Indonesia and the Seduction of Coconut Island

Indonesia is famous for its seductive land of coconut islands. This is because the extent of coconut plantations in Indonesia reaches around 3.7 million hectares, most of which are smallholder plantations. The extent of these coconut plantations places Indonesia as the owner of the largest coconut plantations in the world, and the Philippines is in second place. Coconut trees mainly grow along the coast, and indeed Indonesia also has the longest coastline in the world. Even though Indonesia's coconut plantation area is number 1 in the world, its productivity is still lower compared to the Philippines, so the Philippines is also the number 1 coconut producer in the world. The coconut industry in the Philippines is also more advanced than Indonesia. Indonesia, on the other hand, prioritizes palm oil over coconut. The area of Indonesia's palm oil plantations is currently around 15 million hectares or more than 4 times the area of its coconut plantations.

Especially for VCO (Virgin Coconut Oil) products for the export market, apart from requiring better specifications or quality, they are also generally required to be accompanied by organic certification. Organic certification is something that is not easy, especially for small businesses. Information from APCC (Asia Pacific Coconut Community) states that the Philippines is currently the largest producer of VCO, even though the area of coconut plantations is still below Indonesia, with export volume continuing to increase. It was recorded that the Philippines' VCO exports in 2006 were 461 tons, then nine years later, namely in 2015, it increased to 36,313 tons. The coconut industry in the Philippines is also more developed than in Indonesia, this can be seen from the large number of export commodities made from coconut products. The Philippines exports 30 kinds of coconut products while Indonesia only exports 14 kinds of products.

Coconut is like a sleeping tiger. As a tropical country with the longest coastline in the world, the "sleeping tiger" needs to be awakened. This huge potential must be awakened, not weakened, so that coconut-based industrialization must be boosted especially as the productivity of Indonesian coconut plantations continues to decline, plus the demographic bonus so that the potential of natural resources must be optimized, and the vision of a golden Indonesia 2045. Don't let the demographic bonus become a demographic disaster because it is not properly managed and directed. Optimizing natural resources with a sustainable environmental perspective is a future economic solution that must be a common concern.

Carbonization Furnace Innovations To Improve Coconut Processing Efficiency

Inefficient production processes will encourage waste, resulting in high production costs. Energy is an important factor for a lot of industries, especially in the integrated coconut processing industry. Carbonization or the coconut shell charcoal process is generally inefficient besides it also produces a lot of smoke pollution in the charring process, for more details, please read here. This much wasted energy should be used for various coconut processing, such as making white copra, dessicated coconut (DC), nata de coco, and drying cocofiber or cocopeat. Furthermore, the smoke that comes out of the carbonization process can also be condensed so as to produce liquid smoke product. With the above configuration, the carbonization furnace can be used optimally as well as waste or smoke pollution can also be minimized as little as possible. A simple carbonization furnace scheme is as follows:

The input of the carbonization furnace is mainly coconut shell, but coir/fiber, bunch, and frond can also be used. A heat exchanger is installed to extract or utilize heat from the carbonization process. The air from the environment after passing through the heat exchanger will become hot. The hot air produced can then be used as needed as above. In the production of white copra where only clean hot air is needed, not from smoke or flue gas can take advantage of this hot air, as well as in the production of dessicated coconut (DC). Coconut water, which is still disposed of so much that it pollutes the environment, should also be processed into nata de coco or vinegar. The process of boiling coconut water for the two products above can also take advantage of the heat from the carbonization furnace. With energy costs that can be cut or minimized in this way, coconut processed products become more competitive and provide additional benefits for the producers.

Three in One with Carbonization Furnace Innovation

At present we still encounter a lot of inefficient charcoal production (carbonization). Besides producing a lot of pollution there is also a lot of heat or energy lost, which should be used for others, for example drying copra or cooking coconut water for the production of nata de coco and so on. If the carbonization process can be made more efficiently then it can be integrated with the production of white copra and nata de coco. The production of white copra and nata de coco has also become very economical because energy or heat needs can be supplied from the charcoal process or carbonization. Fuel or energy sources can be minimized or even eliminated altogether.

The heat energy from the charcoal process is very large, so efforts to use it are important to increase production efficiency. The carbonization furnace which is designed for charcoal production while producing heat for copra drying with indirect heating and boiling coconut water for nata de coco production is a solution to increase this efficiency. The quality of the charcoal products produced is also higher and stable because of the better control of the production process. With a minimum raw material capacity of 3 tons/day of the coconut shell carbonization furnace can be operated. This is equivalent to processing 6.5 tons of coconut meat/day or white copra production around 3.25 tons/day and nata de coco 5 tons/day. The scheme of carbonization furnace design is as below.

 

The need for coconut shell charcoal is increasing over time as are other coconut products. Indonesia's export of coconut shell charcoal is about 250 thousand tons / year. White copra is also needed for the production of coconut oil whose quality is better than black copra. The quality of oil from white copra is cleaner and clearer so that it can be consumed directly, while black-black copra is commonly called crude coconut oil. The world's white copra exports were 137 thousand tons in 2013 (APCC-Coconut Statistical Yearbook, 2013) with a total value of more than 2 trillion rupiah. The potential of nata de coco is also no less great in line with the growth of food and beverages, which averages 8% per year and it is estimated that the national potential of nata de coco reaches 1.6 trillion / year. The coconut shell charcoal can also be processed further into briquettes or activated carbon. For the export of briquette charcoal and activated carbon (activated carbon), Indonesia is classified as small, namely 20 thousand tons / year and 25 thousand tons / year. For detailed information on coconut shell carbonization furnace, please email at cakbentra@gmail.com

Reviving the Integrated Coconut Industry Part 8: Coconut Milk, VCO, Dessicated Coconut, Coconut Water, Nata de Coco, Shell Charcoal and Activated Carbon

Basically the campaign to save the coconut plantation (tree of life) is to revive the integrated coconut industry. Damaged and not maintained of coconut plantations due to lack of funding to maintain and develop it in a sustainable manner.

Bioeconomy is defined as knowledge-based production and uses biological resources or living things to produce products, processes, and services in the economic sector within the framework of a sustainable economic system.

Instant coconut milk or packaged coconut milk is almost unthinkable, especially by mothers in Indonesia a few decades ago. Likewise, bottled coconut water, almost all Indonesians were also unthinkable at that time. That is mainly because coconut is very easy to get in almost all corners of the country. But this condition changed when Asian cuisine began to worldwide so that many Western people like it. Coconut milk as one of the main elements of the dish has become a necessity that must be provided. Urban communities with dense population and have a high level of activity, need something practical and instant that makes instant coconut milk products easily accepted. It is also the same as instant food seasoning products that are in demand in urban areas.

Coconut milk and bottled coconut water industry is a type of large industry so it requires a supply of raw materials in large quantities and continuously. To get these conditions in general can only be in coconut plantations which are not infrequently still very remote location. At that location, electricity and a number of supporting infrastructure were not yet available, so the integrated coconut industry could not yet be operated. Electricity is one of the basic needs for industrial operations, so it needs to be made before running the integrated coconut industry such as industries with the main products are coconut milk and bottled coconut water. The production of electricity for this purpose can be done in at least two ways: first, with a steam boiler, as is usually done in a palm oil mill. Coconut coir which has the lowest economic value is used for fuel.

The second way, namely by continuous pyrolysis. Coconut shell can be used as raw material for the pyrolysis. With pyrolysis technology, it would be more profitable because besides electricity generated, heat and charcoal shells are also produced. Electricity and heat can be used for the operation of the coconut processing industry, while shell charcoal can be directly sold or further processed into briquettes or activated carbon. When the need for electricity is large, power plants can use both, namely coconut coir steam boilers and pyrolysis with raw materials for coconut shells. If you want to produce more charcoal, coconut coir can also be used for continuous pyrolysis fuel. The quality of coconut coir is lower than that of coconut shell. This is so that coconut coir charcoal can be used as agricultural charcoal (agri-char / biochar) so that it will increase the productivity of coconut plantations, while coconut shell charcoal for the purposes mentioned above.

Apart from being processed into packaged coconut milk, fruit meat can also be processed into VCO (Virgin Coconut Oil) or dessicated cooconut. VCO production can be done on a medium scale, but currently for the export market or foreign buyers in general require organic certificates. That is also the reason why the production of small-scale VCO for the export market is difficult. Basically, coconuts can be made for a variety of products, according to market needs. Almost all coconut processing industries require electricity and heat for the production process (specifically for the VCO industry, only electricity). The integrated coconut industry approach makes the coconut processing industry more efficient. The combination of the coconut processing industry adjusts to market needs. The dim market for copra & coconut oil, it turns out that little by little is substituted by increasing markets for dessicated coconut, VCO, coconut milk, nata de coco, bottled coconut water and even coconut sugar. Is it possible that the coconut will come back victorious? There are indications there indeed. Wallahu'alam

Reviving the Integrated Coconut Industry Part 7: Production Integration of VCO, Nata de Coco, and Shell Charcoal

Basically the campaign to save the coconut plantation (tree of life) is to revive the integrated coconut industry. Damaged and not maintained of coconut plantations due to lack of funding to maintain and develop it in a sustainable manner.

Bioeconomy is defined as knowledge-based production and uses biological resources or living things to produce products, processes, and services in the economic sector within the framework of a sustainable economic system.

One of the fundamental questions about the integrated coconut industry is why should the coconut business be made in an integrated manner? Why not just process one part of the coconut? In almost all regions coconut is sold in the form of whole coconut without coir. When the raw material is whole coconut, all parts can be processed and become various products. And when only processing one part of coconut as an example of a shell for the production of charcoal and coconut water for the production of nata de coco, then that means only taking waste or byproducts from processing or utilizing the main coconut which in general is coconut meat. This condition is very dependent on the processing or main utilization of the coconut fruit. The same thing is similar to the biomass processing industry such as wood pellets and briquettes originating from sawmill waste or the wood industry. And when all parts of the coconut can be processed, it will be more economical and efficient and no waste will be produced. The combination of these types of coconut processing also determines the level of efficiency and economical production. The efficient use of energy is one of the keys to its success. So if the combination of coconut processing can make energy use efficient, so that the use of external energy can be reduced or even eliminated, then that is the best condition sought.

VCO is quite well known and popular among the people of Indonesia. Some time ago this product exploded in the market and many small industries have sprung up to produce it. Unfortunately this trend only lasted a short time. With the decline in the demand for VCO in the country quite a lot of these producers who close their businesses and switch to other professions. VCO has the main content in the form of lauric acid, which is a medium chain fatty acid (MCFA: Medium Chain Fatty Acid) that has many health benefits. Consuming VCO will also provide instant energy addition, and not be stockpiled in the form of fat. For more clearly read here. Besides being in VCO, lauric acid is also found in palm kernel oil (PKO) and mother breast milk. Palm kernel oil mills (PKO mills or KCP: kernel crushing plants) are not as many as palm oil mills (CPO mills). Many CPO mills do not have kernel processing (KCP) or the palm kernel.

Palm kernel oil (PKO) is also commonly called lauric oil and is a competitor for VCO. This is also the case among competing palm cooking oils and coconut cooking oils. Some parties may be more interested in VCO because it comes from coconuts, whereas PKO comes from palm oil and is currently undergoing a bad campaign from Europe, although this could be part of a trade war. Coconut oil from copra has also experienced the same thing. Indonesia, which has historically been the largest producer of copra, has subsequently its coconut industry been destroyed due to a trade war with soybean oil in the United States.

As for the export market, besides requiring better specifications or quality, it is also generally required to be accompanied by organic certification. Organic certification is something that is not easy especially for small businesses. Information from the APCC (Asia Pacific Coconut Community) that the Philippines is the largest producer of VCO at present even though the area of coconut plantations is still below Indonesia with export volumes continuing to grow. It was noted that the Philippines' VCO exports in 2006 were 461 tons, then nine years later, in 2015 it increased to 36.3 thousand tons. The coconut industry in the Philippines is also more developed than in Indonesia, this is evident from the many export commodities from coconut products. The Philippines exports 30 kinds of coconut products while Indonesia only has 14 kinds of products.

The combination of integrated coconut processing that can be combined with VCO production is the production of nata de coco and coconut shell charcoal. VCO production can be done on a medium scale so that the coconut shell produced is also not so much that the production of charcoal with carbonized furnace in batch is sufficient. The heat lost or wasted from the carbonization process can then be taken again and used to cook coconut water in the production of nata de coco. In addition, if the nata de coco is sold in ready-to-consume form, the nata de coco needs to be cooked at least 3 times so that it becomes soft and clean. Cooking can also use waste heat from the carbonization process. The production of nata de coco will be competitive and more profitable because it does not need to use external thermal energy such as LPG.

Reviving the Integrated Coconut Industry Part 5: Integration of Production of Shell Charcoal, White Copra and Nata De Coco

Basically the campaign to save the coconut plantation (tree of life) is to revive the integrated coconut industry. Damaged and not maintained of coconut plantations due to lack of funding to maintain and develop it in a sustainable manner.

Bioeconomy is defined as knowledge-based production and uses biological resources or living things to produce products, processes, and services in the economic sector within the framework of a sustainable economic system.

Almost all traditional charcoal producers have wasted a lot of energy in the carbonization process. Why is that ? Is not energy really needed in almost all industries, even in a number of industries, energy is the highest cost component? Besides being inefficient, isn't that the same as wasting money in vain? That is because in the production of charcoal with a conversion of around 25%, more than half is wasted. As an illustration like the following count. For example, we take a 25% conversion, with 10 tons of coconut shell raw material, 2.5 tons of charcoal is produced. Coconut shell with a calorific value of around 4,500 kcal / kg, means that 10 tons of raw material amounts to 45,000,000 kcal. Whereas coconut shell charcoal with a heating value of around 8,000 kcal / kg, then 2.5 tons of charcoal will have a heating value of 20,000,000 kcal / kg. Based on these calculations more than 50% of energy is lost or only wasted, which is 25,000,000 kcal. If the conversion to charcoal is lower or 20% then the energy loss is even greater, namely 29,000,000 kcal or more than 60%. Of course it is very inefficient.

If the energy can be used optimally, of course the industry will become efficient and competitive. In the coconut industry where all its parts can be utilized, then it becomes very interesting. That is because the excess energy or energy that was previously only discharged can be used again for the processing of the next products or called the term waste heat recovery. White copra and nata de coco production can utilize the waste heat so that it no longer needs an external energy supply. With this concept, there are three products obtained, namely coconut shell charcoal, white copra and nata de coco.

The use of coconut shell charcoal that can be as direct fuel, or further processed into briquettes or activated charcoal. Besides being used in domestic or local markets, coconut shell charcoal is also an export commodity. Noted the export value of Indonesian coconut shell charcoal reaches 250 thousand tons / year, while by making briquettes and activated charcoal, greater value added will be obtained. Coconut shell charcoal briquette exports reach around 20 thousand tons / year while active charcoal is still relatively low at 25 thousand tons / year while providing the highest added value. Whereas white copra is the raw material for making coconut oil and for the main export destinations are India and Bangladesh. During its heyday, Indonesia was once the largest copra exporter in the world. As the use of coconut oil decreases, copra exports also decline. The world's white copra exports were 137 thousand tons in 2013 (APCC-Coconut Statistical Yearbook, 2013) with a total value of more than 2 trillion rupiah. Whereas nata de coco in general makes packaged drinks and many products can be found in various shops to supermarkets. The needs of nata de coco tend to increase with the population or more specifically in line with the growth of the food and beverage industry which reaches above 8% every year. It is estimated that business value for national nata de coco can reach 1.6 trillion rupiah, if managed properly.

Integrated Coconut Industry Diagram

In the carbonization process (pyrolysis) which is a partial oxidation with limited air even without air, a certain amount of gas will be produced. And because it is not a perfect combustion process, the gas is not only CO2 and H2O, but a number of combustible gas and can also be used as fuel. In the process of copra production, it is necessary to do a drying process of about 50% to 5% moisture content by indirect heating (indirect heating) then the gas produced from the carbonization process (pyrolysis) can be used as a source of energy. Likewise, this energy can also be used to cook coconut water which is used for the production of nata de coco. And if the nata de coco is further processed into a variety of packaged drinks it needs to be cooked at least 3 times for the impurities and soften the fiber. The cooking process also requires energy and gas from carbonization as an energy source. By minimizing these energy costs, production costs can be reduced and business profits increased. For those who are interested in applying the above concept, please contact us at cakbentra@gmail.com