“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
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 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

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 GLOBAL OILS & FATS
PERFORMANCE
WORLD PRODUCTION OF 17 WORLD EXPORTS OF 17
OILS AND FATS: 2014 OILS AND FATS: 2014
Palm
Palm Others Kernel OilTallow Others Palm Oil
Butter Kernel Oil 11% Palm Oil 4% 8%
2% 57%
4% 3% 30% Rapeseed
Lard Oil 5%
4%
Sunflower
Tallow Oil
4% 11%

Sunflower
Oil Rapeseed Soyabean
8% Oil Oil
Soyabean
13% Oil 13%
23%
200 million tonnes

Source: Oil World & MPOB

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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 WORLD MAJOR
PRODUCERS OF PALM EXPORTERS OF PALM
OIL: 2014 OIL: 2014
Colombia Nigeria Others Papua
2% 2% 8% Others
Malaysia Thailand New
7% Guinea
Thailand 33% 1%
1%
3%

Malaysia
40%
Indonesia
51%
Indonesia
52%
59 million tonnes

Source: Oil World & MPOB

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 INDIA : OVERVIEW OF OILS & FATS
Trends : Major Edible Oil Consumed

OTHER, 2001 GNO,

12% 12% OTHER, 2005 GNO,
PALM 14% 7%
SBO, SBO,
PALM 22% , 25%
, 23%
29%
CSO, SFO, RAPE, CSO,
4% 3% 17% 7% SFO, RAPE,
5% 20%

2010 OTHER,
10% 2014 OTHER,
GNO,
SBO, 9% GNO, 2% SBO,
3%
17% 17%

RAPE, RAPE,
PALM 14% PALM 13%
,
, 46%
43% SFO, 9%
SFO, CSO, 8%
CSO,
6%
7% Source : Oil World/ SEA,India
 INDIA : OVERVIEW OF OILS & FATS
Palm Oil Market Share

100%

80% Indonesia,
Market Share

60%
60%

40%

20% M’sia,
27%
39%
19% 18% 24% 32%
0%
2005 2010 2011 2012 2013 2014
Year
2005 2010 2011 2012 2013 2014
Import 3.32 6.65 6.75 7.81 7.04 *7.93
(Mil.T)

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

Cottonseed 0.14

Palm 3.43

Rapeseed 0.60

Groundnut 0.20

0 1 2 3 4
Tonnes/Ha/Year

Source: Oil World Annual 2008

OUTCOMES OF PALM No Adverse
Impact on
OIL RESEARCH 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 sn-
soybean C16:0 1
olive

BACKBONE
GLYCEROL
high oleic sunflower
sn-
canola 2 C18:1
rapeseed
0 20 40 60 80 100
sn-
C16:0 3
sn-2 Fatty Acid Composition
cocoa butter Structure of Fat Molecule
palm olein
lard
groundnut SAFA
soybean MUFA
olive
PUFA
high oleic sunflower
canola
rapeseed
0 20 40 60 80 100
 RED PALM OIL
CAROTINO CAROTINO
Premium Classic

Free Fatty Acids 0.1% max 0.1% max

Moisture & impurities 0.1% max 0.1% max
Iodine value 60min 95min
Approx. Approx.
Carotenes (ppm)
500 125
Vitamin E
Approx. Approx.
(Tocopherols &
800 550
Tocotrienols(ppm)
17
Palm Fatty Acid Distillate

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 Chemical Composition of PFAD
• Major Components • Minor components
- Fatty acids (>85) - Tocotrienols
(0.3-0.5)
- Triglycerides (10-15) - Tocopherol
- Diglycerides (2-3) - Phytosterols (0.4-0.5)
- Monoglycerides (0.3-0.5) - Squalene (0.4-0.6)

Phytonutrients content in PFAD is 4-5

times higher than CPO
Unsap. Value of 1.5%
 Composition of
C16 PFAD
Carbon No. 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
C18:1 40.2 36.5
FA C18:2 10.2 9.6
C18:3 0.3 0.4
Neutral oil
DG
TG >90 10-15
C18:2
TG
DG 2-7 2-3
MG MG <0.1 0.3-0.5
C14
C18:3
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 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)

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Fatty acids in an essential basic oleochemical
used in oleo derivatives

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Reverse Splitting Process
MPOB Patent

12-15% wt.

82-87%wt.
Final product: oleic acid 75% min. 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

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Palm-based Grease

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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,

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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

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 Palm Vitamin E:
Tocopherol and Tocotrienols

20-30%

70-80%

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 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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 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. g-T3
a-T3: 14% min.
g-T3: 19% min.
d-T3: 8% min.
Balance components: a-T3
d-T3
Mono-C18:1/2, fatty acids,
a-T
sterols, squalene, trace DG b-T3

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 PALM VITAMIN E (75% / 90%)

Tocotrienols a-T a-T3 g-T3 d-T3 Total

Preparation (%)

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

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Palm Carotenoids (Natural colorant)

b-carotene
Pro-Vitamin A

a-carotene

b-zeacarotene

Phytoene

Lycopene

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Four types of Natural Carotene
Types of E160a Carotene Commercially Available

Beta Dunaliella Salina

Carotene (Algae)
Natural Natural
identical

Natural Beta- Palm Oil

Carotene Carotene
(Fermented) Natural
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.

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 Products Specifications

• Palm Sterols 95%

Appearance: White solid crystal

Purity (GC): 95% min.

Stigmasterol b-sitosterol

Campesterol

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 Products Specifications

• Palm Squalene 50%

Appearance: Light yellowish liquid

Purity (GC): 50% min.

Squalene
Tocols and Sterols (balance)

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Production Technology

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 Crude Palm Oil RDB 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 Evaporator Palm Sterols 95%

Palm Carotenes 30%

Tempering

Separation System Evaporator Palm Squalene 50-70%

Evaporator Palm Tocols 50-70% Purification Technology

Content of T3
Recovery from PFAD
0.3 - 0.5%

Pure fatty acids

Esterification

0.3 - 0.5% Methyl Ester

Distillation Process Dist. PFAD

Methyl Ester

5 – 10% Distillation Residue

Sterols and
Concentration Process
Squalene

Vitamin E
Concentrate

Purification Process

50 – 70%

Tocotrienols
MPOB
Technology on
Extraction of
Tocotrienols
and Carotenes

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MPOB Technology – Latest Commercial Palm Phytonutrients Plant in
Malaysia
CPO / PFAD

ME

Distilled ME and T3
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 Commercialisation of MPOB
Biodiesel Technologies

Carotino, Malaysia (2005) Sime Darby, Malaysia (2007)

FIMA, Malaysia (2009) SOP, Malaysia (2014)

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 Commercialisation of MPOB
Biodiesel Technologies

ENERTECH BIODIESEL PLANT,

SOUTH KOREA (2006/07)

NEW BIODIESEL CO. LTD.,

THAILAND (2008/09)

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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

SC-CO
Supercritical 2 Chromatography
Fluid Chromatography Unit
4-stage SPD Unit

SC-CO2 Extraction
Unit
 Phytonutrients Research Facilities

Solid-liquid Extraction Mini Reactor Nutsch Filter

System

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 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