1. KERALA AGRICULTURE UNIVERSITY
COLLEGE OF AGRICULTURE, VELLAYANI
Processing and value addition of Oil palm
PRAVEEN GIDAGIRI
2021-22-007
Ph.D. (Hort.) Post Harvest Technology
2. Scientific Name : Elaeis guineensis
Family: Arecaceae
Cr. No.: 2n=32
Origin : West Africa
Common name: Small holders irrigated crop, Crop for future
Oil palm was introduced to India at National Royal Botanical Gardens, Kolkata during the year 1886.
INTRODUCTION
3. The oil palm (Elaeis guineensis) is grown
throughout the humid tropics of West and
Central Africa, Central and South America.
Oil is obtained from both the fleshy
mesocarp of the fruit and the central
kernel.
The fleshy pulp or mesocarp of the fruitlet
contains approximately 50% palm oil by
weight and the kernel between 46 and
57% palm kernel oil.
4. The presence of fatty acids and triacylglycerol makes palm oil suitable
for number of food applications.
The composition of saturated fatty acids and unsaturated fatty acids in
palm oil is 50:50.
There are two types of oil are produced from the palm oil i.e., crude
palm oil which produced from the mesocarp and kernel palm oil from
the inside kernel.
Crude palm oil contain high percentage of carotenoids thus it is also
called as red palm oil.
5. On the basis of internal characteristics of oil palm can be divided into :
Dura: have fruits which contain a thick shell between the mesocarp and the
kernel. The fruit comprise of mesocarp from 45 - 65% and shell 25 -35%.
Pisifera : have fruits which do not contain shell or very thin shell.
Tenera : is a cross between Dura X Pisifera. Tenera fruit contain 75-80%
mesocarp and 17% shell.
6. 1. It is a perennial crop that starts yielding from the 4th year of its planting.
2. Productivity per ha is more compare to other oil seeds. Under favorable conditions it
can yield 4-6 MTs of oil per ha per annum.
3. Cost of cultivation is less compare to other oil seeds
4. Return from unit area is high compare to other plantation crops.
5. It can grow well in almost all types of soil and in varying climatic conditions.
6. Inter crops can be cultivated up to 5 years.
7. The palm leaf can be used as fodder, an ingredient for organic fertilizers, as fire wood
etc.
8. Palm oil is rich in vitamin A and Vitamin E.
9. Ability to withstand even in adverse climatic condition.
Special features of Oil Palm
7. Composition
Palm Oil is extracted from the mesocarp it contains 45-50 % oil. It is known as
Palmolein in trade.
Palm Oil contains an equal proportion of saturated and unsaturated fatty acid
containing about
40% oleic acid –monounsaturated
10% linoleic acid- poly unsaturated
44% palmitic acid
5% stearic acid
Lauric acid
Palm Oil is a very rich source of Beta Carotene, an important source of Vitamin A
and it contains Tocopherols, a natural source of Vitamin E.
Saturated fatty acids
8. Palm oil is one of nine major oils traded in the global edible oil and fat
market. At present, it is the largest source of vegetable oil in the world.
The world Oil palm area is 241.34 lakh Ha and production is 731.68 lakh
MT during 2020 (USDA).
Five countries mainly
Indonesia
Malaysia
Nigeria
Thailand and
Columbia
90% of the world’s total production of FFBs.
9. Sl. No. Country
Palm Oil Consumption
(Lakh MT) in 2020
1 Indonesia 150.25
2 India 87.55
3 China 67.8
4 EU-27 68.05
5 Malaysia 34.35
6 Pakistan 34
7 Thailand 22.27
8 Bangladesh 16.1
9 United States 13.96
10 Nigeria 16.65
Major countries consuming Palm Oil
2020 (USDA)
10. The major Palm Oil importing countries
India, China, European Union, Pakistan, USA & Bangladesh and India is the major palm oil
importing country @ 16.29% of world share (USDA).
13. The major oil palm producing states in India are Andhra Pradesh,
Telangana, Karnataka, Tamil Nadu, Gujarat, Chhattisgarh, Mizoram, Assam and
Orissa.
Andhra Pradesh ranks 1st in Area and Production of Oil Palm in the
country.
Telangana stands 6th in Oil palm area, 2nd in production of Fresh Fruit
Bunches and 1st in Oil Extraction Rate (OER) with 19.22 % (2019-20) in the
country.
14. Different uses of Palm Oil
Food Products Non Food Products
Cooking Oil, Dough fat, Vanaspati Bio fuel and Bio lubricants
Vegetable Ghee Cosmetic products/Aromatherapy
Margarine Pharmaceuticals products
Salad Oil Toiletries, Detergents including
soaps & soap Blends
Chocolate/Ice-cream/ Frying fats,
Specialty fats for coatings
Esters
Coca Butter substitutes Oleo chemicals, Fatty acids & Fatty
Alcohols
15. Economic importance of Oil Palm
1. Highest edible oil yielding plant (4-6 t/ha)
2. High employment potential
3. Supply raw materials for industries: a) Vanaspati b) Soap industries c)
production of oleochemical products such as FA’s, alcohols, glycerols and
other derivatives.
4. By-product utilization: Furniture's from trunk, fibres from frond and empty
fruit bunches.
5. Environmental protection
6. Suitable for sustainable agriculture
16. Oil palm crop is one of the highest oil (palm oil) yielding crops among the all perennial
crops.
Oil palm tree produces edible palm-oil as well as palm kernel-oil.
This oil palm is considered as golden palm due to its high yielding capacity.
Oil palm produces 4 to 5 tonnes per ha of Crude Palm Oil (CPO) and 0.40 to 0.50 tonne
per ha of Palm Kernel Oil (PKO) from 4th to 30th year of its productive life spam.
Oil palm crop provides the excellent substitute of importing the oil.
In India, oil palm is being cultivated in 13 states by covering about
3,15,000 hectares by 2017-18 under irrigated conditions.
Potential states are Andhra Pradesh, Gujarat, Karnataka,
Tamil Nadu and Bihar.
Scope for Oil Palm cultivation
17. Oil palm has a long gestation period and restricts income flow to farmers for at
least 4-5 years.
Small holdings of farmers with limited resources.
Fluctuation in prices of CPO in the international market.
Erratic monsoon leading to shortage of water.
Competition from other economically viable crops such as rubber, arecanut,
sugarcane, banana, coconut etc.
Variation in import duty on edible oils.
Non-availability is shortage of power and limited availability of new electric
connections.
Processing facility at reasonable distance.
Constraints in Oil Palm cultivation
18. In view of the importance and significance of oil palm cultivation, DAC&FW had
taken up Technology Mission on Oilseeds & Pulses (TMOP) in 1991-92 in the
potential states.
A comprehensive centrally sponsored scheme, Oil Palm Development Programme
(OPDP) was taken up during VIII and IX Plan.
During X and XI Plan, Government of India provided support for oil palm
cultivation under Integrated Scheme of Oilseeds, Pulses, Oil Palm and Maize
(ISOPOM).
Further to boost oil palm cultivation, Government of India had supported a Special
Programme on Oil Palm Area Expansion (OPAE) under RKVY during the year
2011-12 with an objective to bring 60,000 ha area under Oil Palm cultivation, which
continued till March, 2014.
Initiatives by Government of India
19. • First harvest can be done 3.5 to 4 years after planting
• Few ripe fruits are loose/fall off indicates the bunch is ready for harvest.
• In Young palms, Chisel harvesting is followed. If palms become taller (from 10th year
onwards), then harvesting is done by hook
• While harvesting a stalk length of 5 cm alone should be left.
• Harvesting should be done at 10-12 days interval.
• During rainy season, harvesting should be done at closer interval of 6-7 days as ripening
is hastened after hot summer.
• In young plantations, we get more bunches with less bunch weight and in adult
plantations the bunch weight is more but the bunch number is less.
Yield:
• At yield stabilizing period (4-8 years) : 12t/ha
• At yield stabilized period (>8 years) : 20t/ha
• 25 – 30 tonnes of fresh fruit bunches/ ha
Harvesting
21. 1. FRUIT BUNCHES: Bunches are cut down with the help of cutter and
transported to mill for further processing.
Steps
22. 2. STERILIZATION : Sterilization of palm fruits is done for heat treatment and
for the absorption of moisture. It prohibits the growth of fungus especially on damaged
fruits. During sterilization an enzyme called lipolytic becomes inactive as well it also
prevent the forming other free fatty acids. The time of sterilization depends upon size
of fruits while the standard time and temperature is 50 minutes at 135ºC.
23. 3. STRIPPING : Striping is done to separate the fruits from bunches. For small mill
which have capacity of 5 ton bunches per hour, beat arm stripper is used while rotary
drum can handle quantity up to 20 tons per hour.
Beat arm stripper
25. 4. DIGESTION : Digestion is preliminary pressing before final extraction where
slowly rotating oil bearing cells are ruptured by rotating beater and thus produces mash
of mesocarp and nuts. The process of digestion is carried out at 95ºC.
26. 5. EXTRACTION : Here, the pulp is pushed in palm oil expeller; it burst all cells
that hold oil and releases the palm oil. This is a main stage that seeks to focus on several
types of presses that usually focus on pressing of fruit pulp. You can use the screw
presses or at that time dare to try the hydraulic presses. In the modern times, the screw
oil push has gained a lot of popularity because of its ability to yield more oil when
pressing mesocarp.
27.
28. 6. CLARIFICATION : The main point of clarification is to separate the oil from its
entrained impurities. The fluid coming out of the press is a mixture of palm oil, water, cell
debris, fibrous material and ‘non-oily solids’. Because of the non-oily solids the mixture is
very thick (viscous). Hot water is therefore added to the press output mixture to thin it. The
dilution (addition of water) provides a barrier causing the heavy solids to fall to the bottom
of the container while the lighter oil droplets flow through the watery mixture to the top.
Water is added in a ratio of 3:1.
29. 7. Drying of oil:
• This clarified oil still contains traces of water and dirt.
• To prevent increasing FFA through autocatalytic hydrolysis of the oil, the
moisture content of the oil must be reduced to 0.15 to 0.25 percent.
• Re-heating the decanted oil in a cooking pot and carefully skimming off the
dried oil from any engrained dirt removes any residual moisture.
30. 8. OIL STORAGE
In large-scale mills the purified and dried oil is transferred to a tank for storage
prior to dispatch from the mill. Since the rate of oxidation of the oil increases with the
temperature of storage, the oil is normally maintained around 50°C, using hot water or
low-pressure steam-heating coils, to prevent Solidification and Fractionation.
Small-scale mills simply pack the dried oil in used petroleum oil drums or plastic
drums and store the drums at ambient temperature.
31. 9. Refining:
Crude palm oil – reddish in colour due to high beta carotene content
Refining is the Process of removal of undesirable impurities from Crude Palm
oil in order of increasing shelf life and quality of oil.
During refining of crude palm oil, FFA are removed in order to achieve the
FFA content of up to 0.1 % max.
Undesirable impurities include:
• Phospholipids,
• Free fatty acid,
• Colouring pigments (Carotenoids),
• Moisture, oxidative material, metal impurities, and water soluble
impurities (glycerol, Phenols, Sugars).
33. Palm oil refining consists of the following sections:
1. Bleaching
2. Deodorisation / De-acidification
3. Fractionation
Refined, bleached, and deodorized (RBD) palm oil - bland, odorless, light
yellow in color, and semisolid at room temperature.
Methods of refining crude vegetable oil:
Physical refining: Physical Refining is the steam distillation of free fatty
acids from oils and fats under high temperature and vacuum conditions.
Chemical refining: Process using strong bases to neutralize most of the free
fatty acids and remove them in the form of soaps. It is also known as alkali
refining process.
34.
35.
36. In order to get the pure and refined oil, there are three main process in
chemical palm oil refinery plant and chemical palm kernel oil refinery plant:
1. Degumming process,
2. Bleaching process and
3. Deodorizing process.
According to the degree of automation, the refinery process can also be
divided into
• Batch Refinery Plant,
• Semi-continuous Refinery Plant
• Continuous Refinery Plant.
Batch type is the ideal choice for mini and small sized production (1-20TPD),
while the latter two are normally designed for middle-large size production line
(10-50TPD).
38. Physical refining is also known as steam refining.
In degumming process, it utilizes citric acid or food grade phosphoric acid to
remove natural gums in the form of phosphatides.
Then, in bleaching process, under vacuum, Fuller’s Earth is used to remove
colouring matters and adsorb any metal ions.
The deacidification and deodorization process is under high temperature and
low pressure.
By use of live steam, the FFA is stripped of. The steam is then recovered
together with the entrained oil is as palm fatty acid distillate.
The off-flavors and odours can also be removed from the crude palm oil in the
steam distillation process.
Before polishing, the refined oil needs to be cooled to 55°C.
Physical palm oil refining process is the most common used type in palm oil
processing industry. It is featured of low production cost, high efficiency, simple
production process and low effluent load.
1. Physical Refining
39. • Degumming process
Through phosphoric acid application, the fatty acid and gum contained in the
palm oil and palm kernel oil will be separated from foreign impurities, like trace
minerals, iron, cooper and other. This process offers necessary preparation for the
next refining process.
• Bleaching process
It adopts vacuum system to remove the impurities and color pigments from
the crude palm oil and crude palm kernel oil.
• Deodorizing process
The palm oil and palm kernel oil are steamed at a temperature of 240°C to
260°C to get away the odors and tastes, and then they are cooled into room
temperature (about 55°C) for further use. This process have great impact on the
quality of the final palm oil and palm kernel oil.
42. In the chemical refining process, the FFA is removed by neutralization with
caustic soda (sodium hydroxide).
This chemical reaction produces neutralized CPO and a soap stock.
By used of a high-speed separator, the soap stock can be separated from the
oil.
Then, through earth bleaching, colour pigments and metal ions are removed
from the neutralized oil.
Then, in deodorization process, odoriferous matters such as ketones and
aldehydes are removed by steam distillation under vacuum.
When refining crude oil with high carotene content, high initial FFA (up to
5%) and low phosphatides, chemical oil refinery plant is suggested, considering
operating costs and refining losses.
2. Chemical Refining Process
43. Palm oil Fractionation
Refined palm oil should go through fractionation process to separate solid
phases (Stearine) and liquid phases (Olein). It is achieved by thermo-
mechanical means. Fractionation can greatly maximize the value of products.
The typical fractionation process of palm oil mill is
• Pre-heating,
• Cooling,
• Crystallization
• Filtering.
47. After palm oil extraction, the nuts and fiber are recovered from the mash. The
mixture of nut and fiber is dried first and then separated from each other in
depericarper (Nut & Fibre separator).
As fibers is light in weight, they are carried away by air flow, while nuts are fall
into a rotary drum.
The separated fibers are used in the boiler as fuel.
The nuts are sent to nut silo.
By use of cracking machinery, the palm kernel will be recovered from the nuts.
The nut shells are collected and feed into boiler with fiber.
The kernels are further processed in palm kernel oil extraction plant to produce
palm kernel oil (PKO) and palm kernel cake (PKC).
The rate of FFA increase is much faster in broken kernels. So try to keep the
kernel breakage as low as possible during the nut crushing processes.
48. The process of kernel extraction includes following steps:
❑ NUT SEPARATION : Earlier for the process of nut separation was carried out with
the help of hydraulic and mechanical separation but now a day pneumatic system is used
for carry out this process.
49. ❑ NUT DRYING AND CRACKING : After processing the palm fruit for oil, the nut is
usually dried in order to loosen the kernel from the shell. The drying is necessary to
enhance the release of whole kernel when the nut is cracked.
Palm nut cracker combined with Kernel/Shell separator (Hormeku Engineering
works, Ghana)
50. ❑ KERNEL SEPARATION : The kernel/shell separation is usually performed in a clay
bath which is a concentrated viscous mixture of clay and water. The density of the clay
bath is such that the shells sink while the lighter kernels float to the top of the mixture.
The floating kernels are scooped in baskets, washed with clean water and dried.
Periodically the shells are scooped out of the bath and discarded. The shells can then be
used for boiler fuel or road surfacing.
❑ DRYING AND BAGGING : Drying of kernel is done to reduce the moisture content
up to 6-7.5% followed by bagging for storage and shipment.
❑ OIL EXTRACTION : Oil extraction is done either by wet method or dry method.
51. Palm kernel
Crushing
Cooking
First pressing Second pressing
Crude oil
Filtering
Crude palm kernel oil
Refining
Refined palm kernel oil
Flow chart of palm kernel oil extraction
52. Palm kernel is an important kind of by-product from palm oil
extraction plant. About 45%-48% of palm nut is kernel. The kernels contain
about 47%-50% by weight of oil. Palm kernel oil is quite different from palm
oil in both characteristics and properties. However, it is more similar to
coconut oil.
Traditional method
Solvent extraction
Mechanical extraction
53. 1. Mechanical Oil Extraction (full pressing)
Basic Section
• Palm Kernel Crushing
• Cooking
• Oil Pressing (expelling)
• Oil Filtering (crude palm kernel oil)
Full pressing extraction is also called single pressing, which is a physical
extraction method that squeezing oil out under high pressure by use of
mechanical screw oil press.
The typical process of screw oil pressing plant is: palm kernel crushing,
flaking, steam conditioning, mechanical oil expelling and oil filtering.
Production cost depends mainly on mechanical wear and tear, electricity and
maintenance expenses.
54. a. Kernel pre-treatment: Proper kernel pre-treatment is necessary to
efficiently extract the oil from the kernels.
1.Cleaning:
The kernels are cleaned of foreign materials, debris, sand etc. using magnetic
separators and vibrating screens
Magnetic separators – to remove metal debris
Vibrating screens - used to sieve sand, stones or other undesirable materials.
2.Size reduction:
Breaking kernels into small fragments using swinging hammer grinder, breaker
rolls or a combination of both.
This process increases the surface area of the kernels, thus facilitating flaking.
55. 3. Flaking:
The kernel fragments subsequently are subjected to flaking in a roller mill.
The thickness of kernel cakes is progressively reduced
4. Steam conditioning: The kernel flakes are then conveyed to a stack
cooker for steam conditioning, the purpose of which is to:
Adjust the moisture content of the meal to an optimum level
Rupture cell walls (initiated by rolling)
Reduce viscosity of oil
Coagulate the protein in the meal to facilitate separation of the oil from protein
materials.
In the palm kernel, the meals are normally cooked to a moisture content of 3
percent at 104-110°C.
56. b. Screw-pressing:
The properly cooked meal is fed to the screw-press, which separates the oil
from the de-oiled cake
c. Oil clarification:
The oil from the presses is drained to a reservoir.
It is then either pumped to a decanter or revolving coarse screen to remove a
large part of the solid impurities.
The oil is then pumped to a filter press to remove the remaining solids and
fines in order to produce clear oil prior to storage.
The cakes discharged from the presses are conveyed for bagging or bulk
storage.
57. Mechanical extraction of kernel oil:
There are three variations:
1. Direct screw-pressing
2. Partial pre-treatment
3. Complete pre-treatment
1. Direct screw-pressing:
Some mills crush the kernels directly in the presses without any pre-
treatment.
Double pressing usually is required to ensure efficient oil extraction.
The screw-presses used normally are less than 10 tonnes per unit per day.
58. 2.Partial pre-treatment:
The kernels are first broken down to smaller fragments by grinding prior
to screw-pressing.
In some cases, cooking is also carried out.
3.Complete pre-treatment:
The full pre-treatment processes are carried out prior to screw-pressing.
Plants with larger capacities (50-500 tonnes per day) choose complete
pre-treatment and the equipment is usually imported from Europe
59. 2. Palm Kernel Solvent Extraction
Basic Section
• Crushing
• Solvent Extraction
• Separating the solvent from miscella
•S eparating solvent from wet meal
• Recycling of solvent
Solvent extraction plant separate the oil by mixing solvent in the material.
Production cost depends mainly on solvent loss and energy used in solvent
recovery. Compared with screw pressing, the oil recovery of solvent extraction
plant is more complete.
60.
61. 3. Traditional method of palm kernel oil extraction:
• Shelling (using stones or mechanical nut cracker)
• Frying palm kernel
• Pounding or grinding to paste in a motorised grinder
• Mixing with water and heated to release the palm kernel oil.
• The released oil is periodically skimmed from the top.
63. Automatic palm kernel oil expeller is also know as integrated oil press machine. It is
designed with oil filter machine and heating system, so the pressed palm kernel oil can be
directly remove the organic impurities by the filter device. It is also the favorite palm
kernel oil processing machines by farmers, small scale business investors, small palm
kernel oil processing plant.
64. Large palm kernel oil expeller is specially designed for the large scale palm kernel oil
production plant due to its large capacity. It has continuous and automatic oil processing
performance. It is also the BEST choice for Palm Kernel Oil Extraction Plant for the pre-
pressing.
65. • Crude Palm kernel oils contains mainly of glycerides and, like other oils in
their crude form may consist of small and variable portions of non-glycerides
components as well.
• In order to render the oils to an edible form, some of these non-glycerides
needs to be either removed or reduced to an acceptable levels.
• The aim of refining is therefore to convert the crude oil to quality oil by
removing objectionable impurities to the desired levels in the most efficient
manner.
Crude Palm Kernel Oil Refining
66. Refining is Same as palm oil refining
Crude Palm Kernel Oil is refined to produce RBD Palm Kernel Oil (RBD PKO).
RBD PKO is fractionated into RBD Palm Kernel Olein (liquid portion) and RBD
Palm Kernel Stearin (solid part).
Olein – Cooking oil
Stearin - Various applications in bakery and confectionary products
67.
68.
69. EQUIPMENT FOR PALM OIL PROCESSING
❑ STERILIZATION EQUIPMENT : This equipment is used for heat treatment of palm
fruits thus preventing the growth of fungus and inhibiting lipolytic enzyme
70. ❑ PALM FRUIT THRESHER : The fruits received at mill are in bunches and they are
detached with the help of thresher or stripper. There are two types of thresher one is
rotating drum and other is fixed drum which are used for stripping palm oil fruits.
71. ❑ OIL EXTRACTOR : Extraction of palm oil is done either by wet method or dry
method. Dry method includes use of screw pressure for extraction oil from palm fruits.
72. ❑ CLARIFICATION MACHINE: Clarification of palm oil is done to remove non oily
solids dirt by passing palm oil through hot water at 95ºC. Oil and dirt separated from each
other where dirt settled down at the lower part while clear oil presents at upper part.
77. 1. Bread.
2. Crisps.
3. Margarine.
4. Vegan cheese.
5. Soap & Skincare.
6. Ice Cream.
7. Pizza bases.
8. Instant noodles
9. Chocolate
Below are 10 things that contain palm oil that most of us probably buy without
realising:
78. Research institutes working on oil palm
International
Nigerian Institute for Oil-Palm Research (NIFOR)
Palm Oil Research Institute of Malaysia (PORIM)
Indonesian oil palm research institute (IOPRI)
National
Directorate of Oil Palm Research, Pedavegi (AP, West Godavari),
AICRP on Oil palm, Gangavati (Karnataka), Vijayarai (Andhra Pradesh),
Mulde (Maharashtra) andAduthurai (Tamil Nadu).
Research Centre of NRC for Oil Palm, Palode (Kerala).
79. References
1. National Food Security Mission – Oil Palm
2. Directorate of Oil Palm Research, Pedavegi, Annual Report 2019.
3. APEDA
4. Department of Agriculture, Cooperation and farmers welfare, Ministry of agriculture
and farmers welfare, government of India.
5. Ministry of food processing Industries , GOI.
6. Department of Spices & Plantation Crops, Horticultural College & Research Institute,
Tamil Nadu Agricultural University, Coimbatore - 3.
7. NIFTEM
8. Google