Crude palm oil (CPO) was physically refined in a 200-kg batch pilot refining plant. A study of the possible role of degumming and bleaching steps in the refining process for a possible critical role in the formation of 3-chloropropane-1,2-diol (3-MCPD) esters was evaluated. For the degumming step, different percentages of phosphoric acid (0.02-0.1%) as well as water degumming (2.0%) were carried out. Six different types of bleaching clays, mainly natural and acid activated clays were used for bleaching process at a fixed dose of 1.0%. Deodorization of the bleached oils was performed at 260°C for 90 min. Analyses showed that 3-MCPD esters were not detected in the CPO. Phosphoric acid degumming (0.1%) in combination with acid activated clays produced the highest levels (3.89 ppm) of 3-MCPD esters in the refined (RBD) oil. The esters were at the lowest levels (0.25 ppm) when the oil was water degummed and bleached with natural bleaching clays. However, the refined oil qualities were slightly compromised. Good correlation of 0.9759 and 0.9351 was obtained when concentration of the esters was plotted against acidity of the bleaching earths for the respective acid and water degumming processes. The findings revealed the contribution of acidic conditions on the higher formation of 3-MCPD esters. In order to lower the esters formation, it is important to reduce acid dosage based on the crude oil qualities or to find alternatives to acid degumming process. Neutralization of the acidity prior to deodorization was effective in reducing the formation of 3-MCPD esters.
Refined, bleached and deodorized palm olein (RBD POo) with an iodine value (IV) of 62 was chemically interesterified with methyl oleate (MO) at a ratio of 50:50 (w/w). The reaction was carried out at 110°C in the presence of sodium methoxide as a catalyst using a 100-kg pilot scale reactor. Randomization between 15 and 30 min resulted in less free fatty acid (FFA) formation and higher oleic content in the interesterified product as compared to longer reaction time of 60-90 min. Sodium methoxidecatalyzed ester interchange increased the oleic content of the interesterified product to more than 57% from its initial content of 45%. The product obtained also has an IV of more than 75. The interesterified oil was then subjected to dry fractionation in a 200-kg De Smet jacketed crystallizer at 8°C to further enhance the oleic content of the liquid olein fraction. The resulted olein had an improved cloud point and higher IV of 81. The solid stearin had a slightly higher IV and oleic content as compared to normal palm stearin. The solid fat content was comparable to normal palm oil. The pilot scale study has proven a successful conversion of laboratory findings to a larger scale production and gave the most realistic information for possible commercialization.
High-oleic palm oil (HOPO) with an oleic acid content of 59.0% and an iodine value (IV) of 78.2 was crystallized in a 200-kg De Smet crystallizer with a predetermined cooling program and appropriate agitation. The slurry was then fractionated by means of dry fractionation at 4, 8, 10, 12, and 15 degrees C. The oil and the fractionated products were subjected to physical and chemical analyses, including fatty acid composition, triacylglycerol and diacylglycerol composition, solid fat content, cloud point, slip melting point, and cold stability test. Fractionation at 15 degrees C resulted in the highest olein yield but with minimal oleic acid content. Due to the enhanced unsaturation of the oil, fractionation at relatively lower crystallization temperature showed a considerable effect on fatty acid composition as well as triacylglycerol and diacylglycerol composition of liquid fractions compared to higher crystallization temperature. The olein and stearin fractionated at 4 degrees C had the best cold stability at 0 degrees C and sharper melting profile, respectively.
Solid fat from fractionation of palm-based products was converted into cake shortening at different processing conditions. High oleic palm stearin with an oleic content of 48.2 % was obtained from fractionation of high oleic palm oil which was produced locally. Palm product was blended with different soft oils at pre-determined ratio and further fractionated to obtain the solid fractions. These fractions were then converted into cake shortenings named as high oleic, N1 and N2 blends. The physico-chemical properties of the experimental shortenings were compared with those of control shortenings in terms of fatty acid composition (FAC), iodine value (IV), slip melting point (SMP), solid fat content (SFC) and polymorphic forms. Unlike the imported commercial shortenings as reported by other studies and the control, experimental shortenings were trans-free. The SMP and SFC of experimental samples, except for the N2 sample, fell within the ranges of commercial and control shortenings. The IV was higher than those of domestic shortenings but lower when compared to imported and control shortenings. They were also observed to be b tending even though a mixture of b and b was observed in the samples after 3 months of storage. The shortenings were also used in the making of pound cake and sensory evaluation showed the good performance of high oleic sample as compared to the other shortenings.
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