Oil palm fronds and leaves are abundant plantation residues with potential for utilization as renewable biomass, including feedstock for bio-pellet production. The utilization of this biomass requires preprocessing, particularly size reduction using a chopping machine. This study aimed to design, fabricate, and evaluate the performance of a chopping machine for oil palm fronds and leaves as an initial stage of biomass preprocessing. The developed machine features a horizontal chopping chamber, 18 spiral-arranged rotating blade holders, removable cutting blades, 10 fixed cutting blades, and a screen for controlling material discharge. The machine has been granted Simple Patent No. IDS000006381. Performance testing was conducted in three trials using 5 kg of oil palm fronds in each trial. The results showed chopping times of 100–110 seconds, with capacities ranging from 163.64 to 180.00 kg/h and an average capacity of 172.24 kg/h. The chopping yield ranged from 50% to 80%, with an average yield of 64.67%. The chopped material has potential for further biomass processing as an initial feedstock for bio-pellet production.
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