From CPO to Cooking Oil Introduction to Palm Oil Processing

Intro to Palm Oil Processing

From CPO to Cooking Oil Introduction to Palm Oil Processing Purwiyatno Hariyadi, PhD [email protected]

Professor of Food Process Engineering Department of Food Science and Technology And Southeast Asian Food & Agricultural Science & Technology (SEAFAST) center BOGOR AGRCIULTURAL UNIVERSITY BOGOR-INDONESIA Intro to Palm Oil Processing - [email protected]

Introduction

Intro to Palm Oil Introduction Processingto -Palm [email protected] Oil Processing h i di@ f

Purwiyatno Hariyadi; [email protected]

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Introduction Total crude palm oil and palm kernel oil production : 41.1 million metric tone

Intro to Palm Oil Processing - [email protected]

Characteristic Unique of Palm Oil 1. Proven –long history of- safe uses for human consumption 2. Wide range of potential applications (cooking oil, shortening, margarine and other)



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Characteristic Unique of Palm Oil 2. Wide range of potential applications


Characteristic Unique of Palm Oil 3. Can be utilized as a good energy source source. 4. No cholesterol and no trans fats



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Characteristic Unique of Palm Oil Trans fats





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Required 01/01/06


Characteristic Unique of Palm Oil



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RPO


Characteristic Unique of Palm Oil 6. Rich in natural carotenoids

RBO Olein

~ 1000 Intro to Palm Oil Processing - [email protected]


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Characteristic Unique of Palm Oil 6. Rich in natural carotenoids


Characteristic Unique of Palm Oil 6. Rich in natural antioxidant ((tocopherol p and tocotrienol))



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Characteristic Unique of Palm Oil PHYTOCHEMICALS in PALM OIL





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Characteristic Unique of Palm Oil 6. Rich in natural antioxidant ((tocopherol p and tocotrienol))

• Decrease Tromboxan A-2 (TXA2) • Increase Prostaglandin I-2 (PGI2) • Decrease Cholesterol • Decrease LDL-Cholesterol



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Characteristic Unique of Palm Oil 7. Balance composition of fatty acids 8. Contain linoleic as essential fatty acid Fatty Acid 12:0 14:0 16:0 16:1 18:0 18:1 18:2 18:3 20:0

% of total Fatty acids Range Average 0.1-1.0 0.2 0.9-1.5 1.1 41.8-46.8 44.0 0103 0.1-0.3 01 0.1 4.2-5.1 4.5 37.3-40.8 39.2 9,1-11.0 10.1 0.0-0.6 0.4 0.2-0.7 0.4 Intro to Palm Oil Processing - [email protected]


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Characteristic Unique of Palm Oil 9. Produce 2 kind of oils. 1. Palm Oil 2 Palm Kernel Oil 2.


Characteristic Unique of Palm Oil 9. Produce 2 kind of oils.



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Characteristic Unique of Palm Oil 9. Produce 2 kind of oils. Composition p of PO Mesocarp p.


Characteristic Unique of Palm Oil 9. Produce 2 kind of oils.



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Characteristic Unique of Palm Oil 10. Researches show that palm oil has positive health effect.


Characteristic Unique of Palm Oil 10. Researches show that palm oil has positive health effect.



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Harvesting

Palm Oil Processing Flow Chart


Fruit Bunch




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FFB Received At Mill



FFB Loaded Into Cages Ready for Sterilization




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Palm Oil Processing Unit Operations Sterilization • Placing sterilizer cages in horizontal vessels at steam pressure off 3 kg/cm k / 2 (143oC); C) 60 minutes i t • Enzyme inactivation Æ prevention of FFA increase • Facilitation of mechanical stripping • Preparation of pericarp for sub-sequential processing • Preconditioning of the nuts to minimize kernel breakage Intro to Palm Oil Introduction Processingto -Palm [email protected] Oil Processing h i di@ f

Palm Oil Processing Unit Operations Stripping • Separation S ti off sterilized t ili d ffruits it ffrom th the b bunch h stalks t lk • Drum type : • Vigorous shaking • Beating



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Palm Oil Processing Unit Operations Digestion • R Reheating h ti th the sterilized t ili d ffruits it ((mixing i i th the ffruits it att 95 95o 100 C, 20 minutes. • To loosen the pericarp from the nuts • To break the oil cell before passing to oil extraction unit


Palm Oil Processing Unit Operations Oil Extraction • Continuous C ti screw pressing i tto produce d : • Mixture of oil (~66%), water (~24%) and non-oily solid (~10%). • Press cake, containing fibers and nuts



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Palm Oil Processing Unit Operations Clarification • Dilution Dil ti with ith water t – to t facilitate f ilit t settling ttli • Screen – to remove fibrous material • Pump to settling tank – to obtain oil and sludge •“Top” oil is skimmed off Æ centrifuge Æ vacuum dryer Æ oil storage •Sludge (~ 10% oil) Æ reclaimed and fed back to main settling tank


Palm Oil Processing Unit Operations Clarification



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Palm Oil Processing Unit Operations Oil Storage • IInternally t ll coated t d with ith epoxy material t i l tto preventt iiron pickup • Oil : water content 0.1 -0.12%; impurities < 0.02%. • Temperature controlled : Storage 32-40oC, (loading/unloading : 50-55oC (heating rate 5oC per 24 hr)



CPO •Color: Dark Red •Rich in Micronutrient: (Carotenoids; Tocoferol; Tocotrienol; Fitosterol) •“Need to be refined” Refining Process Intro to Palm Oil Introduction Processingto -Palm [email protected] Oil Processing h i di@ f


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Palm Oil Processing Flow Chart CPO • Commonly y consists of desirable triglycerides, gy , unsaponifiable matter together with small amount of impurities. • Impurities contribute undesirable effects to the oil, for instance color, flavor, odor, instability and foaming. • Should be removed by a purification step in order to produce good quality of refined oil with minimal possible oil loss or damage to the oil and desirable materials such as tocopherols and carotenes.


Palm Oil Processing Flow Chart CPO Oil

Ti l Triglyceride, id Di Diglyceride l id , M Monoglyceride; l id Phospholipids, Glycolipid and Lipoprotein; Free fatty acids

Oxidized Products

Peroxides, Aldehydes, Ketones, Furfurals (from sugars)

Non-oil (but oil soluble)

Carotene, Tocopherols, Squalene, Sterols

Impurities

Metal particles, Metal ions, Metal complexes

Water Soluble

Water (moisture), Glycerol, Chlorophyll pigments, Phenols, Sugars (soluble carbohydrates) Intro to Palm Oil Processing - [email protected]


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Palm Oil Processing Flow Chart CPO Æ Typical composition


Palm Oil Processing Flow Chart – further processing (refining process)

CPO

Physical Refining

Chemical Refining Intro to Palm Oil Introduction Processingto -Palm [email protected] Oil Processing h i di@ f


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CPO


Palm Oil Refining Processing Unit Operations -Degumming of CPO • Crude oils contain complex organo-phosphorus compounds referred to as phospholipids (phosphatides) or more usually, as gums. • Phospholipids should be removed because of their strong emulsifying action and if they are not removed, the oil will went through undue darkening during deodorization at high temperature • Th The phospholipids h h li id ((phosphatides) h h tid ) are removed dd during i processing i by a variety of treatments collectively referred to as degumming. • The treatment usually involves hydration with water, orthophosphoric acid, and polybasic organic acids either singly or in combination, followed by centrifuging the precipitated material or by its adsorption on bleaching earth or filter. Intro to Palm Oil Introduction Processingto -Palm [email protected] Oil Processing h i di@ f


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Palm Oil Refining Processing Unit Operations -Degumming of CPO

X

X = choline (phosphatidyl choline or PC) X = ethanolamine (phosphatidylethanolamine or PE) X = inositol (phosphatidylinositol or PI) X = hydrogen (phosphatidyl acid or PA) Intro to Palm Oil Processing - [email protected]




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Palm Oil Refining Processing Unit Operations -Bleaching of CPO • Treatment that is given to remove color producing substances and to further purify the fat or oil. • The usual method of bleaching is by adsorption of the color producing substances on an adsorbent material. • There a lot of adsorbent materials are being used in vegetable oil industry for examples; acid activated bleaching earth, natural bleaching earth, activated carbon and synthetic silicates. • Acid activated bleaching earth (fuller’s earth) or clay, sometimes called b t it iis th bentonite, the adsorbent d b t material t i l th thatt h has b been used d mostt extensively. t i l • This substance consists primarily of hydrated aluminum silicate. Usually, bleaching earth does not remove all the color producing materials, much of which are actually removed by thermal destruction during the deodorization process. • Activated carbon is also used as a bleaching adsorbent to a limited extent. Intro to Palm Oil Processing - [email protected]

Palm Oil Refining Processing Unit Operations - Deodorization of CPO • D Deodorization d i ti iis a vacuum steam t di distillation till ti process ffor the purpose of removing undesirable flavors and odors, mostly arising from oxidation, in fats and oils. • Using steam under reduced pressure the volatile compounds are removed from fats and oils. • Typical yp conditions approximate pp 250oC at 2.0 mm absolute pressure for 1-4 hr with strong steam sparging. • The deodorization utilizes the differences in volatility between off-flavor and off-odor substances and the triglycerides. Intro to Palm Oil Processing - [email protected]


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Palm Oil Refining Processing Unit Operations - Deodorization of CPO Typical deodorization conditions


Palm Oil Refining Processing Unit Operations - Deodorizations



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Palm Oil Refining Processing Unit Operations A. Physical Refining


Palm Oil Refining Processing Unit Operations A. Physical Refining -Degumming and pre-bleaching of CPO - Add concentrated (80 (80-85%) 85%) phosphoric acid (dose at 0 0.0505 0.2% of fed oil), 13-30 minutes -

Precipitate nonhydratable phosphatides

- Adsorptive cleansing with bleaching clay (add as slurry 0.8 – 2%); under vacuum 20-25 mmHg; 95-110oC, 30-45 min). -

Adsorb impurities (trace metal, moisture, insoluble, and part of the carotenoids t id and d other th pigments i t

-

Adsorb/reduce oxidation products

-

Adsorb phospholipids precipitated by phosphoric acids

-

Remove any excess phosphoric acids



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Palm Oil Refining Processing Unit Operations A. Physical Refining -Deacidification & Deodorizations - Oil is deaerated Æ heating 240-270oC (using external HE) Æ pumped into deodorizer (2-5 mmHg). - Remove FFA (incl volatile odoriferous, oxidation products (aldehyde and ketone). - Thermally compose carotenoids - Produced P d d light-colored, li ht l d bland bl d RBDPO


Palm Oil Refining Processing Unit Operations A. Physical Refining -Deacidification & Deodorizations

Residu ual Carotene (%)

100 80 60 40

180oC (356oF)

20

200oC (392oF) 240oC (464oF)

0

20

40

60 Minutes



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Palm Oil Refining Processing Unit Operations A. Physical Refining -Desirable Quality of pretreated and RBDPO Pretreated PO (Degummed/Bleached)

RBDPO

Same as Crude feed

0.10%, max

0

0

Moisture and Impurities (wt, %), max

0.1

0.1

I Iron (mg/kg), ( /k ) max

0 12 0.12

0 12 0.12

Copper (mg/kg), max

0.05

0.05

4

4

Parameter

FFA (as C16:0; %) Peroxide value (mEq/kg)

Phosphorus, (mg/kg), max


Palm Oil Refining Processing Unit Operations A. Chemical Refining -Desirable Quality of pretreated and RBDPO



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Palm Oil Refining Processing Unit Operations A. Chemical Refining -Alkali Refining Heating CPO to 80-90 80 90oC Dose concentrated (80-85%) phosphoric acid at 0.05-0.2% (of fed oil) Add caustic soda solution (4N = 20Be) with calculated excess of ~20% Soap removal by centrifugation - Lighter phase (oil with 500-1000 mg soap/kg oil; moisture) Æ Neutralized Palm Oil (NPO) phase ((soap, p insoluble impurities, p g gum, p phosphatides, p - Heavier p excess alkali, and loss oil/emulsion). - Washing NPO with 10-20% hot water Æ centrifugation - Washed oil is dried under vacuum to a moisture level < 0.05%. -


Palm Oil Refining Processing Unit Operations A. Chemical Refining -Bleaching - NPO is bleached (similar process as that of physical refining) - Adsorptive cleansing with bleaching clay (add as slurry 0.8 – 2%); under vacuum 20-25 mmHg; 95-110oC, 30-45 min). ¾ Adsorb impurities (trace metal, moisture, insoluble's, and part of the carotenoids and other pigments ¾ Adsorb/reduce oxidation products ¾ Adsorb phospholipids precipitated by phosphoric acids ¾ Remove any excess phosphoric acids



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Palm Oil Refining Processing Unit Operations A. Chemical Refining -Deodorization - NBPO is deodorized (similar process as that of physical refining) - Oil is deaerated Æ heating 240-270oC (using external HE) Æ pumped into deodorizer (2-5 mmHg). - Remove FFA (incl volatile odoriferous, oxidation products (aldehyde and ketone). - Thermally compose carotenoids - Produced light-colored, bland NBDPO - RF (refining factor) : Æ RF = % total Oil Loss/% FFA in the Oil Æ 1.5 – 2.0


Palm Oil Refining Processing Unit Operations A. Chemical Refining -Desirable Quality of pretreated and NBDPO Parameter

N-PO

NB-PO

NBD-PO

0.15%, max

0.15%, max

0.10%, max

-

0

0

0.1

0.1

0.1

I Iron (mg/kg), ( /k ) max

-

0 15 0.15

0 12 0.12

Copper (mg/kg), max

-

0.06

0.05

Phosphorus, (mg/kg), max

-

4

4

20

0

0

FFA (as C16:0; %) Peroxide value (mEq/kg) Moisture and Impurities (wt, %), max

Soap Content (mg/kg)

Intro to Palm Oil Processing [email protected] - [email protected]


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CPO


Palm Oil Processing Flow Chart – further processing (refining process) & fractionation

Intro Intro to Palm Oil Processing - [email protected]


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Palm Oil Processing Flow Chart – further processing (refining process) & fractionation

Intro Intro to Palm Oil Processing - [email protected]

Palm Oil Processing Fractionation

1 CPO 2.CP Olein 3. CP Stearin 4 RBO Olein 4. 5. RBD Stearin 6. RBD PO



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• T Triacylglycerols/triglyceride i l l l /t i l id (TAG) off PO consist i t of combination of FAs • 3 commercial methods of fractionations • Dry fractionation • Detergent fractionation • Solvent fractionation



Olein

• To separate olein (lowmelting lti liquid li id phase) h ) and stearin (highmelting solid phase) fraction • Olein usually used for cooking ki oilil

RBDPO

• Stearin usually for margarine and industrial frying Stearin



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• Dry fractionation • Oil is kept homogenized at 70oC • Cooled at specific cooling program; up to 20oC (depend on quality requirement) • Filtration Filt ti (filt (filter press; membrane b filt filter)) • About 65-75% olein + 25-35% stearin


Palm Oil Processing Fractionation • Dry fractionation



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Palm Oil Processing Fractionation • Detergent fractionation • Usually done on CPO • Hot oil is cooled up to –usually about 20oC) • Add and mix with aqueous detergent solution (0.5% sodium lauryl sulfate/SDS) • Stearin crystals y are wetted with SDS Æ g go to aqueous phase • Centrifugation Æ olein is washed with hot water Æ vacuum dried • Yield ~ 80% olein Intro to Palm Oil Processing - [email protected]

Palm Oil Processing Fractionation • Solvent fractionation • Most expensive, need lower temp; more safety feature • Hexane and acetone • Oil is dissolved in the solvent Æ cooled Æ filtration • Yield ~ 80% Olein • Viable in production of high value products Æ PMF Æ cocoa butter equivalent Intro to Palm Oil Processing - [email protected]


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Palm Oil Processing Fractionation Palm Oil (100%)

1st Fractionation

Olein Fraction 65-75 -80%

Stearine Fraction 10-35%

2nd Fractionation

2nd Olein Fraction (Super Olein) 55-65%

Palm oil Midfraction 25-30%


Palm Oil Processing Fractionation PALM OIL 1st Fractionation

Acetone:oil=4:1 Crystallize at ~ 0oC

Reheat to 40oC LOW MELTING FRACTION

add more acetone (acetone:oil=4:1)

Yield >60% M.Pt. 65

Crystallize at 20-24oC

2nd Fractionation

PALM MIDFRACTION HIGH MELTING FRACTION

Yield 25-30% M.Pt. 30-35oC 16:0 ~60% IV > 32-36 POP = 56% POS = 10% SOS = 1%

Yield >10% M.Pt. 55-60oC 16:0 ~80% IV > 10



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Palm Oil Processing Fractionation PALM OIL 1st

Fractionation

Acetone:oil=4:1 Crystallize at ~ 0oC

Reheat to 40oC LOW MELTING FRACTION

add more acetone (acetone:oil=4:1)

Yield >60% M.Pt. 65

Crystallize at 20-24oC

2nd Fractionation

PALM MIDFRACTION HIGH MELTING FRACTION

Yield 25-30% M.Pt. 30-35oC 16:0 ~60% IV > 32-36 POP = 56% POS = 10% SOS = 1%

Yield >10% M.Pt. 55-60oC 16:0 ~80% IV > 10





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Palm Oil Refining Processing Processing Aids


Thank You ... Resources/References : • • • •

APOC (http://www.americanpalmoil.com/) (http://www americanpalmoil com/) Palm Oil World (http://www.palmoilworld.org/) PPKS (iopri.org/) MPOB (www.mpob.gov.my/)

• Info Sawit (http://www.infosawit.com/) •

•

Hariyadi, P. Editors. 2000. Antisipasi Penerapan Trade Barrier oleh Negara Maju terhadap Produk Kelapa Sawit. Prosiding. Masyarakat Perkelepasawitan Indonesia. Hariyadi, P. Andarwulan, N, Nuraida, L., Guritno, P., Sugiyono, Elisabeth, J., and Toruan-Mathius, N. 2007. Rencana Induk Kegiatan Riset Unggulan Strategis Nasional Pengembangan Industri Kelapa Sawit. Kementerian Negara Riset dan Teknologi, Masyarakat Perkelapasawitan Indonesia (MAKSI) dam Institut Pertanian Bogor. Intro to Palm Oil Processing - [email protected]


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