SAIFUL IRWAN ZUBAIRI PMIFT, Grad B.E.M. B. Eng. (Chemical-Bioprocess) (Hons.), UTMM. Eng. (Bioprocess), UTM

ROOM NO.: 2166, CHEMISTRY BUILDING,TEL. (OFF.): 03-89215828,FOOD SCIENCE PROGRAMME,CENTRE OF CHEMICAL SCIENCES AND FOOD TECHNOLOGY, UKM BANGI, SELANGOR

PROCESSING OBJECTIVESPROCESSING OBJECTIVES

Preserve active phytochemical ingredients

Concentrate the active phytochemical ingredients

Covert the raw material into the most convenient form

Remove the unwanted materials

Adding economic value to herb material to satisfy

To obtain pure phytochemical

Chart of Classification and Separation of Plant MaterialBased on Solvent Polarity and Process

(Phytochemicals Approach)

Plant Material

H2O-GlycerolExtraction

Non-Polarcompoundextraction

SFE(Phytonics:Phytosol)

Terpenoids

Essential Oil (e.g. mono &Esquiterpenes: geraniol, limonese

Diterpenoids (Phytol, abietic acid)

Triterpenoids (Cucurbitacin)

Carotenoids (β-Carotene, lutien,Zeaxanthin, etc)

Multi SolventExtraction

Process

Terpenoids (e.g. Menthol, carrone, squalene,α-Carotene, lycopene)

Lipids

Polar Compound Extraction Flavanoid (e.g. anthocyanin-cyanidin, flavanols-Kaemferol, isoflavanoid-rotenone)

Polar alkaloid (e.g. Ephedrine)

Sugar & Derivatives (e.g. monosacharide,Oligosacharide, sugar alcol)Fiber

Acid Hydrolysis

filtrate Cellulose

filtrate Hemicellulose

filtrate Lignin

Chart of Classification and Separation of Plant Material

Based on Solvent Polarity and Process

(Herbal Approach)

Plant Material

SolventExtract

filtrate

Freeze dried Whole concrete extract

Membrane Filtration or Low T vacuumevaporation

Whole concentrate extract

WaterExtract

Spray driedWhole powder extract

Freeze driedWhole freeze dried extract

Spray driedConcentrate extract

EXAMPLES OFRAW MATERIALS

TEA TREE

PANDAN CITRONELLA

EUCALYPTUS

CINNAMONKESUM

CURRY

TONGKAT ALI

OVERALL PROCESSING TECHNIQUES

PRETREATMENT OF HERBS

PREPARATION OF RAW MATERIAL AND THE PROCESSING OF ESSENTIAL OILS

RAW MATERIAL

PRETREATMENTPROCESS

EXTRACTION

PURIFICATION

Percolation Process

Reflux Extraction

Soxhlet Extraction

Steam Distillation

Phytosol Extractor (industrial scale)

PURIFICATION PROCESSES

FREEZE DRYING

• Freeze drying is the process of removing water or other solvent from a frozen product by sublimation.

• Conventional drying cause the material to shrink, damaging the cells while in freeze drying process, the solid components are held in place by rigid ice.

• Freeze drying is also used toprepare tissue samples for electron microscopy.

SPRAY DRYER

• SPRAY DRYING is the most widely used industrial process involving particle formation and drying.

• Highly suited for the continuous production of dry solids in either powder, granulate or agglomerate form liquid feed stocks as solutions, emulsions and pump able suspensions.

• Spray dryer involves the atomization of a liquid feedstock into a spray of droplets and contacting the droplets with hot air in a drying chamber.

PHYTOCHEMICAL PROCESSING :

CASE STUDIES

CASE STUDY I:Production of Cinnamon Oil from Cinnamon Leaves

Process Flow Chart for Crude Cinnamon Oil Production

Cinnamon Leaves

Drying

Size Reduction

Extraction

(Apply heat & agitation)

Condensation

Product (Crude Essential Oil)

Deionized Water

Steam is formed carrying along essential oil

Process Flow Chart for Crude Cinnamon Oil Purification

Crude Essential Oil

Neutralization (pH Control)

Separation (centrifuge)

Other method: clarifying, purifying and decanting

Product (Essential Oil)

Distillation

(using laboratory set)

Solvent Solubility

(add solvent)

Evaporation

CASE STUDY I:Production of Cinnamon Oil from Cinnamon

Leaves

C

Cinnamon Leaf(1000 kg)

1000 kg

COARSE GRINDER

Deionized water (5000 kg)

Condensation Rate :700 kg/hr

Water

Oil (15%) Oil (85%)

Leaf + 30% water

Water + Oil

1 L 0.5 M NaOH

26 L Cinnamon Oil

C

Soap

PurifiedCinnamon Oil(25 L)

CASE STUDY I:Production of Cinnamon Oil from Cinnamon Leaves

Process Flow Chart for Herb Processing – Tongkat AliTongkat Ali

Sizing (Grinding)/Drying

Extraction

Filtration

Product (Concentrate Extract)

Packaging

Solvent

(Deionized Water)

Spray Dryer (other product intensification method can also be used - freeze drying)

Concentrate

Product (Powdered Form)

EXTRACTION

CASE STUDY II:Production of Phyto-Extract from Tongkat

Ali

CASE STUDY II:Production of Phyto-Extract from Tongkat Ali

Deionized Water (120kg)

T = 120OCt = 2 Hr

Extract+ fibre(40kg)

Slurry

Water Extract T feed = 70OC1.5 brix

FILTERefficiency = 56%

EXTRACTOR

SPRAY DRYERefficiency = 80%

Hot Air 306 kg/hrT = 170OC

T1 = 170OC

T2 = 103OC

Evaporation Rate = 12.6 kg/hrRecovery = 3%Moisture content = 2%

t = 7 hrs

HOLDINGTANK

Temperature = 700C

Tongkat Ali (40kg)

Soy bean

Soak (24 hrs)

Dehulling

Wet Grinding (Soy: Water 1:4)

Soy Extract

Product

Solvent

(Deionized Water)

Filtration

Spray Dry

T = 900C, t = 1 hr

5% Maltodextrin, 1% Sodium Casienate

CASE STUDY III:Production of Soybean Powder

Dehulling

Wet Grinding

Filter Press

1000 kg Soy

4000 kgDeionizedwater

Soy Fiber

4000 kg extract

200 kg Maltodextrin

40 kg SodiumCasienate

T = 900Ct = 1 hr

2420 kg Soy Solution2 brix

T1 = 1850C

T2 = 1050C

Hot Air Feed(2300 kg/ hr)

t = 24 hrs

Evaporation Rate = 100 kg/ hrProduct Flow Rate = 20.16 kg / hrRecovery = 20 %Moisture content = 2 %

CASE STUDY III:Production of Soybean Powder

Process Flow Chart for Production of CucurminoidTurmeric

Sizing & Drying

Steam Distillation

Wet Turmeric

Fine Grinding

Crystallization

Solvent

(Deionized Water)

Drying

Vacuum Distillation

Volatile Oil

CASE STUDY IV:Extraction of Oleoresin (Curcuminoid) from

Turmeric

Product (Curcuminoid)

Packaging

Ethanol

CASE STUDY IV:Extraction of Oleoresin (Curcuminoid) from Turmeric

Coarse Grinder

Fine Grinder

1000 Kg Turmeric

5000 kg Dioinized water Evaporation Rate: 833 kg/hr

4200 kg water+ volatile Oil

Water20 kgvolatile oil

70% Water

600 kgfine turmeric

800 kg water+ 1000 kg turmeric

DRYER

VACUUMDISTILLATION

UNIT

STEAMDISTILLATION

UNIT

OILSEPARATOR

OILSTORAGE

Volatile OilPackaging

CRYSTALLIZER 24 Kg CurcuminoidFILTER

UNIT

EXTRACTIONVESSEL

Raw Material

Sizing (Grinding)/Drying

Extraction

Filtration

Ultrafiltration

Spray Dryer

Solvent

(Deionized Water)

Microfiltration

Reverse Osmosis

PURIFICATION

CASE STUDY V:Production of Plant-Based Sugar from

Stevia

Product (Stevioside: 66%)

T = 1000C, t = 2 hrs

Maltodextrin

Sweet Tea(100kg)

Deionized Water (2500kg)

T = 100OCt = 2 hrs

Water Extract

Water Extract (400 kg solution + 2 kg maltodextrin)T feed = 70OC1.5 brix

EXTRACTOR

SPRAY DRYERefficiency = 80%

Hot Air 550kg/hrT = 170OC

T1 = 170OC

T2 = 103OC

Evaporation Rate = 100 kg/hrProduct Flow Rate = 1.75 kg/hrRecovery = 5%Moisture content = 2%Purity = 66%

t = 4 hrs

PURIFICATION(microfiltration,UltrafiltrationReverse osmosis)

Impurities

CASE STUDY V:Production of Plant-Based Sugar from Stevia

CASE STUDY VI:Production of Pegaga Powder

MEXTRACTOR

M M

Pegaga (cleaned and ground)

Deionized Water

BLENDINGTANK

EVAPORATOR

SPRAY DRYER

PLATE &FRAME FILTER

T = 1200C t = 2 hrs

T = 700C

Water Extract T feed = 70OC

5 brix

Hot Air 306 kg/hrT = 170OC T1 = 170OC

T2 = 103OC

Recovery = 2% from raw materialMoisture content = 2% max

Water

Process Plant Layout for the Production of Pegaga Powder

Pegaga

Cleaning

Sizing

Extraction

Evaporation

Blending

Spray Drying

Packaging

Dehydrated Product

Figure 1: Process Flow for the Production of Pegaga Powder