversion biomass into electrical energy............................ 16
LIST OF FIGURES
1 Mass balance model level I .................................................................................. 6
2 Mass balance model level II (symbol description in Table 2) .............................. 6
3 Mass balance model level III (symbol description in Table 4) ............................ 9
4 Mass balance model level III (symbol description in Table 4) .......................... 13
5 Self-sufficient energy production process model of cacao processing industry
(4,500 kg/day) .................................................................................................... 17
6 Closed system production of cacao processing industry .................................... 18
LIST OF APPENDICES
1 The mass balance model calculations of level II ................................................ 23
2 The mass balance model calculations of level III............................................... 24
INTRODUCTION
Background
The cacao processing industry produces intermediate products which are
cocoa butter and cocoa powder. This production processes consume electrical
energy amounting to 50 GJ/t cacao (BC 2013; Ntiamoah and Afrane 2008). In
current practice, the energy is powered by the state electricity company (PLN) that
in general derived from the power plants of fossil fuel combustion.
The availability of fossil fuels has been declining due to an excessive
exploitation to meet the very massive and fast growing demand. The annual
availability of fossil fuels such as oil and gas declines to 4% and 8% (BPS 2015).
This conditions will continue and will end up in energy crisis of industrial
production in near future, so industry requires a source of renewable energy.
Development of a production system has the aspect of saving the usage of raw
materials and energy from nature, so as to reduce and prevent the incidence of
problems of energy and environment (Robert et al. 2002). Utilization of biomass in
by-product to produce energy can be an alternative to reduce or even replace the
consumption of fossil fuel.
The cacao processing industry produces a by-product containing lot of energy
(Prasertsan et al. 2002). The results of the by-product have more percentage
compared with the main product. Fresh cacao fruit will produce 6.7% cacao dried
bean (Effendi 1995) and over 80% by-product in the form of pod husk, pulp,
placenta, and bean shells (Patabang 2011; Uwagboe et al. 2010). The processing of
cacao fruits generates a large amount of cacao pod husk discarded as by product
represents between 70 to 75% of the whole cacao fruits weight (Alemawor et al.
2009; Cruz et al. 2012) and 8–11% cacao beans shells of the whole wet cacao beans
weight (Olubamiwa et al. 2006). By-product is a potential alternative energy source
because it contains many energy and abundant for its availability.
by-product which can be used as an alternative energy source is the pod husk
and bean shells. The energy contained within the cacao pod husk is 4,063 kcal/kg
(Syamsiro et al. 2012) and within bean shells is 4,116 kcal/kg (Pabisa 2013;
Spilacek 2014). The energy needs of the cacao processing industry are expected to
be fulfilled from the by-product. That large amount of energy can be reutilized as
alternative energy source with direct combustion and steam turbine system.
Biomass combustion such as burning cacao pod husk is to provide heat and power
linked in the renewable energy to provide sustainable service in the form of heat,
power, and electricity (Madguni and Singh 2013).
The moisture content of pod husk is 10–14% wb (Daud et al. 2013; Hamzat
and Adeola 2011) and in cacao beans shell is 4.9–11.2% wb (Domfeh 1972), that it
can burn directly in a boiler to produce steam and drive a turbine that produces
electricity (Diji 2013). The energy produced can be used as an energy input for
processing cacao to form a closed system. Other benefits of the application of a
closed system is that it is directly reducing the amount of waste produced by cacao
processing industry so it can reduce costs for handling the waste.
Development of closed systems for cacao processing industry is needed to
improve the efficiency of the production process and by-product that can be
2
generated. Analysis of alternative energy sources derived from biomass is needed
to find out the potential of the independent energy of cacao processing industry.
The mass balance model developed is expected to form a closed system for cacao
processing industry.
Research Objectives
This research’s objective was to develop independent energy production
system design in the cacao processing industry, with a minimum input and optimum
output. These objectives were achieved by:
1. Calculating mass flow in the process and constructing the mas balance model
of the production of cocoa butter and cocoa powder.
2. Calculating the energy needs of optimum production process and energy yield
content of the by-product.
3. Designing the flow of a process independent of the energy production system,
with a minimum input and optimum output.
Scope of The Research
The scope of this research was on cacao processing industry that produces
cocoa butter and cocoa powder product with an energy source from pod husk and
bean shells. Analysis to establish the model performed on the mass transfer flow of
materials during the production process (mass balance equilibrium), losses during
the production process, the use of energy for the production process, and the
analysis of the potential energy of by-product. The results of each model is in
comparison to analyze the level of consistency models and compared to the actual
factory data to analyze the level of accuracy of the model. Actual data based on the
cacao processing industry factory with a capacity of 5,000 kg of cacao fruit per day.
The closed system of mass flow and energy in cacao processing industry was
analyzed and established.
METHOD
Data Collection
The data used in the research data were secondary and primary data. The
secondary data used were journals, research papers, thesis, dissertations, and books
that included mass balance process and resource requirements. Most secondary data
were taken from data of production of dried cacao beans, cocoa powder and cocoa
butter that implemented the independent energy system. Meanwhile, the primary
data were the actual mass balance based on the cacao processing industry in
Lampung.
3
System Boundary
Cacao processing industry has a complex production system because it
involves many factors that are interconnected with each other. The factors are
material and energy (input) required in the production process as well as the byproduct (output) generated from the production process, which is interconnected.
These factors require a comprehensive approach to find the optimal solution of
energy used. Therefore, the systems approach used to analyze the flow of mass,
energy needs, including energy potential by-product of the production process of
cocoa butter and cocoa powder.
Cacao processing process consists of two main processes, namely the process
of upstream and downstream processes. Upstream process is converting raw
materials of cacao fruits and becoming dry beans, while the downstream processes
is to convert raw dried cacao beans into cocoa butter and cocoa powder. In building
this model between the upstream and downstream process needs to be integrated.
In this research, the primary processes were divided into four compartment such as
upstream processes, liquoring process, fat or butter separation process, and flouring
process. The main input material was cacao fruit with a capacity of 4,500 kg per
day and an additional ingredient (potassium carbonate) in the downstream
processes (Dyer 2003). The output is cocoa butter, cocoa powder, and by-product
such as pod husk, pulp, placenta, water vapour, and bean shells.
Model Description
Mass balance model was developed based on the process of flow of
compartment that can describe the actual production process. The model was
developed to obtain independent variables as input and dependent variables as
output. The model was built by using the ratio (coefficient of efficiency) of the
independent and dependent variables based on the principles of linear equations by
using a calculation tool namely Microsoft Excel.
Results of the model calculations were compared with actual production
process of cacao processing industry in Lampung. The results were used to identify
and calculate the amount energy potential of by-products as a source of energy to
meet the requires of the production process. This model has a high degree of
accuracy and in accordance with the actual production process forming the basis of
analysis of potential energy of by-products to develop more energy namely
independent production process.
Mass Balance
Mass balance model was created by identifying compartments that can
describe the production process. Later, the model was built by creating a mass
balance equation that connects the input (cacao and supporting materials) and
output (cocoa butter, cocoa powder, and by-products). The mass balance model was
developed from a simple model to an increasingly complex one. The simple model
was formed from the assumption that the single compartment system without
spesific flow of input and output.
4
Mass balance equations was solved by building a matrix based on the
efficiency factor (the ratio of the variable value) from secondary data on the mass
flow of cacao processing industry. After identifying tha mass balance and efficiency
factor, then the value of the efficiency equations and mass balance can be
determined.
Energy Content of By-Product
Based on a mass balance model that describes the actual condition of the
cocoa processing industry, the potential energy of by-product can be calculated with
the equation:
Potential Energy kCal = Mass kg × Caloric Value kCal/kg
Which, the mass of by-product was obtained from the calculation model, while the
caloric values were obtained from the literature.
Calculation assumptions used were derived from the caloric values of pod
husk of 4,063 kCal/kg (Syamsiro et al. 2012) and bean shells of 4,116 (Pabisa 2013;
Spilacek 2014). In this research it was used assumption of efficiensy boiler of
76.8% (Bora and Nakkeeran 2014) and turbine efficiency of 43.5% (Wolowicz et
al. 2012).
Process Flow of Self-Sufficient Energy
The by-product of cacao processing was examined in its utility as the main
energy source for the energy needs of the cacao processing industry. Analysis of
the energy usage begins with the calculation of the equilibrium of the mass balance
through observations of the input-output system of the mass of the material. The
resulting by-product and the potential conversion of mass into energy by-product.
Energy needs was analyzed from a classification tool (machines) used in the
production process, the calculation of the amount of energy used for the production,
and the sources of energy available.
The cacao processing industry used electrical energy in the production
process. However, the energy needs of the cacao processing industry differ from
one another, depending on the applied process technology. Electrical energy on the
cacao processing industry in Lampung used in the drying process, the liquor process,
milling process, pressing process, and the separation process. Specifications of the
engine used in the cacao processing industry with a capacity of 5,000 kg of cacao
fruit per day is presented in Table 1.
5
Table 1 The cacao processing industry process specsificationsa
Engine Spesification
Energy
Total of
Process
Capacity
Consumption Machines
(kg/h)
(kW)
Drying process I
60
20.92
2
Drying process II
80
10.18
1
Liquor process
50
19.15
1
Pressing process
18
669.4
2
Milling process
8
45.44
3
Separation process
30
45.3
1
a
Source: Prepared from Hamdani (2009)
The potential energy of by-product in the cacao processing industry can
determine the level of sufficient energy by way of comparison with the consumption
of the energy it uses. If the energy is greater or equal than the energy needs of the
plant, the plant could potentially be self-sufficient in energy. However, if the energy
obtained is smaller than the needs, the plant still requires energy from outside the
production system and the plant is not independent of energy.
MASS BALANCE MODEL OF CACAO PROCESSING
Modeling of the process of cacao processing is made into a model of level I,
II, and III. In making mass balance model, the first thing to do is identify the
compartments. Each compartment in the model of equations of mass balance was
made to determine input and output generated per compartment. The general
equations of the mass balance were the same as the input and the output. These
equations were identified with secondary data about the mass flow of cacao
processing to determine the value of the element of efficiency and balance of
masses.
The resulting output of each compartment as the product and the by-product
was to be reutilized so it has a higher value than if it was only processed into waste.
By-products that still have potential energy are reused as input in the process of
energy production. The by-product mass were obtained from the mass balance
model calculations and the heat value derived from literary sources. The potential
of the energy produced will be reduced by the energy need in the production process
to determine the level of energy self-sufficiency in the cacao processing industry.
Mass Balance Model Level I
Model level I was formed from the assumption that the system is the one
compartment thoroughly without specific flow linking inputs (I), products (P), and
by-product (W) (Figure 1). This model was developed based on the input and output
6
of the industry of dried cacao beans, cocoa butter and cocoa powder. The mass
balance equation for level I:
Figure 1 Mass balance model level I
I=P+W
Efficiency a =
P
I
The Mass Balance Model of the Level I has 1 compartment process with raw
materials input of 4,500 kg of cacao fruit per day and additional material of
potassium bicarbonate (Dyer 2003). The amount of raw materials used as model
inputs was in accordance with the yield observations.
Mass Balance Model Level II
Model level II was developed by building four compartments based on the
main process in the cacao processing industry so that each compartment can be
identified in greater detail. The compartment are the upstream processes (I), the
liquor process (II), the process of fat separation (III), and the flouring process (IV)
(Figure 2).
Figure 2 Mass balance model level II (symbol description in Table 2)
7
Table 2 Symbol description of mass balance models level II
Symbol
Explanation
I
Process of cacao fruits into dry beans
II
Process of dry cacao beans into cocoa liquor
III
Process of cocoa liquor into cocoa butter
IV
Process of cocoa cake into cocoa powder
I11
Cacao
I41
Potassium carbonate
X11
Dry cacao beans
X21
Cocoa liquor
X31
Cocoa cake
W11
Pod husk
W12
Water vapour
W13
Pulp and placenta
W21
Bean shell
P31
Cocoa butter
P41
Cocoa powder (fine)
Mass balance equations:
I
:I −X −W −W −W =
…………… (2.1)
II
:I −X −X −W =
…………………… (2.2)
III
: X − X − P = …………………………… (2.3)
IV
: X − P = …………………………………… (2.4)
Efficiency coefficient equation
The production of dried cacao beans (a1)
a =
X
=
I
dried cacao beans
cacao fruits
……………………………… (2.5)
The processes of 446 g cacao fruits produced 31.58 g of dried cacao beans (Maulina
2013). The percentage of dry beans was 7.08% of the cacao fruits (Maulina 2013)
or 7.5% of the cacao fruits (Adzimah 2010), then a1 was about 0.07.
The production of cacao pod husk (a2)
a =
I
=
………………………………… (2.6)
The cacao pod husk generated from processing the fruit into cacao beans was 70.4%
of cacao processed fruits (Adzimah 2010) but according to Nguyen (2014), cacao
fruits contained 70.15% of pod husk. Based on the data, a2 used for the model was
0.70.
8
The production of pulp and placenta (a3)
=
a =
………………………… (2.7)
Percentage of separable pulp and the placenta was 2.38% of the dried cacao beans
produced (Adzimah 2010; Pusporini 2013), then a3 was 0.02.
The production of cocoa liquor (a4)
a =
=
………………………… (2.8)
Cocoa liquor generated from processing dried cacao beans is 7.80 kg cocoa liquor
from 9.77 kg of dried beans (Elisabeth et al. 2007). According to Akinnuli et al.
(2014), researched that a total of 15733.46 kg cocoa liquor was obtained from
19987.73 kg of dried cacao beans. The percentage of cocoa liquor was 78.72%
(Akinnuli et al. 2014) and 79.83% (Elisabeth et al. 2007) of the cacao beans dried,
than a4 is 0.79.
The production of cocoa butter (a5)
a =
P
=
………………………………… (2.9)
Cocoa butter resulted from the processing of cocoa liquor into cocoa butter is about
35.87% (Akinnuli et al 2014) and 39% (Indarti 2007; Sudibyo 2006). The chosen
percentage used for a5 was 0.39 which was the greatest percentage that can be
generated.
Based on equation of efficiency coefficient factor, the summary of efficiency
coefficient can be seen in Table 3. The calculation of the value of the coefficient of
efficiency required to complete the matrix in building model level II, the full matrix
can be seen in Appendices 1.
Table 3 Mass balance model efficiency coefficient level II
The Value of
Symbol
Reference
Coefficient of Efficiency
a1
0.07
Adzimmah (2010); Maulina (2013)
a2
0.70
Adzimmah (2010); Nguyen 2014)
a3
0.02
Adzimmah (2010); Pusporini 2013)
a4
0.79
Akinnuli et al. (2014); Elisabeth et al. 2007)
a5
0.39
Indarti (2007); Sudibyo (2006)
9
Mass Balance Model Level III
Model level III was the development of a model of level II with detailing the
compartment into the process unit that has independent input and dependent
variables as the output of a process (Figure 3). The yield value of Mass Balance
Models Level III was better because it details the compartment into 9
compartments. The compartment was arranged by any processing that occurs in the
cacao processing industry.
A Mass Balance Model Level III model has 9 unit process with 2 independent
variables (I11 and I81) and 16 dependent variables (X11 to X91; W11 to W51; P71 and
P91). On dependent variables X61 can be ignored because it was only as a process
identifiers and wasa direct flow, therefore it has no flow coming out of the system.
The more specific a modeling was made the better results will be shown. A more
detailed calculation will produce a model with better results and will be able to
describe the actual conditions that actually occur in the cacao processing industry.
Figure 3 Mass balance model level III (symbol description in Table 4)
10
Table 4 Description of mass balance models symbol level III
Symbol
Explanation
1
The cracking process of cacao fruits
2
The fermentation process of cacao beans
3
The drying process of cacao beans
4
The roasting process of cacao beans
5
The separation process of beans (nib)
6
The grinding process of nib
7
The pressing process of cocoa liquor
8
The grinding process of cocoa cake
9
The separation process of cocoa powder
I11
Cacao fruits
I81
Potassium carbonate
X11
Cacao beans with pulp and placenta
X21
Wet cacao bean
X31
Dried cacao bean
X41
Roasted cacao bean
X51
Nib
X61
Cocoa liquor
X71
Cocoa cake
X81
Cocoa powder (fine and coarse)
X91
Cocoa powder (coarse)
W11
Pod husk
W21
Pulp and placenta
W31 and W41 Water vapour
W51
Beans shells
P71
Cocoa butter
P91
Cocoa powder (fine)
Mass balance equation:
1
:I −X −W
2
:X −X −W
3
:X −X −W
4
:X −X −W
5
:X −X −W
6
:X −X =
7
:X −X −P
8
:I +X +X
9
:X −X −P
=
………………………………………… (3.1)
=
………………………………………… (3.2)
=
………………………………………… (3.3)
=
………………………………………… (3.4)
=
………………………………………… (3.5)
………………………………………………… (3.6)
= …………………………………………… (3.7)
−X =
…………………………………… (3.8)
= …………………………………………… (3.9)
Efficiency coefficient equation
The production of cacao beans with pulp and placenta (a1)
a =
I
=
w
……………………… (3.10)
11
Cacao beans produced from the process of cracking the fruit has a percentage
amounting to 21.7% (Adzimah 2010; Nguyen et al. 2001; Velayutham et al. 2013),
then a1 was 0.22.
The production of wet cacao beans (a2)
a =
=
…………………… (3.11)
w
Percentage of separable pulp and the placenta was 2.38% generated from cacao
beans with pulp and placenta (Adzimah 2010; Pusporini 2013), then a2 was 0.02.
The production of dried cacao beans (a3)
=
a =
……………………………………… (3.12)
w
As much as 25 kg of wet beans with moisture content of 60% (wet basis) wasdried
to moisture content of 6.45-7% (Guehi et al. 2010; Napitupulu et al. 2012).
Percentage dried bean up to 43% of the wet beans, then the a3 was 0.43.
The production of roasted cacao bean (a4)
a =
=
…………………………………… (3.13)
Roasted cacao beans resulted from roasting process was 9.77 kg with input (dried
cacao beans) 10.13 kg (Elisabeth et al. 2007). Based on the research of Akinnuli et
al. (2014), a total of 20,957.3 kg of roasted cacao beans produced from the dried
cacao beans was 21,500 kg. Percentage of roasted beans resulted from roasting
process were 96.54% (Elisabeth et al.2007) and 97.48% (Akinnuli et al. 2014), then
a4 is 0.97.
The production of nib (a5)
=
a =
………………………………… (3.14)
Percentage of the nib that can be produced from the separation of the nib with shells
amounting to 82% of the roasted cacao beans produced (Azizah 2005; Pusporini
2013), the a5 was 0.82.
The production of cocoa butter (a6)
a =
P
=
w
………………………………………… (3.15)
Cocoa butter resulted from the processing of cocoa liquor into cocoa butter has a
percentage of 39% (Indarti 2007; Sudibyo 2006), then a6 was 0.39.
12
The production of cocoa powder (fine) (a7)
a =
P
=
w
w
………………………… (3.16)
Cocoa powder (fine) resulted from the grinding process and separation process was
4.77 kg with the input of the cacao beans (coarse and fine) 5 kg (Elisabeth et al.
2007). Percentage of cocoa powder produced from the milling process and
separation process was 95.4% (Elisabeth et al. 2007; Joel et al. 2013), then a7 is
0.95.
Based on equation of efficiency coefficient, the summary of factor efficiency
coefficient can be seen in Table 5. The value of the coefficient of efficiency of
model level III used to supplement matrix in building a model of level III
(Appendices 2).
Symbol
a1
a2
a3
a4
a5
a6
a7
Table 5 Mass balance model efficiency coefficient level III
The Value of Coefficient
Reference
of Efficiency
Adzimmah (2010); Nguyen et al. (2001);
0.22
Velayutham et al. (2013)
0.02
Adzimmah (2010); Pusporini (2013)
Guehi et al. (2010); Napitupulu et al.
0.43
(2012)
Akinnuli et al. (2014); Elisabeth et al.
0.97
(2007)
0.82
Azizah (2005); Pusporini (2013)
0.39
Indarti (2007); Sudibyo (2006)
0.95
Elisabeth et al. (2007); Joel et al. (2013)
RESULT AND DISCUSSION
Mass Balance Model Output
Based on the Mass Balance Model Level I, II, and III had consistent results
of cocoa butter and cocoa powder per dried cacao beans, presented in Table 6. The
consistency of the results of each mass balance models proved that the calculated
model has consistent results. The Mass Balance Model Level I was the basic
calculation that becomes a comparison for Mass Balance Models for Level II and
III.
13
Table 6 Comparison of mass balance models yield level I, II, III, and actual
factorya
Model of
Model of Model of
Factory
Materials
Level I
Level II
Level III Actual Data
Cocoa butter (%)
30.86
30.8
32
32.8
Cocoa powder (%)
47.86
48.2
50
42.5
a
per amount of dried cacao beans
The Mass Balance Model Level II has a ratio value greater than the Mass
Balance Model Level I and there was an increased level of efficiency system that
became 100%. The Mass Balance Model Level II entire mass flow can be identified
so that no loss occurs in Mass Balance Model Level I.
Mass Balance Model Level III had the greatest value of the cocoa butter and
cocoa powder than the Mass Balance Model Level II. This model has a
compartment that development was more complex than the Mass Balance Model
Level II that the resulting product ratio was better. The efficiency of the system on
a Mass Balance Model Level III was the same with the Mass Balance Model Level
II can also identify all of its flow. The model has compartment and increasingly
detailed, will resulting in the better product ratio and can describe the actual
condition of the production process.
Result obtained from Mass Balance Model Level III of cocoa butter was equal
with factory’s actual data, while a higher result obtained in cocoa powder than
factory’s actual data. The difference was due to the actual data on the factory that
still incurred loss of 5–8% on the liquor processing and pressing process. The
production system in factory also does not re-mill (cycle) cocoa powder that were
still coarse that the final yield of cocoa powder (fine) was lower compared to every
model because the factory was focus more on cocoa butter, but the cocoa powder
only becoming additional product.
Figure 4 Mass balance model level III (symbol description in Table 4)
14
Cocoa butter and cocoa powder yield can be increased if the machine works
in optimal conditions and also applying the cycle system for cocoa powder that is
still rough. Comparison between products on a model level III with factory’s actual
data will show the potential of production improvement. Potential yield
improvements can be increased on the cocoa powder product to 7.5% that can be
seen in Table 6.
Increasing cocoa powder yield can be done by not washing the cacao beans
after fermentation. Washing will remove the bean shells thereby reducing the yield
of cocoa cake and cocoa powder yield will be reduced. Moisture content of cacao
beans also affect the yield of cocoa powder produced. The shrinkage and volume
change were associated with the cacao beans moisture contents, which can reduce
the cacao mass (Asiedu 1989; Gereke and Niemz 2010). The increase rate of 4% of
moisture content will increase the linear dimensions of 3%, sperichity values of 2%,
and deformation linearly of 57% (Plange et al. 2012).
Energy Self-Sufficient in Cacao Processing Industry
The cocoa processing industry produces semi-finished products namely
cocoa butter and cocoa powder. The cocoa butter and cocoa powder made from
cocoa liquor through the several processing stages with the initial input is the dried
cacao beans. In addition to producing the aforementioned products, cacao
processing industry also produces by-product in the form of beans shell. Cacao
beans shell contains small amounts of energy that can be used as an energy source.
But the energy produced from the shell of the cacao beans are not enough to meet
the energy needs of the production sector.
The fulfillment of energy for production can be met from a by-product
produced in the process of the upstream of the cacao processing. The upstream
process cacao produces more than 75% by-product in the form of pod husk, pulp,
placenta and water vapour that is still not used (Patabang 2011). The number of byproduct is more compared to the resulted product. Whereas the by-product still
contains considerable amounts of energy to meet the energy needs of the production
sector. The by-product in the form of pod husk contains energy amounting to
4,063.1 kcal/kg (Syamsiro et al. 2012) and bean shells of 4,116 kcal/kg (Pabisa
2013; Spilacek 2014).
The cacao processing industry requires electrical energy to do the production
process. The main processing applied by the cacao processing industry is the
upstream process, liquor process, pressing process (separation of cocoa butter), and
the milling process. In each major process there are some machines that use
electrical energy, as in Table 1. Based on Table 1 industry with the capacity of 4,500
kg per day needs electric energy sources amounted 14,436 kWh, complete
calculation is in Table 7.
15
Table 7 Cacao processing industry energy needsb
Engine
Operation
Input
Total of
Spesification
time
Process
Machine
(kg) (kg/h) (kW)
(hours)
Drying I
970.2
60
20.92
2
8.1
Drying II
417.2
80
10.18
1
5.2
Separation I
404.7
80
20.74
1
5.1
Grinding
331.8
50
19.15
1
6.6
Pressing
331.8
18 669.40
2
9.2
Milling
202.4
8
45.44
3
8.4
Separation II 213.0
30
45.30
1
7.1
Total of Energy Consumed
Energy
Consumed
(kWh)
338.3
53.1
104.9
127.1
12,340.7
1,149.7
321.7
14,436.0
b
Source: Prepared from Hamdani (2009)
A closed system model of the cacao processing industry (Figure 5) is an
energy independent production model that is able to meet the needs of energy
without input from the outside of production systems beside the input of raw
materials and supplementary materials. The potential energy at the pod husk and
the beans shell is calculated based on the value of heat (heating value) multiplied
by the sum of the mass of the model level III.
The amount of energy obtained from the by-product of production processes
is reutilized to meet the needs of electric energy during the production process. Byproduct was converted into heat energy by steam turbine system. Pod husk and
beans shell were burned directly to produce steam used in the turbine to produce
electrical energy. In the theoretical calculations, the electrical energy generated
from the potential energy of the pod husk and beans shell is the 27,555.2 kWh per
day. The conversion of biomass into electrical energy calculations are presented in
Table 8 and the model (Figure 5) explains that energy needs for production process
can be self-sufficient in energy and still have a surplus as much as 91%.
16
Table 8 The calculation of conversion biomass into electrical energy
PARAMETER
Plant capacity
Avalability of pod husk
Avalability of bean shells
UNIT
kg cacao/day
kg/day
kg/day
AMOUNT
4,500.0
3,510.0
72.8
Energy Content
Pod husk
Bean shells
kCal/kg
kCal/kg
Total Energy of Biomass
Pod husk
kCal
Bean shells
kCal
Total Steam
Heat required to produce steam (derived from
kCal/kg
the steam table for saturated conditions 30 bar)
Boiler efficiency
%
Steam from pod husk
kg/day
Steam from bean shells
kg/day
Total generated steam per day
kg/day
Total generated steam per second
kg/s
Total Electrical Energy
Conversion of steam in the turbine
kg/s
Turbine efficiency
%
The power from turbine
kWh
Electrical energy generated
kWh/day
The plant's energy needs
kWh/day
Electrical Energy Can be Met
Source: c Syamsiro et al. 2012
4,063.1c
4,116d.0
14,261,481.0
299,812.2
669.9
76.8e
16,355.6
343.8
16699.4
0.5
61f.0
43.5 f
833,000 f.0
27,555.2
14,436.0
191%
d
Pabisa 2013; Spilacek 2014
Bora and Nakkeeran 2014
f
Wolowicz et al. 2012
e
The use of cacao pod husk and bean shells as the fuel of power plant for the
production process can replace the electrical energy obtained from coal power
plants of PLN. A total of 8.1 tons of coal can generate electricity amounting to
24,000 kWh (Sulistyono 2012). In meeting the demand for electricity in the
production process as much as 14,436 kWh, PLN needs as much as 0.6 tons of coal.
The uses of cacao pod husk and bean shells as fuels of power plants can save the
use of coal as much as 4.8 tons per day. Cacao pod husk and bean shell of 1 tons
can save the coal consumption as much as 1.3 tons.
Emissions from cacao shells combustion have very small levels of SO2
around of 90 mg/m3, but the level of NO are mostly between 1,000-1,400 mg/m3
(Spilacek 2014). Biomass such as cacao pod husk and bean shells remains will
decompose that it will still release pollution of C, H, N, O, and S which contained
the by-product.
17
Figure 5 Self-sufficient energy production process model of cacao processing industry (4,500
kg/day)
18
Closed System Production of Cacao processing Industry
In forming a closed system production, by-product that has the potential to be
reutilized or processed into additional products need to be built into the system. A
production system produces a by-product in the form of water vapour, pulp and
placenta, cacao pod husks and bean shells. The by-product which still contains
amount of energy such as pod husks and bean shells are reutilized as energy inputs,
but not all by-products can be reutilized as energy input due to the high level of
moisture content, such as water vapour, pulp and placenta.
The water vapour produced from the drying process and the roasting process
reutilized by condenser to produce a water, that can utilized for irrigation in the
cocoa groves or industrial activity. The pulp and placenta resulted from the
fermentation process can be reutilized as bio-herbicide. Pulp and placenta results of
the fermentation of cocoa beans containing and produce acetic acid which can
damage the weeds with a dose of 500 L/ha (Pujisiswanto 2011). A closed system
production of cacao processing industry shown in Figure 6, which all of output from
cacao production systems can be reutilized.
Figure 6 Closed system production of cacao processing industry
19
CONCLUSIONS AND SUGGESTIONS
Conclusions
The cacao processing industry is an industry that can be self-sufficient in
energy by performing processing from upstream processing (cacao fruit). The
upstream process produces a by-product that contains more energy than with
downstream process. The resulted by-product can not be used to generate all the
energy (electricity) due to high moisture content. Utilization of pulp and placenta
can be used as bio-herbicide for the cacao plant. The resulted water vapour can be
reutilized as a source of water for irrigation in the cocoa groves or industrial activity.
The generated potential energy comes from the cacao pod husk and beans shells.
On the cacao processing industry with a capacity of 4,500 kg of fruit per day,
produces cacao pod husk is 3,510 kg and cacao beans shell is 72.8 kg. The byproduct such as pod husk and bean shells can generate electrical energy by as much
as 27,555.2 kWh per day with the production of electricity for energy needs as much
as 14,436 kWh so the cacao processing industry can be said to be energy
independent and still surplus of electricity as much as 91%. Cacao pod husk and
bean shell of 1 tons can save the coal consumption as much as 1.3 tons. In addition
to independent energy cacao processing industry can also produce bio-herbicide
and water. Energy independent production model on this research can be developed
into a cacao processing industry production system that is independent of energy.
The cacao processing industry can be developed into a closed system production of
industry.
Recommendations
Further research in applying this system needs to be done to adjust energy
needs. This adjustment needs to be done because every industry has a long operation
and engine specifications of different machines that their energy needs will be
different.
20
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Robert KH, Schmidt-Bleek B, Aloisi LJ, Basile G, Jansen JL, Kuehr R, Price