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Implementation Case Study: Betagard 9700 Enzyme Technology for FFA Reduction at Palm Oil Mill

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Industry

Palm oil industry

Challenge

A palm oil mill experienced persistently high free fatty acid (FFA) levels in crude palm oil (CPO) due to inconsistent fruit quality, prolonged storage durations, elevated natural lipase activity, microbiological contamination, and unstable storage temperature and moisture. These factors led to an FFA content exceeding 5%, which in turn caused a reduction of up to 40–50% in CPO sale price, increased refining chemical consumption, darker oil color, and a heightened risk of product rejection by downstream buyers. The resulting financial impact was severe, with monthly losses surpassing Rp 1 billion due to oil loss, high alkali usage, and downgraded oil grades. Addressing this issue was critical for maintaining operational profitability and meeting industry quality standards.

Results

After the deployment of Betagard 9700 enzyme technology, the palm oil mill achieved a reduction in FFA to below 5%, leading to improved oil brightness (DOBI), lower moisture content, and stable iodine values (IV). Analytical testing confirmed enhancements in oil quality metrics approaching food-grade standards. The implementation also resulted in significant operational cost savings, including reduced oil loss (Rp 825 million/month), lower alkali consumption (Rp 120 million/month), and increased product sale value (Rp 200 million/month), generating an overall ROI of 8–20 times the enzyme investment. Plant management reported marked improvements in process stability, oil quality, and refining efficiency.

Betagard 9700

betagard 9700

After using Betagard 9700 for several weeks, we observed a very significant reduction in FFA levels. The application process is simple, stable at our operating temperatures, and the results are consistent in every batch. In addition to the FFA reduction, our oil’s DOBI value increased, the color became brighter, and oil loss decreased substantially. This product has truly delivered an immediate economic impact to our mill.

David

Supervisor Produksi PKS

picture of an office, with a few people working at desks

About

For the past 40 years, leveraging our extensive experience and strong partnerships with customers, suppliers, and local farmers, we have ensured a traceable, responsibly sourced, and inclusive wood raw material supply. We collaborate with more than 3,600 farmers across Indonesia, whom we proudly recognize as our sustainable wood sources for producing high-quality wood products.

With the growing global demand for palm oil and its derivatives in the vegetable oil market, we expanded into the palm oil industry. This strategic move has positioned us as one of the leading players in sustainable palm oil. Today, our palm oil business segment contributes more than 80% of our total revenue.

The Challenge

The palm oil mill faced excessive FFA levels in its CPO, driven by variability in incoming fruit quality, prolonged storage durations, high enzymatic hydrolysis, microbiological contamination, and unstable storage conditions. These operational challenges resulted in FFA levels consistently exceeding the 5% threshold, leading to significant financial penalties through reduced selling prices, increased refining chemical consumption, diminished oil color and stability, and a higher risk of rejection by downstream refineries. The cumulative impact generated substantial monthly losses, creating an urgent need for a robust and reliable solution to restore product quality and economic viability.

The Solution

The mill evaluated various options to address the FFA issue and ultimately selected the Betagard 9700 enzyme technology from PT Beta Pramesti Asia due to its high effectiveness, low dosage requirements, and ability to consistently improve oil quality without damaging the oil structure. The implementation process involved dispersing Betagard 9700 in water and applying it to the CPO under controlled agitation and temperature in accordance with the recommended SOP. Throughout the application, critical oil quality parameters were monitored to ensure compliance with industry standards. The plant management reported: “The improvement in quality is very significant. The oil is more stable, brighter in color, and FFA levels dropped drastically. Refining costs are now much more efficient.”

The Results

After implementing Betagard 9700, the palm oil mill successfully reduced FFA levels to below 5%, meeting both quality and market requirements. Oil brightness (DOBI) increased, moisture content decreased, and iodine value stability was achieved—indicating improved product quality. Operational data showed substantial savings, including approximately Rp 825 million per month from reduced oil losses, Rp 120 million per month from reduced alkali consumption, and an additional Rp 200 million per month from improved oil grade and selling value. The total financial benefit exceeded Rp 1 billion per month, with a return on investment (ROI) ranging from 8 to 20 times the enzyme cost—demonstrating the effectiveness and economic impact of the Betagard 9700 enzyme technology.

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