Three routes of oil palm fresh fruit bunch (FFB) processing in Nigeria namely, industrial, small-scale and traditional were compared by means of determining fruit losses associated with each route. The fruits that are not recovered after each process were hand-picked and quantified in terms of crude palm oil (CPO), palm kernel (PK), mesocarp fibre (MF) and palm kernel shell (PKS). The energy value of empty fruit bunch (EFB), MF and PKS were used to determine the value of energy lost for each route. Additionally, the environmental implications of disposal of EFB were estimated, and socio-economics of the industrial and small-scale routes were related. The analysis showed that 29, 18, 75 and 27 kg of CPO, PK, MF and PKS were lost for every 1000 kg of FFB processed with the industrial route, whereas 5.6, 3.2, 1.4 and 5.1 g were lost with the small-scale route, respectively. Approximately 89 kWh and 31 kWh more energy were lost from MF and PKS with the industrial route than the other two routes, respectively. An equivalent of 6670 tonnes carbon dioxide equivalent of methane and nitrogen oxide was released due to the disposal of 29,000 tonnes of EFB from one palm oil mill. The monetary value of lost CPO per 1000 kg of FFB processed in the industrial route is more than the labour cost of processing 1000 kg of FFB in the small-scale route. The advantages of the industrial route are high throughput in terms of FFB processed per hour and high quality of CPO; however, high fruit loss is associated with it and therefore, the poorly threshed EFB is recommended to be fed into the small-scale route.
Keywords: Fresh fruit bunch; crude palm oil; empty fruit bunch; mesocarp fibre; oil palm processing; palm kernel shell.