Value Added Products from PFAD

“VEGOIL TECH” – National Seminar on Technology Upgradation in
Vegetable Oil Industry Hyderabad, India. 17-18 April 2015
Value Added Products from PFAD
DR. HARRISON LAU LIK NANG
Principal Research Officer
Leader, Biodiesel Technology Research Group
and
DATUK DR. CHOO YUEN MAY
Director-General
1
OUTLINE
•
•
•
•
MPOB Video Presentation (10 min)
World Oils and Fats
Palm Oil as Premium Oil
Value addition of PFAD (include CPO)
(1) Fatty acid and its derivatives
(2) Tocotrienols
• Conclusion
2
GLOBAL OILS & FATS
PERFORMANCE
WORLD PRODUCTION OF 17
OILS AND FATS: 2014
Palm
Butter Kernel Oil
3%
4%
Others
11%
Palm Oil
30%
Lard
4%
WORLD EXPORTS OF 17
OILS AND FATS: 2014
Palm
Kernel OilTallow Others
8%
4%
2%
Rapeseed
Oil 5%
Palm Oil
57%
Sunflower
Oil
11%
Tallow
4%
Sunflower
Oil
Rapeseed
8%
Oil
13%
200 million tonnes
Soyabean
Oil
23%
Soyabean
Oil
13%
Source: Oil World & MPOB
3
Global consumption of vegetable oils from 1995/1996
to 2014/2015, by oil type (in million metric tons)
Source: Statista, 2015
GLOBAL OILS & FATS
PERFORMANCE
WORLD MAJOR
PRODUCERS OF PALM
OIL: 2014
Colombia
2%
Nigeria Others
8%
2%
Thailand
3%
WORLD MAJOR
EXPORTERS OF PALM
OIL: 2014
Others
7%
Malaysia
33%
Malaysia
40%
Indonesia
52%
Papua
Thailand New
Guinea
1%
1%
Indonesia
51%
59 million tonnes
Source: Oil World & MPOB
5
INDIA : OVERVIEW OF OILS & FATS
Trends : Major Edible Oil Consumed
OTHER,
12%
2001
GNO,
12%
SBO,
22%
PALM
,
29%
CSO, SFO,
4%
3%
2010
2014
SBO,
17%
RAPE,
14%
PALM
,
43%
CSO,
7%
2005 GNO,
7%
CSO,
7% SFO,
5%
RAPE,
17%
OTHER,
10%
GNO,
3%
PALM
,
23%
OTHER,
14%
SFO,
6%
RAPE,
20%
OTHER,
9% GNO, 2%
SBO,
17%
RAPE,
13%
PALM
, 46%
Source : Oil World/ SEA,India
SBO,
25%
SFO, 9%
CSO, 8%
INDIA : OVERVIEW OF OILS & FATS
Palm Oil Market Share
Market Share
100%
80%
Indonesia,
60%
60%
40%
20%
0%
M’sia,
39%
27%
19% 18% 24% 32%
2005 2010 2011 2012 2013 2014
Year
Import
(Mil.T)
2005
2010
2011
2012
2013
2014
3.32
6.65
6.75
7.81
7.04
*7.93
Source : Oil World/ SEA,India
*Estimated
Palm Oil as Premium Oil
Food Requirement
World Health Organization (WHO):
• Every person needs 20–22 kg oil / year
• Equivalent to 30% of total energy
• 2015 - world population: 7.3 billion
oil requirement: 153 million tonnes
• 2025 - world population: 8 billion
oil requirement: 168 million tonnes
India requires about 26 million tonnes
of vegetable oils based on 1.25 billion
population currently
PALM OIL Vs SUNFLOWER , RAPESEED &
SOYABEAN OIL PRODUCTIVITY (MT / Ha / Yr)
Soyabean
0.36
Sunflower
0.42
0.14
Cottonseed
3.43
Palm
0.60
Rapeseed
0.20
Groundnut
0
1
2
3
Tonnes/Ha/Year
4
Source: Oil World Annual 2008
OUTCOMES OF PALM
OIL RESEARCH
No Adverse
Impact on
Cholesterol
Palm oil contains almost equal
amounts of unsaturated and
saturated fats. In the body, it
behaves
more
like
a
monounsaturated fat and has no
adverse impact on cholesterol
levels.
Previous Findings on
Palm Oil vs. Olive Oil
• Palm olein and olive oil have the same effect on
serum lipoprotein cholesterol. Ng, T.K. J. Am.
Coll. Nur. 1992,11(4): 383-399
• Palm olein and olive oil have similar beneficial
effect on blood cholesterol. Choudhury, N. J.
Am. Coll. Nur. 1995, 61(5): 1043-1051
• No different between blood lipid in fasting and
non-fasting situation. Voon, P.T. J. Am. Coll. Nur.
2011,94(6): 1451-1457
Palm Oil behaves like olive oil
Stonehouse et al. 2015 Atherosclerosis
CHAPTER 10 OF WHO REPORT:
FAT AND FATTY ACID INTAKE AND METABOLIC EFFECTS
IN THE HUMAN BODY
TC and LDL-C raising effects of palmitic acid are lower for vegetable than
animal sources because it is present predominantly in the sn-1 and sn-3
position as opposed to sn-2 position as in animal fats such as lard.
References cited: Ng et al. 1992 JACN; Choudhury et al. 1995 AJCN; Zhang et al. 1997 APJCN
METABOLISM OF TAG
Total Fatty Acid Composition of oils and fats
cocoa butter
palm olein
lard
groundnut
soybean
olive
high oleic sunflower
canola
rapeseed
sn2
0
20
40
60
80
100
C18:1
C16:0
sn-2 Fatty Acid Composition
sn1
GLYCEROL
BACKBONE
C16:0
sn3
Structure of Fat Molecule
cocoa butter
palm olein
lard
groundnut
soybean
olive
high oleic sunflower
canola
rapeseed
SAFA
MUFA
PUFA
0
20
40
60
80
100
RED PALM OIL
CAROTINO
Premium
CAROTINO
Classic
Free Fatty Acids
0.1% max
0.1% max
Moisture & impurities
0.1% max
0.1% max
60min
95min
Carotenes (ppm)
Approx.
500
Approx.
125
Vitamin E
(Tocopherols &
Tocotrienols(ppm)
Approx.
800
Approx.
550
Iodine value
17
Palm Fatty Acid Distillate
18
Chemical Composition of PFAD
•
-
Major Components
Fatty acids (>85)
Triglycerides (10-15)
Diglycerides (2-3)
Monoglycerides (0.3-0.5)
•
-
Minor components
Tocotrienols
(0.3-0.5)
Tocopherol
Phytosterols (0.4-0.5)
Squalene (0.4-0.6)
Phytonutrients content in PFAD is 4-5
times higher than CPO
Unsap. Value of 1.5%
Composition of
PFAD
C16
Carbon No.
C18:1
FA
CPO
PFAD
C12
0.1
0.2
C14
1.2
1.2
C16
43.5
47.4
C18:0
4.5
4.7
C18:1
40.2
36.5
C18:2
10.2
9.6
C18:3
0.3
0.4
Neutral oil
DG
C18:2
TG
MG
TG
>90
10-15
DG
2-7
2-3
MG
<0.1
0.3-0.5
C14
C18:3
20
Value Addition: Purification of
Fatty Acid from PFAD
• High price of fatty acid e.g. purified oleic
acid is USD 1150 per tonne
• Technologically achievable
• Ready market
• Medium investment
• Low production cost (depending on
process selection)
21
Fatty acids in an essential basic oleochemical
used in oleo derivatives
22
Reverse Splitting Process
MPOB Patent
12-15% wt.
Final product: oleic acid 75% min.
82-87%wt.
FFA >95%
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Example: Oleic acid derivative - DHSA
•
•
•
•
•
Primary and secondary emulsifier
Coating agent for pigments e.g. lipsticks
Gelling agent for cosmetics
Liquid foundation for PC products
Mascaras, compact powder, metal soap etc.
Source: Awang et al., 2001.
24
Example: Oleic acid derivative
Trimethylolpropane (TMP) – Trioleate
Oleic acid
TMP
Pour point = -51 deg C
Kinematic viscosity (40) = 46.4
(Zhang et al., 2002, Lau et al., 2015)
Example: Oleic acid derivative
2,3-butanediol monooleate
2,3-butanediol monooleate
2,3-butanediol
Oleic acid
•
2,3-butanediol monooleate
melted at -48.6°C with
viscosities of 19.7 cp at
40°C, and 5.4 cp at 80°C.
(Yao et al., 2014)
Palm-based Mould Oil for Steel
/ Concrete Industry
27
Palm-based Grease
28
PFAD upgrade to stearic acid powder
• Raw material: Mixed stearic acid and palmitic acid
• Powder stearic acid produced using spray drying
technology
• USP/Ph.Eur Grade: as excipent for pharmaceutical
products, lubricant in manufacturing tablets and
capsules, lubricant for injection molding and
pressing ceramic powder,
29
Value addition: Extraction of
Tocotrienols from PFAD
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Phytonutrients Recovery
• CPO
(1) Refined oil, tocotrienols and carotenes
(2) Dist. ME, tocotrienols and carotenes
• PFAD
(1) Pure fatty acids, tocotrienols
(2) Dist. ME, tocotrienols
31
Palm Vitamin E:
Tocopherol and Tocotrienols
20-30%
70-80%
32
33
GRAS Status from FDA for
Tocotrienols (April 2010)
Tocotrienol is now intended for use in the following
foods:
• Margarines and spreads
• Designer fats and oils
• Salad dressing and Mayonnaise
• Potato chips and salty snacks
• Bakery products
• Cookies & crackers
• Ready To Eat (RTE) cereals, cereal bars, granola
bars, protein bars and power bars
• Meal replacement and other functional beverage
products and mixes
• Meatless meat products (soy-based)
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35
36
37
38
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Products Specifications
• Palm Vitamin E (50%)
Appearance: Fresh reddish colour oil
suspension / paste
Colour (Lovibond): 38R max.
Moisture: 1% max.
Vitamin E Profile:
a-T: 9% max.
b-T3: 0.5% min.
a-T3: 14% min.
g-T3: 19% min.
d-T3: 8% min.
Balance components:
Mono-C18:1/2, fatty acids,
sterols, squalene, trace DG
g-T3
d-T3
a-T3
b-T3
a-T
40
PALM VITAMIN E (75% / 90%)
Tocotrienols
Preparation
a-T
a-T3
g-T3
d-T3
Total
(%)
Palm Vitamin E (TRF)
17.8
17.1
23.0
17.2
75.1
MPOB-T3 Mix88 (TEF)
2.6
25.2
37.9
24.9
90.6
Source: Gapor, MPOB
41
Commercial Tocotrienols Products
Produced in Malaysia
42
Palm Carotenoids (Natural colorant)
b-carotene
Pro-Vitamin A
a-carotene
b-zeacarotene
Phytoene
Lycopene
43
Four types of Natural Carotene
Types of E160a Carotene Commercially Available
Beta
Carotene
Dunaliella Salina
(Algae)
Natural
identical
Natural
Natural BetaCarotene
(Fermented)
Natural
Palm Oil
Carotene
Natural
Products Specifications
• Palm Carotenes 30%
Appearance: Opaque reddish paste
AV (mg/g): 1% max.
Moisture: 1% max.
Carotenoids Complex (UV-VIS): 30% min.
a-carotene:Total carotenoids ratio: 35 % min.
45
Products Specifications
• Palm Sterols 95%
Appearance: White solid crystal
Purity (GC): 95% min.
Stigmasterol
b-sitosterol
Campesterol
46
Products Specifications
• Palm Squalene 50%
Appearance: Light yellowish liquid
Purity (GC): 50% min.
Squalene
Tocols and Sterols (balance)
47
Production Technology
48
RDB Palm Oil
Crude Palm Oil
PFAD
Methyl Esters
Tocotrienols 50-70%
Vacuum Distillation
Distilled ME
Extraction Technology
Phytonutrients
Concentrates
Reactor Units
Cleaning Column
Falling Film Evaporator
High Vacuum Evaporator
Mixer
Molecular Sieves
Separators
Palm Sterols 95%
Evaporator
Palm Carotenes 30%
Tempering
Separation System
Evaporator
Evaporator
Palm Squalene 50-70%
Palm Tocols 50-70%
Purification Technology
Recovery from PFAD
Content of T3
0.3 - 0.5%
Esterification
0.3 - 0.5%
Methyl Ester
Distillation Process
5 – 10%
Pure fatty acids
Dist. PFAD
Methyl Ester
Distillation Residue
Concentration Process
Sterols and
Squalene
Vitamin E
Concentrate
Purification Process
50 – 70%
Tocotrienols
MPOB
Technology on
Extraction of
Tocotrienols
and Carotenes
51
52
MPOB Technology – Latest Commercial Palm Phytonutrients Plant in
Malaysia
CPO / PFAD
ME
Distilled ME and T3
53
Commercialisation of MPOB
Biodiesel Technologies
Carotino, Malaysia (2005)
FIMA, Malaysia (2009)
Sime Darby, Malaysia (2007)
SOP, Malaysia (2014)
54
Commercialisation of MPOB
Biodiesel Technologies
ENERTECH BIODIESEL PLANT,
SOUTH KOREA (2006/07)
NEW BIODIESEL CO. LTD.,
THAILAND (2008/09)
55
MPOB Pilot Facilities for the Production of C16 and
C18 Mixed Fatty Acids and Methyl Ester
Crystallization Plant
(250 kg per batch)
Fractional Distillation Plant
(50 kg hour)
56
MPOB Green Technology Facilities for
Phytonutrients Research
4-stage SPD Unit
SC-CO
Supercritical
Fluid
Chromatography Unit
2 Chromatography
SC-CO2 Extraction
Unit
Phytonutrients Research Facilities
Solid-liquid Extraction
System
Mini Reactor
Nutsch Filter
58
Conclusion
• Palm oil is a good source of dietary energy and
micronutrients for meeting the needs of the
world expanding population at affordable prices
• Technologies to recover the phytonutrients from
PFAD and CPO have been developed and
commercialised
• We continuously seeking international research
collaboration to compliment and enhance our
knowledge to serve the vegetable oil industry
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THANK YOU