THE EFFECT OF HOLES PARAMETER

ON THE PROPERTIES OF SUPER FAST DRIED OIL PALM LUMBER (OPL)

By

FARID BIN RAMLI

FACULTY OF FORESTRY

UNIVERSITI PUTRA MALAYSIA

2018
 TABLE OF CONTENTS

TITLE PAGE

TABLE OF CONTENTS i

LIST OF FIGURES iii

LIST OF ABBREVIATION iv

CHAPTER

1 INTRODUCTION

1.1 Background 1

1.2 Problem Statement 3

1.3 Justification 3

1.4 Objective 4

1.4.1 General Objective 4

1.4.2 Specific Objective 4

2 LITERATURE REVIEW

2.1 Oil Palm Tree Botanical 5

2.2 Oil Palm Plantation in 6

Malaysia

2.3 Utilization of Oil Palm Trunk (OPT) 6

2.4 Oil Palm Trunk Characteristic 7

2.5 Physical Properties of Oil Palm 8

2.5.1 Density 8

2.5.2 Moisture Content 9

2.5.3 Shrinkage 10

i
 2.6 Mechanical Properties of Oil Palm 10

2.7 Sawing Pattern of Oil Palm Wood (OPW) 11

2.8 Super-Fast Drying Method 12

2.9 Holing of Wood 13

3 METHODOLOGY

3.1 Raw Materials 14

3.2 Experimental Design 15

3.3 Preparation of Samples 16

3.4 Hot Pressing 17

3.5 Evaluation of Properties 18

3.6 Statistical Analysis 18

3.6 Expected Outcome 19

REFERENCES 20

ii
 LIST OF FIGURES

Page

Figure 2.1 Density Variation in OPT 9

Figure 2.2 Polygon Sawing And Reverse Cant Sawing 11

Figure 3.1 Cutting Process of OPT 14

Figure 3.2 OPL Soaked with Borax 14

Figure 3.3 Experimental Design 16

Figure 3.4 Holes Template for 1.5 Inch And 2.0 Inch 17

iii
 LIST OF ABBREVIATION

MPOB Malaysian Palm Oil Board

OPL Oil Palm Lumber

OPT Oil Palm Trunk

OPW Oil Palm Wood

MC Moisture Content

MPOC Malaysian Palm Oil Council

iv
 CHAPTER 1

INTRODUCTION

1.1 Background

Oil palm (Elaeis guineensis) was first introduced to Malaysia as a plant ornament in

1870 according to the Malaysian Palm Oil Board (MPOB). It was planted rapidly in

1960 and reached 1.5 million hectares of oil palm plantation in 1985 (MPOB, 2011).

In the mid-20th century, Malaysia has become the world's largest producer of palm

oil. However, this record has been addressed by Indonesia in 2006 (MPOB, 2011).

In 2016, based on the description of MPOB, Malaysia reached 5.74 million hectares

of oil palm plantations while based on data Association of Palm Oil Indonesia

(Gapki), there are about 11.8 million hectares of Indonesia represented by oil palm

plantations (Prudential Indonesia, 2017). These data show the development of the

palm oil industry in both countries that have created one of the most successful

stories in the history of the country's agricultural sector.

Malaysia is the world's second-largest producer and exporter of palm oil (Palm Oil

Export by Country, 2016). Palm trees have an economic life of about 25 years.

Subsequently, replanting will be carried out as oil palm fruit production declines after

25 years. The expansion of the palm oil sector has created a critical environmental

problem during cardboard production. Oil palm tree stems are usually left aside after

replanting, not only can lead to soil pollution but also affect the growth of young palm

trees. The utilisation of oil palm trunk is not limited in biomass purpose only; it also

can be used as raw material for wood composite products.

1
The deficiency of solid wood as a crude material of plywood and the plenitude of oil

palm trunk (OPT) waste in Malaysia have turned OPT to be one of the potential

replacements for timber. OPT is a lignocellulosic material exists an immense

amount; however, they low in quality. The poor dimensional stability, bad machining

properties, low strength and defencelessness to bio gradable agents are the reasons

why many wood industries decline to utilize OPT as their raw materials (Bakar et al.,

2013).

To address the oil palm solid waste (OPSW) problem, many investigations have

been conducted from around the world. Among all the research, intensive research

is the use of OPT. This is because the lack of solid wood raw materials has forced

the wood-based industry to find alternate alternatives for wood raw materials.

Furthermore, the OPT is low cost, low density, safe handling, renewable,

economically feasible and can be simplified compared to ordinary timber in the

market (Dungani et al., 2013). However, most timber manufacturers still refuse to

use OPT as raw material as it has some inherent defects compared to ordinary

timber. OPT has inconsistent weight, high moisture content (MC), high-density

variation, and a high percentage of tissue parenchyma (Mokhtar et al., 2011). These

properties may cause some wood drying defects such as twisting, warping and at the

same time increasing the cost of processing and manufacturing time.

The defects can be reduced by utilizing the right drying technique and drying

conditions. As of late, there are a few new drying advancements that have been

offered to create high recovery and enhance the quality of oil palm lumber (OPL) and

additionally to make reasonable drying tables for OPL. The "Super-fast drying"

2
method is one of the newest innovations created by Bakar et. al. (2016). This

method just takes 3 hours of drying procedure to dry the OPL with a minimal

imperfection. It includes 2 stages of drying, which incorporates hot plate contact

drying to certain MC and high-temperature kiln drying to a targeted MC. There are

holes in the OPL samples to accelerate the drying process. Be that as it may, gaps

in the OPL have constrained its utilization. Thus, an investigation has been done

where the holes are drilled to a certain depth to form blind-hole OPL.

1.2 Problem statement

The super-fast drying method of OPL involves holing process to speed up the

evaporation of moisture. From the previous study, it is found that holing process is

essential and cannot be eliminated from the super-fast drying method. Due to the

holing process, the dried OPL has exceptionally constrained applications without

expelling the openings because of its holing appearance. Besides that, it additionally

caused the working time long, decrease the quality and appearance of the board and

utilized an excessive amount of adhesive in the production of laminated OPL.

1.3 Justification

Oil palm trunk is felled and abandoned in the estate since oil palm trunk has poor

machining, physical and mechanical properties. The oil palm factories create up to

18 million OPT biomass consistently every year (Harun and Loh, n.d.). The OPT

biomass are colossal and likewise considered as a common lignocellulosic polymer,

3
for example, wood. Hence OPT is utilized as a substitute material for the wood

composite product.

Super-fast drying method needs some improvement so that it can be

commercialized. The blind-holed super-fast drying method is used in this study with

only one sided clear surface OPL. This is to build the capability of OPL to be utilized

as a part of different applications without influencing its properties as full holing dried

OPL. Besides that, the depth and distance of holes are optimized to reduce the

adhesive used during the production of laminated OPL.

1.4 Objective

1.4.1 General Objective

To study the effect of holing variable of super-fast dried OPW for laminated lumber

application.

1.4.2 Specific Objective

To determine the effect of holing distance on the drying rate and drying defect of

super-fast dried OPW

To determine the effect of holing depth on the drying rate and drying defect of super-

fast dried OPW

4
 CHAPTER 2

LITERATURE REVIEW

2.1 Oil Palm Tree Botanical

Oil palm tree known as Elaeis guineensis or African oil palm is a sort of palm. As

indicated by the American Journal of Biochemistry and Molecular Biology (2012), the

oil palm stems are upright and stand straight. Young and mature tree trunks are

wrapped with swollen shaping harsh and uneven appearance (Obahiagbon, 2012).

The more seasoned tree has a clearer stem other than the scars left by the dried

leaves and fall. It can achieve a height of sixty feet and progressively when it

develops completely. Palm trees are monoecious plants where they bear male and

female blossoms on a similar tree (MPOC, n.d.).

Oil palm tree is a worthy wellspring of palm oil where it is generally utilized as a part

of human life today. Palm oil is gotten from oil palm tree which takes about half year

to develop from fertilization to development. Nonetheless, most manufacturers only

focus on palm oil production, disregard the biomass that prompt genuine biomass

stockpiling and natural issues. One of the biomass is oil palm trunks (OPT); it can be

cut off following 25 years old. This is on account of amid this time, yields might be

lower and the stature of the collecting procedure turns out to be more troublesome

(Lim and Gan, 2005) Most palm oil in the homestead can go about as a rearing

ground for a pet in view of its high dampness content (MC). A few examinations have

been taken to address this issue.

5
2.2 Oil Palm Plantation in Malaysia

Oil palm was originally from Africa, but the most productive industry was in Malaysia

and Indonesia. These countries offer most oils into the international trade (Corley &

Tinker, 2003). According to the Malaysian Palm Oil Council (MPOC), palm oil was

introduced to Malaya by the British in early 1870 as ornamental plants (Anthony,

2013). In 1917, it was commercially grown in Selangor as the first palm oil plantation

in Malaysia. In the early 1960s, oil palm cultivation grew rapidly under the

government's agricultural diversification program.

The Government also introduced a land settlement scheme for oil plantations to

reduce poverty for small farmers and smallholders. The development of oil palm

cultivation areas has been increasing year by year and it is estimated that the annual

replanting rate is 2.5% (Bakar, 2016). Oil palm trees will be cut down when they

reach an economic age which is 25 years old. The main economic measure for

logging is the height of palm reaching 13 m and above, and the annual yield of

bunches is less than 10 to 12 t / ha (Sulaiman et al., 2008).

2.3 Utilization of Oil Palm Trunk

Malaysian wood industry had been making a lot of effort to obtain available raw

material to replace wood lumber at a reasonable price. As stated by Sulaiman et al

(2012), the best choices are OPT because it is abundantly available and it is less

expensive lignocellulosic.

6
OPT has been used to produce a lot of products. The core material for the

production of blackboard and plywood is OPT according to Lim & Gan (2005). It can

be processed to form forming material for the manufacture of cushioning furniture

(Lim & Khoo, 1986). Besides that, a certain part of OPT can be used to form veneers

for the manufacturing of plywood, especially for furniture components. Lim & Khoo

(1989) stated that OPT also can be used as raw materials to produce composite

products such as particleboard, wood cement-board and gypsum fibreboard.

However, because of the high proportion of low-density core wood, OPT is not

suitable to use as sawn timber as it faces the problems of high (Haslett, 1990). The

low-density OPT (inner part OPT) is also having a high moisture content, blunting of

tools, high decay and insect susceptibility, and poor appearance, machining and

jointing properties. Therefore, this had caused huge rejection on low properties inner

part OPT. Oil palm-based plywood mills only use 40% of OPT and the other 60% is

rejected due to low properties according to Tan et. al. (2009).

2.4 Oil Palm Trunk Characteristic

Lai et. al. (2015) stated that oil palm tree is a non-wood tree, also known as

monocotyledonous species, where, it does not have cambium secondary growth,

growth rings, ray cells, sapwood, heartwood, branches, and knots. Oil palm

anatomical structure mainly consists of vascular bundles and parenchyma cells while

hardwood and softwood consist of mostly fibers, tracheid, vessels parenchyma and

ray parenchyma cells (Sulaiman et. al., 2012). The growth in OPT diameter results

7
from the overall cell division and cell enlargement in fibers of vascular bundles and

parenchymatous ground tissues (Lai et. al., 2015).

Oil palm trunk is made up mostly of vascular bundle and parenchymatous cell.

Vascular bundles are constituted by fibres, xylem and phloem to provide reinforcing

and transport system in the oil palm trunk, while the function of parenchymatous

cells is storing food. The existence of vascular bundles getting lesser as towards the

inner region, but parenchymatous cells is getting more and more. From bottom part

to top part of oil palm trunk, the number of vascular bundle increase. (Darwis,

Nurrochmat, Massijaya & Safe`i, 2014).

2.5 Physical Properties of Oil Palm Trunk

2.5.1 Density

The density of the OPT refers to the weight of the OPT per unit of OPT volume.

Githiomi and Kariuki (2010) indicate that the structure of palm oil is formed in the cell

wall diameter, wall thickness and length of the cell.

The core of the OPT has a lower density than the peripheral area due to different cell

arrays. Hoong et al. (2011) state that the central stem consists of low-density

parenchyma tissue with thin cell walls and less vascular bundle than the outside of

the stem. Therefore, it causes variation of density in OPT. The low density of oil palm

core restricts its use to basic mechanical products.

8
 Figure 2.1: Density variation in OPT (Source: Lim & Khoo, 1986)

The scientists explain that these variations are due to several factors. The wood

density is directly related to the number and thickening of vascular bundles; the

number of vascular bundles per square unit decrease towards the centre (Lamaming

et. al., 2014). However, variations of density along the trunk height are due to the

vascular bundles at the top part of the OPT is younger compared to the lower part of

the OPT (Lim & Khoo, 1986). (Figure 2.1)

2.5.2 Moisture Content

The OPT contains high water content. According to Lamaming et. al. (2014), the

moisture content can range from 120% to more than 500% while Bakar et. al. (1998)

stated that the moisture content is between 258% and 575% based on the depth of

the stem. The outer part of the OPT contains the lowest humidity value and gradually

increases towards the inside of the OPT (Lim & Khoo, 1986). The difference in

humidity content is due to the distribution of parenchyma cells that can absorb more

9
water compared with vascular bundles. Bakar et. al. (1998) states that stem height

may be a factor affecting humidity content; there may be a tendency to moisture

content decreasing from below to the top of the palm tree due to the gravity of the

earth. The high moisture content of the OPT may cause problems during the drying

process (Lim & Gan, 2005).

2.5.3 Shrinkage

The shrinkage percentage of OPT was varied in between 25% and 74% (Bakar et.

al., 1998). By using the trunk depth as the parameter, the central has the highest

value of shrinkage and decrease accordingly towards the outer part of the OPT.

However, by using the trunk height as the parameter, there is also a gradual

increase in the shrinkage value from the bottom of the OPT to the top.

2.6 Mechanical Properties of Oil Palm

Poor mechanical properties are one of the unfavourable properties of oil palm wood

(Ebadi et al., 2015). The resistance of oil palm wood to exterior force is the important

specification and mechanical properties that should be known in the production line

as it will affect its application. The weak properties are resulted by density variations

inside the trunk itself and the anatomical structure of the trunk which comprises solid

vascular bundle and loose parenchyma cells (Abdullah, Jawaid, Shawkataly & Rawi,

2013). This is supported by Sulaiman et al. (2012) where the outer part of OPT is

comprised of a small number of parenchyma cells and a large number of vascular

bundles which give more stability in the mechanical properties of the oil palm trunk.

10
Haslett (1990) indicated that outer part of OPT with high density and better

mechanical properties has potential to be employed as load-bearing proposes. The

low strength properties of wood from inner zones have limited the use of an

application. Therefore, researchers tried many ways to improve the mechanical

properties of oil palm wood such as thermal treatment, chemical modification and

impregnation (Ebadi et al., 2015).

2.7 Sawing Pattern of OPW

OPW cannot use the standard sawing patterns such as quarter, life, round and cant

sawing where it will produce lumbers that have uneven density and moisture content

that will cause many drying defects. A sawing method known as "Polygon Sawing" is

developed specifically for sawing oil palm logs. According to (Bakar et. al., 2006), the

polygon sawing is developed specifically for sawing oil palm trunk. The researcher

also mentions that this method yield higher quality outer lumber of wider width with

27% recover under relatively short time.

Figure 2.2: Polygon sawing and reverse cant sawing (Source: Bakar et al., 2006,

2016)

11
However, Polygon sawing needs skilful operators and good carriage in order to

minimise the ineffectual time. If the ineffectual time for polygon sawing increases, the

cost for sawing operation might be increased (Bakar et al., 2006). For this study, a

simple sawing pattern known as reverse cant sawing (Figure 2.2). Bakar (2016)

stated that this sawing pattern is easier to handle compared to polygon sawing. It

can produced wane shaped outer lumber and square shaped inner core.

2.8 Super-Fast Drying Method

Drying OPL to optimum MC with minimum defects is always a challenge due to its

high moisture content. A new method has been invented by Bakar et al. (2016)

where it only required 3 hours of the drying process. This method also gives

minimum drying defects (<3%), improved properties, and applicable for both

peripheral and the core of the trunk. However, there will be some limitation for super-

fast dried method which is holed appearance.

This method involves holes drilling and 2-step drying which is hot pressing and kiln

drying. In the hot pressing process, the hot plates will reduce to the wood to certain

MC and then high temperature to the targeted MC. The peripheral and core region of

the trunk has 2 different types of treatment due to their differences in MC and

density.

12
2.9 Holing of Wood

Holing is a process of drilling holes into solid materials. For wood drying, it involves

the movement of water molecules, either as vapour or liquid (fluids), through a

complex biological structure, with changes in phase such as thawing and

evaporation (Keey et al., 2000). By drilling holes, the distance water have to travel

within the wood structure to the evaporating surface will decrease; the result is an

increase in drying rate (William, 1985).

Chudnoff (1972) proposed the ideas of drilling patterns of holes on wood for

balancing the wide range of specific gravity mixture of tropics species. From the

research, it is hypnotised that the equalisation would reduce the range of processing

and mechanical properties. But, the experimental work restricted to the effect of

holes on mechanical properties. However, the concept would reduce the drying rate

and preservative treating time.

13
 CHAPTER 3

METHODOLOGY

3.1 Raw Materials

The mature oil palm tree will be cut from the plantation at Bandar Saujana Putra and

sent to Forest Research Institute Malaysia (FRIM). Debarking and cutting to

manageable size shall be done in FRIM. The trunk is cut by using the "Cant sawing"

pattern (Figure 3.1) and treated with borax (Figure 3.2). After the cutting process, the

lumbers will be sent to Faculty of Forestry UPM and stored in a refrigerator to avoid

decay.

Figure 3.1: Cutting process of OPT Figure 3.2: OPL soaked with Borax

In the laboratory, the stored lumbers are taken from a small sample of 10 x 10 x 10

mm size of each trunk to obtain the moisture content (MC). The inner and outer parts

of the OPL are found through the determination of initial MC. The weight of samples

shall be recorded as W1 before putting in the oven of 103 ± 2°C.

14
After 24 hours, the sample is reweighed and recorded as W2. The MC will be

calculated by using the formula below:

MC (%) = x 100

Where,

W1 = Initial weigh (g)

W2 = Oven dried weight (g)

The oil palm lumber that has initial moisture content more than 200% consider as

inner part whereas moisture content less than 200% consider an outer part.

3.2 Experimental Design

The research will be divided into two different part which is inner part and outer part.

Each part will be consist of a different parameter which is the depth of holes and

distance between holes. The research shall be carried out according to four different

depths of holes and two different holes distance.

15
 Figure 3.3: Experimental design

Four replications are done for each parameter to improve the significance of the

experimental result. Figure 3.3 shows the experimental design of this research.

There will be a total of 64 samples of OPL board.

3.3 Preparation of samples

The centre region of OPL will be cut to sample size which is 500 mm long, 50 mm

wide and 20 mm thick. The positions of the hole are marked using marker pen

following the prepared holes template. There are 2 different types of a template

according to the distance of holes either 1.5 inches or 2 inches.

16
 Figure 3.4: Holes template for 1.5 inches (top) and 2.0 inch (bottom).

The diameter of holes is 7 mm. The depth of holes is 1/2, 1/3, 2/3 and full depth of

the thickness of the board.

3.4 Hot Pressing

The drilled OPL samples will be dry using two-step contact drying method. The first

step is hot pressing at 180°C for 40 minutes. During the hot pressing, the press will

be released for 3 times to allow the water vapour to be released. For every 10

minutes, the weight of the board will be recorded to determine the moisture loss.

After hot pressing, the samples are dry in the oven at 103 ± 2°C for 3 hours until the

target moisture content which is less than 10%. Again, the weights of the board

record for every 1 hour. The samples will be placed in conditioning room and prepare

to be tested for mechanical properties and physical properties.

17
3.5 Evaluation of Properties

The drying rate of the OPL lumbers will be evaluated through the loss of moisture

content. The weight of the board will be recorded for each drying process which is

hot press and high-temperature drying. For the hot press, the weight of the board will

be recorded every 10 minutes and for the high-temperature drying, the weight is

recorded every 1 hour. The data will be collected for every depth of holes which is

1/2, 1/3, 2/3 and full depth.

Besides drying rate, the deformation and defect of the board also will be measured

through observation. The defects are observed and recorded in three level either no

or slightly, moderate and severe level.

3.6 Statistical Analysis

The data of this study will be analyzed through the Statistical Package for Social

Science (SPSS). One-way analysis of variance (ANOVA) will be produced at 95%

confident level or p value less than 0.05. When the variance analysis signposted a

significant effect among the factors and level, a multiple comparison of the means

was performed by employing a Duncan test. This is to identify the group that have

significant different. Correlation produce had been run to study the relationship

between the holes depth and holes distance.

18
3.7 Expected Outcome

The final result of this research is to expect to establish the optimum holing

parameters of super-fast dried OPL. Besides that, it is also to establish the minimum

defects of super-fast dried OPL in term of holes distance and holes depth.

19
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