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for Malaysian Palm Oil Milts

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 Guidance for Industry
The Gode of Good
Man ufactu ri ng Practices
(GMP) for Malaysian
Palm Oil Mills

First Edition

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nastrr PERSATUAN MINYAK SAWIT MALAYSIA
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MALAYSTAN PALM OtL ASSOCTATTON (MpOA)
MPOA
PEAsAAAN M NYAK sAW T
(Nombor Pendaftaran Pertubuhan 1045)
MPOA may revise and reissue this guidance from time to time as the
slate of technology advances relative to process control in a palm oil mill.
we will accept comments from members of MpoA on this edition of this
guidance at any time for consideration in preparing a future edition.
Comments should be addressed to:

MALAYSIAN PALM OtL ASSOCIATTON (MPOA)

12th Floor, Bangunan Getah Asli (Menara)
148, Jalan Ampang, 50450 Kuala Lumpur

Telephone 603-27105680
Facsimile 603-27105679
Website http://www.mpoa.orq. mv
Email mpoa@mpoa.orq.mv

Copyright 2005 Malaysian Palm Oil Association

All rights reserued

MPOA BOOKLET SERIES: 3/2006

 TABLE OF CONTENTS

Foreword

Abbreviations

1. lntroduction

2. Scope

3. Reference Documents

4. Definitions

5. General Requirements 6
5.1 GAP from FFB suppliers 6
5.2 Documenttraceability b
5.3 Mill construction and design 6
5.4 Hygiene and sanitation 7

6. Milling Operations 8
6.1 FFB reception 8
6.2 Sterilisation I
6.3 Crane/ tipper/ threshing 9
6.4 Digestion and pressing 10
6.5 Clarification 10
6.6 Crude palm oil storage 11

6.7 Crude palm oil transportation 12

6.8 Kernel recovery plant 12
6.9 Nut drying process 13
6.1 0 Nut cracking process 13
6.11 Kernel/ shell separation process 13

MPOA BOOKLET SERIES: 3/2006

 6.12 Kernel drying process 13
6.13 Palm kernel storage 14
6.14 Kernel transportation 14

7. Environment 15
7.4 Palm Oil Mill Efftuent (POME) 15
7.5 Fibre and shell 15
7.6 EFB 15

8. Laboratory 15

9. Human Resources 16

10. Control of Non-conforming Products 16

MPOA BOOKLET SERIES: 3/2006

 FOREWORD

Food Safety is everybody's concern, and palm oil as one of the world's
major edible oils is not exempt from this concern: it has to be food safe.
The Malaysian palm oil industry is committed towards ensuring its palm
products are safe to eat and also comply with the requirements of
internationally recognised and accepted Food Safety programs. ln Iine
with this, the Food Safety Committee (FSC) of the Mataysian patm Oit
Association (MPoA) has recommended the implementation of Hazard
Analysis critical control Points (HACCP) and the adoption of ISo 22ooo,
Food Safety Management System certification when it becomes
available.

HACCP is a PREVENTIVE Food Safety program, which requires Good

Hygiene Practices and Good Manufacturing Practices as prerequisites.
The FSC, as such, formed a Working Group to drawn up this Code of
Good Manufacturing Practices (GMP) in a move towards HACCP. ln view
of the large number of mills within the ambit of the Association, this code
of GMP has to be generic in nature to cater for variations in facilities and
processing techniques among MPOA member mills. The general
principles as laid down in this Code of GMP, however, remain unchanged
and should be adhered to. lt is recommended that every mill should come
up with its own Code of GMP as applicable to their mill.

This code of GMP marks yet another significant milestone for the palm oil
industry. Of special mention is that the Working Group was drawn up from
a wide range of representatives from the palm oil industry - from
researchers in both the private and public sectors, enforcement officers,
engineers working for plantation houses, as well as mill owners. This
document, as such, is the culmination of views from across the industry.
The coming together of such a group with such diverse backgrounds
reflects our single-minded objective of wanting to implement Food Safety
for the good of the industry. Credit must go to the following Working
Group members for their dedication in coming up with this document.

MPOA BOOKLET SERIES: 3/2006

Name Orqanisation
Madam Jacqueline Foo Sueh Kuantan Trading Company Sdn Bhd
Chuan
lr Teoh Guan Eng FELDA Palm Industries Sdn Bhd
lr Jagjit Chinjer Golden Hope Plantations Bhd
Mr Joseph Tek IJM Plantations Bhd
lr Telochan Singh United Plantations Bhd
Mr Chew Jit Seng Malaysian Palm Oil Association
Miss W. Amintha Perera Malaysian Palm Oil Association
PuanZur'ain Madon Malaysian Palm Oil Association
Dr Ainie Kuntom Malaysian Palm Oil Board
Dr Chong Chiew Let Malaysian Palm Oil Board
Dr Chow Mee Chin Malaysian Palm Oil Board
Puan Rozita Baharudin Malaysian Palm Oil Board

I am grateful to MPOB officers for their significant contribution in this

committee and I am indebted to Mr M R chandran, former chief
Executive of MPoA, for his confidence in the FSC and for his unwavering
support and participation in the initial phase in the drafting of this code of
GMP. The involvement of Encik Azizi Meor Ngah, the incumbent chief
Executive of MPoA and his inputs in our FSC's discussions, reflect the
seriousness and his commitment towards this cause. Lasfly, I would like
to express my sincere thanks to my Group chief Executive, Dato' Abd
wahab Maskan, Kumpulan Guthrie Berhad for consenting to my
involvement in MPOA.

lr Ng Say Bock
Chairman, Working Group on Code of GMp
Chairman, Food Safety Committee
Malaysian Palm Oil Association
22 Julv 2005

MPOA BOOKLET SERIES: 3/2006

 ABBREVIATIONS
cPo Crude Palm Oil
EFB Empty Fruit Bunches
FFB Fresh Fruit Bunches
GAP Good Agricultural Practices
GMP Good Manufacturing practices
HACCP Hazard Analysis Critical Control points
PK Palm Kernel
PKO Palm Kernel Oil
POME Palm Oit Milt Efftuent
MPOA Malaysian Palm Oil Association
MPOB Malaysian palm Oil Board

MPOA BOOKLET SERIES: 3/2006 3

1. !NTRODUCTION

This code of GMP has been prepared by a working Group under the
MPOA Food Safety Committee.

It is intended to be a general outline of the good practices that should be

followed by MPoA member mills aiming to achieve the desired GMp and
quality standards demanded by consumers today.

It is hoped that this Code will lead to the eventual harmonisation of milling
practices among MPOA member mills.

As we prepare ourselves to meet increasingly higher standards

demanded by consumers, we need to showcase our industry's
achievements as a competitive edge in an increasingly competitive global
business environment.

Following the advent of the Roundtable on sustainable palm oil (RSpo)

in 2003 and the introduction on 1't January 2005 of European Union
regulations on traceability, there is now greater emphasis on food safety
and sustainability issues, with pressure not only on upstream producers
to comply, but also on downstream players along the entire supply chain.

To ensure that our palm oil is the product of preference, we need to lead
the palm oil milling industry by forging ahead on the platform of quality
and hygiene. lt is hoped this Code of GMP will be the catalyst for the
industry's first step forward.

2. SCOPE

This Code of GMP provides the good milling practices for the processing
of oil palm FFB, from FFB reception at the mill through to transportation of
CPO and palm kernel out of the mill.

It also covers the general requirements pertaining to the control of non-

conforming products, human resources and laboratory practices.

MPOA BOOKLET SERIES: 3/2006 4

3. REFERENCE DOCUMENTS

The following reference documents are indispensable for the application

of this document.

MS 15'14 : 2001, General Principles of Food Hygiene

MS 1480:1999, Food safety According to Hazard Anatysis and criticat
Control Points (HACCP) Sysfem
The code of Good Manufacturing Practice for the Australian Grape and
Wine lndustry
Unilever Code of Working Practice for Oit Mills (Tropical Oils)

4. DEFINITIONS

For the purpose of this document, the following definitions shail apply:

4.1 Clean water

Raw water that has been treated by the mill for use in processing, or
that obtained directly from authorised water companies.

4.2 Pure oil

oil recovered from the clarifier before the purifier and vacuum drier.

4.3 Storage tank foots

Remnant or residual oil from the storage tank.

4.4 Building

Any enclosed permanent structure used for processing and storage.

4.5 Contamination

Any substance that is not palm oil or that is foreign to palm oil.

MPOA BOOKLET SERIES: 3/2006

5. GENERAL REQUIREMENTS

5.1 GAP from FFB suppliers

Mills should request for GAP from their FFB suppliers, which
includes cleanliness of external transportation used in FFB
conveyance.

5.2 Document traceability

All deliveries should be comprehensively documented for

traceability purposes.

5.3 Mill construction and design

5.3.1 Building and structure

5.3.1 .1 Proper facilities and equipment should be provided
for processing FFB.

5.2.2.2 Plant buildings and structures should be suitable in

size, construction and design to facilitate
maintenance and to provide a conducive
environment for the production of good quality,
contaminant-free oil palm products from the mill.

5.3.2 Mill design

5.3.2.1 ln designing a mill, the following should be taken
into consideration:

a) provision of sufficient space for placement of

equipment and storage of materials necessary
for the production of good quality CPO and PK;

b) proper process layout to prevent contamination

of processing matenals;

c) provision of good lighting at all processing

stations, particularly for night operation, and at
all sample collection points for analysing and
testing of samples;

MPOA BOOKLET SERIES: 3/2006

 d) proper layout of plant equipment to facilitate
cleaning and maintenance; and

e) provision, where necessary, of adequate

screening or other protection against pests.

5.3.3 Mill equipment and related facilities

5.3.3.1 All plant equipment and related facilities should be
operated using laid down procedures and all
maintenance should be well documented.

5.3.3.2 Procedures for maintaining cleanliness of the mill

area and facilities should be established and
implemented.

5.3.3.3 lnstruments and controls used for measuring,

regulating or recording and which impact on quality
should be accurately calibrated, adequately
maintained, and adequate in number for their
designated uses.

5.3.3.4 Portable equipment in contact with CPO and PK

surfaces should be properly cleaned and dry before
use.

5.3.3.5 Equipment coming into contact with CPO and PK

should be made of materials not detrimental to
CPO quality, preferably stainless steel. Copper or
alloys of copper should not be used.

5.3.3.6 The storage tank should be re-calibrated when

inaccuracy is detected.

5.4 Hygiene and sanitation

5.4.1 Mill buildings, fixtures and other physical facilities should be

maintained in a sanitary condition and in good repair to
prevent contamination of oil palm products.

5.4.2 Mill management should take all reasonable measures and

precautions to ensure cleanliness of the mill premises,
equipment and personnel.

MPOA BOOKLET SERIES: 3/2006

 5.4.3 AII storage equipment such as CPO storage tanks and
kernel bunkers and any processing equipment with surfaces
coming into direct contact with CPO or PK should be
cleaned at planned intervals, and at least once ayear.

5.4.4 Adequate washing points, emergency showers, changing

rooms and toilets should be provided for good sanitary
practices.

5.4.5 All oil spillages and oil leakages should be cleaned

immediately.

6. MILLING OPERATIONS

6.1 FFB reception

6.1.1 Weighbridge
6.1.1.1 The area at the weighbridge should always be free
from mud, debris, stagnant pools of water and
loose fruits.

6.1.1.2 All documentation regarding receipt of FFB and

dispatch of CPO and PK should be maintained
systematically for easy retrieval and must meet the
minimum requirements set by the relevant
authorities.

6.1.1.3 Annual inspection and calibration of the

weighbridge should be carried out as required in
compliance with legal requirements. ln addition, the
accuracy of all weighings should be monitored and
where applicable, corrective action should be taken
immediately.

6.1-1.4 Security procedures should be in place at the

weighbridge so that all FFB, CPO and PK
weighings are correctly carried out and recorded.

MPOA BOOKLET SERIES: 3/2006

 6.1.2 FFB ramp and hoppers/bays

6.1.2.1 The FFB ramp and hoppers/bays should be

maintained in a clean and satisfactory condition.
The ramp should at least be concreted.

6.1.2.2 All FFB shoutd preferably be ptaced direcfly into the

FFB hoppers/bays.

6.1.2.3 Processing of FFB should be on a first-in first-out

basis.

6.1.2.4 Care should be taken to minimise bruising of fruits.

6.1.3 FFB grading

FFB should be graded according to the guidelines contained

in the latest grading manual issued by MpOB, or according
to in-house standards, whichever is more stringent.

6.2 Sterilisation

6.2.1 Steam sterilisation should be done efficienfly following the

regimes set by mill management.
6.2.2 The sterilisers, cages and steriliser hoppers/bays should be
kept clean.

6.2.3 Oil recovered from the steriliser condensate should not be

added to the normal process or final CPO.

6.3 Crane/tipper/threshing

6.3.1 Any leakages and spillages from damaged oil seals and
hoses should be attended to immediately.

6.3.2 The use of food-grade lubricants is encouraged.

MPOA BOOKLET SERIES: 3/2006

6.4 Digestion and pressing

6.4.1 Any lubrication and hydraulic oil leakages at the digester and
press gear drives and at the screw press cone section
should be attended to immediately.

6.4.2 The digester level should always be kept to the maximum

and the temperature of the digested mash should not exceed
95'C.

6.4.3 At the end of processing, the digester should be emptied

completely.

6.4.4 The screw presses should be operated such that oir ross and
the amount of broken kernel in fibre are minimised according
to the mill's standard operating procedures.

6.4.5 The use of food-grade lubricants for gears and bearings is

encouraged.

6.5 Clarification

6.5.1 Oilclarification
6.5.1.1 For effective oil separation, the crude oil from the
press should be diluted with clean water to reduce
viscosity.

6.5.1.2 Coarse solids particles should be removed from the

diluted crude oil by using a preset mesh size
vibrating screen that is free from tears.

6.5.1.3 The temperature of the screened diluted crude oil

should be maintained at approximately 95"C.

6.5.1.4 Any crude oil spillage should be cleaned up

immediately using procedures appropriate to the
location of the spillage.

6.5.'1.5 The clarifier should be routinely desludged

according to procedures established by the mill.

MPOA BOOKLET SERIES: 3/2006 1O

 6.5.1.6 Cleaning and inspection of the tank's internal
should be carried out regularly.

6.5.2 Oil recovery from clarifier underflow

6.5.2.1 The temperature of the sludge tank should be
maintained at approximately 90o C.

6.5.2.2 Cleaning and inspection of the sludge tanks should

be carried out regularly.

6.5.3 Oil purification and drying

6.5.3.1 The temperature of the pure oil tank should not

exceed 95oC.

6.5.3.2 The pure oil tank should be cleaned at regular

intervals.

6.6 Crude palm oil storage

6.6.1 The quality of CPO in the storage tanks should be analysed

and recorded on a daily basis.

6.6.2 For short-term (less than one month) storage, the

temperature of the CPO should be maintained at 50 to 55.
C

6.6.3 Longterm storage of the CPO should be at ambient

temperature and any equlpment for heating for the CPO
should be turned off.

6.6.4 Localized overheating or pressure build-up should be

avoided.

6.6.5 CPO storage tanks should be cleaned regularly, at least

once a year or more frequently if necessary. A record should
be maintained of when storage tanks are cleaned. To
prevent build-up of storage tank foots, daily draining of
storage tanks is recommended.

6.6.6 During cleaning, the storage tank foots should not be added
back to the final CPO.

MPOA BOOKLET SERIES:3/2006 11

6.7 Crude palm oil transportation

6.7.1 When more than one storage tank is in use, CpO should be
dispatched on a first- in first-out basis.

6.7.2 The loading and unloading of CPO should be properly

documented.

6.7.3 Empty lorry tankers arriving to collect CPO should be clean

and secured.

6.7.4 The tankers should be clean, dry and fit for the
transportation of CPO. The use of dedicated Iorry tankers is
highly encouraged.

6.7.5 Representative samples of CPO should be taken and tested

as per contract.

6.7.6 After loading of the CPO into the lorry tanker, all access
points of the lorry tanker should be securely sealed with
numbered seals.

6.7.7 The time of departure should be recorded in the dispatch

document as prescribed by the relevant authorities.

6.8 Kernel recovery plant

6.8.1 Nut/fibre separation

6.8.1.1 The rotary nut-polishing drum should be correctly
operated to ensure proper polishing of nuts and
removal of fibres.

6.8.1.2 The nut conveying system and the filling of the nut
bins should be controlled. Spilled nuts should be
collected and dealt with according to established
procedures.

6.8.1.3 The nut bins should be cleaned at planned intervals

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6.9 Nut drying process

Where nut driers are in use:

6.9.1 The temperature of the drying medium and the retention time
of the nuts in the silos should be controlled to ensure proper
drying of nuts.

6.9.2 The silos should be thoroughly cleaned at regular intervals.

6.10 Nut cracking process

Nut cracking should be carried out with minimum breakage of pK.

6.11 Kernel/shell separation process

6.11.1 The kernel/shell separators should be operated according to

specified conditions to achieve minimum dirt content in pK
and minimum kernel losses.

6.11.2 lf clay solution is used as the separating medium, the pK

discharged from the clay baths should be properly rinsed
with clean water. The specific gravity of the clay solution
should be measured and monitored at regular intervals. The
clay used should be free from heavy metal.

6.12 Kernel drying process

6.12.1 The temperature of the drying medium and the retention time
of the kernels in the silos/tray driers should be controlled for
proper drying of kernels.

6.12.2 Silos/tray driers should be thoroughly cleaned at regular

intervals.

6.12.3 Any off-quality PK produced should be segregated and dealt

with according to established procedures.

MPOA BOOKLET SERIES: 3/2006 13

6.13 Palm kernel storage

6.13.1 A cleaning programme for all kernel storage facilities should

be in place.

6.13.2 lndividual kernel storage units should be clearly identified.

6.13.3 The kernel storage facilities should be well ventilated,

covered from the elements and protected against pest
infestation.

6.13.4 Any off-quality PK being stored should be properly

segregated from normal production and handled according
to established procedures.

6.13.5 Precautionary measures should be in place to prevent

contamination of PK in storage by foreign matter.

6.14 Kernel transportation

6.14.1 PK should be dispatched in clean, well-covered and properly

sealed lorries.

6.14.2 Before loading, the loading compartments should be

inspected for clean iness.
I

6.14.3 Strict security measures should be observed to prevent

contamination of the PK by any foreign materials during
transportation to the buyer.

6.14.4 Representative PK samples should be taken and tested as

per contractual specification.

6.14-5 ln the event that spillages of petrol/ diesel or lubricant from

the vehicles occur during loading or unloading, the
petrol/diesel or lubricant must not be allowed to come into
contact with any PK.

6.14.6 PK should be stored and dispatched on a first-in first-out

basis.

6.14.7 All stock movements should be properly documented.

MPOA BOOKLET SERIES: 3/2006 14

7. ENVIRONMENT

7.1 All relevant environmental legislation should be complied with.

7.2 Policies and procedures for minimising the production of waste and
its impact on the environment should be developed, implemented
and maintained.

7.3 All waste products should be appropriately disposed of in

accordance with existing legislation.

7.4 Palm Oil Mill Effluent (POME)

The treatment system adopted must be continuously and regularly

maintained to meet the requirements of the Malaysian
environmental authorities.

7.5 Fibre and shell

Any excess fibre and shell should be stored and dealt with
according to established procedures.

7.6 EFB

EFB should be properly managed in compliance with environmental

legislation.

8. LABORATORY

Mill laboratories should be sufficiently equipped for their purpose and

should be staffed with competent personnel.

MPOA BOOKLET SERIES: 3/2006 15

9. HUMAN RESOURCES

All milling operations should be conducted by competent personnel on the

basis of appropriate training, education and experience.

10. CONTROL OF NON.CONFORMING PRODUCTS

Non-conforming in-coming raw materials and processed products should

be dealt with according to established procedures.

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