How to Achieve High-Efficiency, Low-Cost Palm Oil Extraction with Twin-Screw Presses

Are you struggling with low oil yield or high energy consumption in your palm oil processing line? If so, you're not alone—many small-to-mid-sized mills still rely on outdated single-screw systems that waste raw material and power. But here’s the good news: twin-screw presses can boost your output by up to 30% while cutting electricity use by 20%, as seen in real-world applications across Southeast Asia and Africa.

The Science Behind Dual-Screw Efficiency

Unlike traditional presses where material moves slowly through a single channel, twin-screw presses use two intermeshing screws rotating in opposite directions. This creates a continuous shearing and compression force that enhances both mass transfer and oil release. The result? A consistent, high-density cake with less moisture—and more oil extracted per ton of fresh fruit bunches (FFB).

Parameter Tuning for Optimal Performance

To maximize efficiency, adjust these key settings based on feedstock conditions:

• Feed Rate: Keep it steady at 1.5–2.5 tons/hour per screw to avoid overloading or underutilization.
• Screw Pitch: Use tighter pitches (e.g., 60–70mm) for wet FFB to improve mechanical pressing; wider pitches (80–100mm) for drier materials.
• Rotation Speed: 40–60 RPM is ideal for most applications—higher speeds increase friction heat but may degrade oil quality if not controlled.

For example, one Indonesian processor reduced unit energy consumption from 0.8 kWh/kg to 0.64 kWh/kg after fine-tuning screw speed and inlet moisture levels. That’s nearly 20% savings per ton of oil produced—money that goes straight to the bottom line.

Adapting to Raw Material Variability

Whether your FFB has 50% moisture (wet) or 30% (dry), the twin-screw system adapts naturally. Wet batches benefit from higher torque and slower rotation to prevent slippage; dry batches need faster throughput and optimized screen design to maintain pressure gradients.

Pro tip: Always test with a sample batch first. Adjust parameters incrementally until you achieve a cake moisture below 35% and free fatty acid (FFA) content under 1.5%. These are the sweet spots for quality and cost control.

Maintenance That Keeps You Running

Prevent downtime with a simple schedule:

1. Inspect wear plates every 3 months — replace when thickness drops below 5mm.
2. Lubricate bearings weekly using food-grade grease (ISO 2133).
3. Check motor alignment quarterly—misalignment causes vibration and premature bearing failure.

With proper care, your twin-screw press will last over 10 years—even in high-volume operations.