Pra-Rancangan Pabrik Pembuatan Glukosa Kristal dari Pisang Kepok Mentah melalui Proses Hidrolisis Asam dengan Kapasitas 10.000 Ton per Tahun

Abstract

The preliminary design of a crystalline glucose production plant from raw kepok banana using an acid hydrolysis process is proposed with a production capacity of 10,000 tons per year and an operating time of 330 days per year. The main raw material used is raw kepok banana at a flow rate of 2,037 kg/h, supported by process water, sodium hypochlorite (NaOCl) for pretreatment, sulfuric acid (H₂SO₄) as the hydrolysis catalyst, and ion exchange resins for purification. The crystalline glucose production process consists of three main stages, namely raw material preparation, reaction stage (hydrolysis), and purification and crystallization stage. During the preparation stage, raw kepok bananas are soaked in a 3% NaOCl solution to reduce lignin content, followed by drying, milling, and sieving to obtain banana flour with a particle size of 100 mesh. The banana flour is then hydrolyzed in a hydrolysis reactor at a temperature of 165 °C and a pressure of 7 bar using 2.5 M sulfuric acid as a catalyst, achieving a conversion of 94.5%. The hydrolysis product is separated from solid residues using a rotary filter, and the glucose solution is further purified through an anion exchanger to remove corrosive sulfate ions. The purified glucose solution is concentrated to 78%, decolorized using activated carbon, crystallized, dried, and sieved to obtain the final crystalline glucose product with a production rate of 1,246.88 kg/h. The plant is planned to be located in Kutai Timur Regency, East Kalimantan, with a total land area of 22,393 m², close to the raw material source. Economic evaluation indicates a total investment cost of IDR 276,858,991,536, annual production costs of IDR 97,436,589,546, and annual sales revenue of IDR 166,937,474,880. The feasibility analysis results in a Profit Margin (PM) of 31%, Break Even Point (BEP) of 55%, Return on Investment (ROI) of 19%, Return on Net Worth (RON) of 31%, Pay Out Time (POT) of 5 years and 5 months, and an Internal Rate of Return (IRR) of 23%. Based on these indicators, the establishment of a crystalline glucose plant from raw kepok banana is considered technically and economically feasible.