CPO Cooking Oil PH PDF

Intro to Palm Oil Processing
From CPO to Cooking Oil

Introduction to Palm Oil Processing
Purwiyatno Hariyadi, PhD
hariyadi@seafast.org
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 - hariyadi@seafast.org
Introduction
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
Purwiyatno Hariyadi;
hariyadi@seafast.org 1
Introduction
Total crude palm oil and
palm kernel oil production :
41.1 million metric tone
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)
Palm Oil
2. Wide range of potential applications
Palm Oil
3. Can be utilized as a good energy

source
source.
4. No cholesterol and no trans fats
Palm Oil
Trans fats
Palm Oil
Trans fats
Palm Oil
Trans fats
Required
01/01/06
Palm Oil
Palm Oil
RPO
Palm Oil
6. Rich in natural carotenoids
RBO Olein ~ 1000
Palm Oil
6. Rich in natural carotenoids
Palm Oil
6. Rich in natural antioxidant

((tocopherol
p and tocotrienol))
Palm Oil
PHYTOCHEMICALS in PALM OIL
Palm Oil
Palm Oil
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
Palm Oil
Palm Oil
Palm Oil
Palm Oil
Palm Oil
Palm Oil
Palm Oil
Palm Oil
7. Balance composition of fatty acids
8. Contain linoleic as essential fatty
acid
% of total Fatty acids
Fatty Acid Range Average
12:0 0.1-1.0 0.2
14:0 0.9-1.5 1.1
16:0 41.8-46.8 44.0
16:1 0103
0.1-0.3 01
0.1
18:0 4.2-5.1 4.5
18:1 37.3-40.8 39.2
18:2 9,1-11.0 10.1
18:3 0.0-0.6 0.4
20:0 0.2-0.7 0.4
Palm Oil
9. Produce 2 kind of oils.
1. Palm Oil
2 Palm Kernel Oil
2.
Palm Oil
Palm Oil
Composition
p of PO Mesocarp
p.
Palm Oil
Palm Oil
10. Researches show that palm oil has
positive health effect.
Palm Oil
10. Researches show that palm oil has
positive health effect.
Harvesting Palm Oil Processing

Flow Chart
Fruit Bunch Palm Oil Processing

Flow Chart
FFB Palm Oil Processing

Received At Mill
Flow Chart
FFB Loaded Into Cages Ready Palm Oil Processing

for Sterilization
Flow Chart
Palm Oil Processing

Flow Chart
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
Palm Oil Processing

Flow Chart
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
Palm Oil Processing

Unit Operations
Sterilization
• Placing sterilizer cages in horizontal vessels at steam
k / 2 (143oC);
pressure off 3 kg/cm 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
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
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
Palm Oil Processing

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

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
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
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
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
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
Palm Oil Processing

Unit Operations
Clarification
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)
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
Palm Oil Processing

Flow Chart
CPO
•Color: Dark Red
•Rich in Micronutrient:
(Carotenoids; Tocoferol;
Tocotrienol; Fitosterol)
•“Need to be refined” Refining Process
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
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 DiDiglyceride
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)
Palm Oil Processing

Flow Chart
CPO Æ Typical composition
Palm Oil Processing

Flow Chart CPO
– further processing (refining process)
Physical Refining
Chemical Refining
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
Palm Oil Processing

Flow Chart CPO
Intro to Palm Oil

Introduction
Processingto -Palm
Oil Processing -
h i di@ f
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 ddduring
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
Oil Processing -
h i di@ f

Unit Operations
-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)

Unit Operations
-Degumming of CPO

Unit Operations
-Degumming of CPO

Unit Operations
-Degumming of CPO

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.

Unit Operations
- Deodorization of CPO
• D
Deodorization
d i ti iis a vacuum steamt 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.

Unit Operations
- Deodorization of CPO
Typical deodorization conditions

Unit Operations
- Deodorizations

Unit Operations A. Physical Refining

-Degumming and pre-bleaching of CPO

- Add concentrated (80(80-85%)
85%) phosphoric acid (dose at 0
0.05-
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
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

-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 blandbl d RBDPO

-Deacidification & Deodorizations

100
ual Carotene (%)
80
60
40
Residu
180oC (356oF)
20 200oC (392oF)
240oC (464oF)
0
20 40 60 Minutes

-Desirable Quality of pretreated and RBDPO

Parameter Pretreated PO
RBDPO
(Degummed/Bleached)
FFA (as C16:0; %) Same as Crude feed 0.10%, max

Peroxide value (mEq/kg) 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
Phosphorus, (mg/kg), max 4 4

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

-Alkali Refining
- 80 90oC
Heating CPO to 80-90
- 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)
- Heavier p phase ((soap,
p insoluble impurities,
p g
gum, p
phosphatides,
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%.

-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

-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

-Desirable Quality of pretreated and NBDPO

Parameter
N-PO NB-PO NBD-PO
FFA (as C16:0; %) 0.15%, max 0.15%, max 0.10%, max

Peroxide value (mEq/kg) - 0 0
Moisture and Impurities (wt, %), max 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
Soap Content (mg/kg) 20 0 0

- hariyadi@seafast.org
Palm Oil Processing

Flow Chart CPO
Palm Oil Processing

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

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

Fractionation
1 CPO
2.CP Olein
3. CP Stearin
4 RBO Olein
4.
5. RBD Stearin
6. RBD PO
Palm Oil Processing

Fractionation
• 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
Palm Oil Processing

Fractionation
• To separate olein (low-

melting
lti liquid
li id phase)
h )
and stearin (high-
melting solid phase)
fraction
Olein
• Olein usually used for
RBDPO cooking
ki oilil
• Stearin usually for
margarine and
industrial frying
Stearin Intro to Palm Oil Processing - hariyadi@seafast.org
Palm Oil Processing

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
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
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
Palm Oil Processing

Fractionation Palm Oil
(100%)
1st Fractionation
Olein Fraction Stearine Fraction

65-75 -80% 10-35%
2nd Fractionation
2nd Olein Fraction Palm oil Midfraction

(Super Olein) 25-30%
55-65%
Palm Oil Processing

Fractionation
PALM OIL
Acetone:oil=4:1
Crystallize at ~ 0oC
1st Fractionation
Reheat to 40oC
add more acetone
LOW MELTING FRACTION (acetone:oil=4:1)
Yield >60%
M.Pt. <15oC Crystallize at 20-24oC
16:0 ~35% 2nd Fractionation
IV > 65
PALM MIDFRACTION
Yield 25-30% HIGH MELTING
M.Pt. 30-35oC FRACTION
16:0 ~60% Yield >10%
IV > 32-36 M.Pt. 55-60oC
POP = 56% 16:0 ~80%
POS = 10% IV > 10
SOS = 1%
Palm Oil Processing

Fractionation
PALM OIL
Acetone:oil=4:1
Crystallize at ~ 0oC
1st Fractionation
Reheat to 40oC
add more acetone
LOW MELTING FRACTION (acetone:oil=4:1)
Yield >60%
M.Pt. <15oC Crystallize at 20-24oC
16:0 ~35% 2nd Fractionation
IV > 65
PALM MIDFRACTION
Yield 25-30% HIGH MELTING
M.Pt. 30-35oC FRACTION
16:0 ~60% Yield >10%
IV > 32-36 M.Pt. 55-60oC
POP = 56% 16:0 ~80%
POS = 10% IV > 10
SOS = 1%
Palm Oil Processing

Fractionation

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.

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Intro to Palm Oil Processing

From CPO to Cooking Oil

Professor of Food Process Engineering

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

3. Can be utilized as a good energy

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

RBO Olein ~ 1000

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

6. Rich in natural antioxidant

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

6. Rich in natural antioxidant

• Decrease Tromboxan A-2 (TXA2)

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Intro to Palm Oil Processing - hariyadi@seafast.org

Harvesting Palm Oil Processing

Intro to Palm Oil Processing - hariyadi@seafast.org

Fruit Bunch Palm Oil Processing

Intro to Palm Oil Processing - hariyadi@seafast.org

FFB Palm Oil Processing

Intro to Palm Oil Processing - hariyadi@seafast.org

FFB Loaded Into Cages Ready Palm Oil Processing

Intro to Palm Oil Processing - hariyadi@seafast.org

Palm Oil Processing

Intro to Palm Oil

Palm Oil Processing

Intro to Palm Oil

Palm Oil Processing

Palm Oil Processing

Intro to Palm Oil

Palm Oil Processing

Intro to Palm Oil

Palm Oil Processing

Intro to Palm Oil

Palm Oil Processing

Intro to Palm Oil

Palm Oil Processing

Intro to Palm Oil Processing - hariyadi@seafast.org