Download - Phytochemical Processing
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