From CPO to Cooking Oil Introduction to Palm Oil Processing

Intro to Palm Oil Processing

Purwiyatno Hariyadi; hariyadi@seafast.org 1

From CPO to Cooking OilIntroduction to Palm Oil Processing

Purwiyatno Hariyadi, PhDhariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Professor of Food Process EngineeringDepartment of Food Science and Technology

AndSoutheast Asian Food & Agricultural Science & Technology (SEAFAST) center

BOGOR AGRCIULTURAL UNIVERSITYBOGOR-INDONESIA

Introduction

Intro to Palm Oil Processing - hariyadi@seafast.org Introduction to Palm Oil Processing -h i di@ f

Total crude palm oil andpalm kernel oil production :

41.1 million metric tone

Introduction

1. Proven –long history of- safe uses for human consumption

Characteristic Unique of Palm Oil

2. Wide range of potential applications (cooking oil, shortening, margarine and other)

2. Wide range of potential applications

3. Can be utilized as a good energy source

source.4. No cholesterol and no trans fats

Trans fats

Required01/01/06

Characteristic Unique of Palm Oil6. Rich in natural carotenoids

RBO Olein ~ 1000

Characteristic Unique of Palm Oil6. Rich in natural carotenoids

6. Rich in natural antioxidant (tocopherol and tocotrienol)

PHYTOCHEMICALS in PALM OIL

6. Rich in natural antioxidant (tocopherol and tocotrienol)

• Decrease Tromboxan A-2 (TXA2)

• Increase Prostaglandin I-2 (PGI2)

• Decrease Cholesterol

Decrease Cholesterol

• Decrease LDL-Cholesterol

7. Balance composition of fatty acids8. Contain linoleic as essential fatty

acid% of total Fatty acids

Fatty Acid Range Average12:0 0.1-1.0 0.214:0 0.9-1.5 1.116:0 41.8-46.8 44.016:1 0 1 0 3 0 1

16:1 0.1-0.3 0.118:0 4.2-5.1 4.518:1 37.3-40.8 39.218:2 9,1-11.0 10.118:3 0.0-0.6 0.420:0 0.2-0.7 0.4

9. Produce 2 kind of oils.1. Palm Oil2 Palm Kernel Oil

2. Palm Kernel Oil

Characteristic Unique of Palm Oil9. Produce 2 kind of oils.

Composition of PO Mesocarp.p p

10. Researches show that palm oil has positive health effect.

Palm Oil Processing Flow Chart

Harvesting

Fruit Bunch

FFBReceived At Mill

FFB Loaded Into Cages Readyfor Sterilization

Palm Oil Processing Unit Operations

Sterilization• Placing sterilizer cages in horizontal vessels at steam

f 3 k / 2 (143oC) 60 i tpressure of 3 kg/cm2 (143oC); 60 minutes

• Enzyme inactivation prevention of FFA increase

• Facilitation of mechanical stripping

• Preparation of pericarp

for sub-sequential processing

• Preconditioning of the nuts to minimize kernel breakage

Introduction to Palm Oil Processing -h i di@ f

StrippingS ti f t ili d f it f th b h t lk• Separation of sterilized fruits from the bunch stalks

• Drum type :

• Vigorous shaking

• Beating

DigestionR h ti th t ili d f it ( i i th f it t 95• Reheating the sterilized fruits (mixing the fruits at 95-100oC, 20 minutes.

• To loosen the pericarp from the nuts

• To break the oil cell before passing to oil extraction unit

Oil ExtractionC ti i t d• Continuous screw pressing to produce :

• Mixture of oil (~66%), water (~24%) and non-oily solid (~10%).

• Press cake, containing fibers and nuts

ClarificationDil ti ith t t f ilit t ttli

• Dilution with water – to facilitate settling

• Screen – to remove fibrous material

• Pump to settling tank – to obtain oil and sludge

•“Top” oil is skimmed off centrifuge vacuum dryer oil storage

•Sludge (~ 10% oil) reclaimed and fed back to main settling tank

Clarification

Oil StorageI t ll t d ith t i l t t i

• Internally coated with epoxy material to prevent iron 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

CPO• Commonly consists of desirable triglycerides, y g y ,

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

• 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.

Oil T i l id Di l id M l id

Oil Triglyceride, Diglyceride , Monoglyceride; 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)

CPO Typical composition

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

Physical Refining

Chemical Refining

• Crude oils contain complex organo-phosphorus compounds

-Degumming of CPO

Palm Oil Refining Processing Unit Operations

• 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 h h li id ( h h tid ) d d i i

• The phospholipids (phosphatides) are removed during processing 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.

-Degumming of CPO

X = choline (phosphatidyl choline or PC)X = ethanolamine (phosphatidylethanolamine or PE)X = inositol (phosphatidylinositol or PI)X = hydrogen (phosphatidyl acid or PA)

-Degumming of CPO

-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 i th d b t t i l th t h b d t t i l

bentonite, is the adsorbent material that has been used most extensively. • 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.

D d i ti i t di till ti f

- Deodorization of CPO• Deodorization is a vacuum steam distillation process for

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 conditions approximate 250oC at 2.0 mm absolute

yp pppressure 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.

Typical deodorization conditions

- Deodorization of CPOTypical deodorization conditions

- Deodorizations

A. Physical RefiningPalm Oil Refining Processing Unit Operations

-Degumming and pre-bleaching of CPOAdd concentrated (80 85%) phosphoric acid (dose at 0 05

- Add concentrated (80-85%) phosphoric acid (dose at 0.05-0.2% 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 t id d th i t

carotenoids and other pigments- Adsorb/reduce oxidation products- Adsorb phospholipids precipitated by phosphoric acids- Remove any excess phosphoric acids

-Deacidification & Deodorizations

- Oil is deaerated heating 240-270oC (using external HE) pumped into deodorizer (2-5 mmHg).

- Remove FFA (incl volatile odoriferous, oxidation products (aldehyde and ketone).

- Thermally compose carotenoids P d d li ht l d bl d RBDPO

- Produced light-colored, bland RBDPO

-Deacidification & Deodorizations

A. Physical Refining

idu 40

180oC (356oF)

200oC (392oF)

240oC (464oF)

20 40 60 Minutes

-Desirable Quality of pretreated and RBDPO

FFA (as C16:0; %)

Peroxide value (mEq/kg)

Moisture and Impurities (wt, %), max

I ( /k )

Same as Crude feed

0.10%, max

Parameter Pretreated PO(Degummed/Bleached) RBDPO

Iron (mg/kg), max

Copper (mg/kg), max

Phosphorus, (mg/kg), max

-Desirable Quality of pretreated and RBDPO

A. Chemical RefiningPalm Oil Refining Processing Unit Operations

-Alkali Refining- Heating CPO to 80-90oC

Heating CPO to 80 90 C- 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) Neutralized Palm Oil (NPO)

- Heavier phase (soap, insoluble impurities, gum, phosphatides,

p ( p p g p pexcess alkali, and loss oil/emulsion).

- Washing NPO with 10-20% hot water centrifugation- Washed oil is dried under vacuum to a moisture level < 0.05%.

-Bleaching- NPO is bleached (similar process as that of physical refining)

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).Adsorb impurities (trace metal, moisture, insoluble's, and part of the carotenoids and other pigmentsAdsorb/reduce oxidation productsAdsorb phospholipids precipitated by phosphoric acids

Remove any excess phosphoric acids

-Deodorization- NBPO is deodorized (similar process as that of physical refining)

NBPO is deodorized (similar process as that of physical refining)- Oil is deaerated heating 240-270oC (using external HE) 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) :RF = % total Oil Loss/% FFA in the Oil1.5 – 2.0

-Desirable Quality of pretreated and NBDPO

FFA (as C16:0; %)

Peroxide value (mEq/kg)

Moisture and Impurities (wt, %), max

I ( /k )

0.10%, max

Parameter NBD-PO

0.15%, max

Iron (mg/kg), max

Copper (mg/kg), max

Phosphorus, (mg/kg), max

Soap Content (mg/kg)

hariyadi@seafast.org

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

Intro to Palm Oil Processing - hariyadi@seafast.org Intro to Palm Oil Processing - hariyadi@seafast.org

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

Intro to Palm Oil Processing - hariyadi@seafast.org Intro to Palm Oil Processing - hariyadi@seafast.org

Palm Oil Processing Fractionation

1 CPO2.CP Olein3. CP Stearin4 RBO Olein

4. RBO Olein5. RBD Stearin6. RBD PO

T i l l l /t i l id (TAG) f PO i t• Triacylglycerols/triglyceride (TAG) of PO consist of combination of FAs

• 3 commercial methods of fractionations

• Dry fractionation

• Detergent fractionation

• Solvent fractionation

• To separate olein (low-lti li id h )

melting liquid phase) and stearin (high-melting solid phase) fraction

• Olein usually used for ki il

Intro to Palm Oil Processing - hariyadi@seafast.org Stearin

cooking oil

• Stearin usually for margarine and industrial frying

• Dry fractionation• Dry fractionation• Oil is kept homogenized at 70oC

• Cooled at specific cooling program; up to 20oC (depend on quality requirement)

Filt ti (filt b filt )

• Filtration (filter press; membrane filter)

• About 65-75% olein + 25-35% stearin

• Dry fractionation• Dry 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 are wetted with SDS go to

y gaqueous phase

• Centrifugation olein is washed with hot water vacuum dried

• Yield ~ 80% olein

• Solvent fractionation• Most expensive, need lower temp; more

safety feature

• Hexane and acetone

• Oil is dissolved in the solvent cooled filtration

• Yield ~ 80% Olein

• Viable in production of high value products PMF cocoa butter equivalent

Palm Oil (100%)

1st Fractionation

Olein Fraction65-75 -80%

Stearine Fraction10-35%

2nd Fractionation

2 Fractionation

2nd Olein Fraction (Super Olein)

55-65%

Palm oil Midfraction 25-30%

Acetone:oil=4:1Crystallize at ~ 0oC1st Fractionation

PALM OIL

LOW MELTING FRACTIONYield >60%M.Pt. <15oC16:0 ~35%

IV > 65

Reheat to 40oCadd more acetone(acetone:oil=4:1)

Crystallize at 20-24oC2nd Fractionation

HIGH MELTING FRACTIONYield >10%

M.Pt. 55-60oC16:0 ~80%

IV > 10

PALM MIDFRACTIONYield 25-30%M.Pt. 30-35oC

16:0 ~60%IV > 32-36

POP = 56%POS = 10%SOS = 1%

Acetone:oil=4:1Crystallize at ~ 0oC1st Fractionation

PALM OIL

LOW MELTING FRACTIONYield >60%M.Pt. <15oC16:0 ~35%

IV > 65

Reheat to 40oCadd more acetone(acetone:oil=4:1)

Crystallize at 20-24oC2nd Fractionation

HIGH MELTING FRACTIONYield >10%

M.Pt. 55-60oC16:0 ~80%

IV > 10

PALM MIDFRACTIONYield 25-30%M.Pt. 30-35oC

16:0 ~60%IV > 32-36

POP = 56%POS = 10%SOS = 1%

Palm Oil Refining Processing Processing Aids

Thank You ...Resources/References :• APOC (http://www americanpalmoil com/)• APOC (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. MasyarakatPerkelepasawitan Indonesia.

Perkelepasawitan Indonesia.• Hariyadi, P. Andarwulan, N, Nuraida, L., Guritno, P., Sugiyono,

Elisabeth, J., and Toruan-Mathius, N. 2007. Rencana Induk KegiatanRiset Unggulan Strategis Nasional Pengembangan Industri KelapaSawit. Kementerian Negara Riset dan Teknologi, Masyarakat Perkelapasawitan Indonesia (MAKSI) dam Institut Pertanian Bogor.

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