Introduction
Over the past century or so, edible oil processing technology has largely stuck to traditional ways. Mechanical extraction, solvent extraction using traditional solvents like hexane, and certain specialty extraction processes have been go-to techniques in almost every edible oil processing plant. In recent years, however, a revolution has been brewing silently in laboratories, centres for innovation, and other research spaces. Encompassing new vegetable oil processing steps, the extraction of value from non-edible oils, and the development of novel products from plant- and animal-based oils and fats, this revolution is on the precipice of moving from the lab to industry.
In my decades of experience in the oils and fats industry, the moderate advancements I've seen in non-edible and edible oil processing technology have been driven by the demand for quality and cost-savings. Today, these concerns still stand, but they are accompanied by the looming threat of climate change. As changing climates wreak havoc on agricultural yields - the main source of inputs in our industry - it has become essential to find ways to do more with fewer resources. Increasing awareness about humankind's adverse impacts on the environment has lent even more momentum to this movement for sustainability. Accordingly, advances in the oils and fats industry are increasingly seeking energy efficiency, better waste management, and value addition in downstream processes.
With 80+ years of engineering experience in oil extraction and refining, Kumar has had the opportunity to witness the evolution of the oil processing industry and the oils and fats market. I'm proud to say that we - especially through our OM Innovation Centre and partnerships with world-renowned organisations like Crown and Anderson - have stayed abreast with industry innovations so that we can deliver the very highest quality to our customers.
But the wheels keep turning. As research offers new avenues in edible oil processing technology, we can't wait to incorporate them into our own product offerings. I'm taking this opportunity to introduce to you the developing techniques that you should keep an eye out for. Techniques which have the potential to transform the industry. Techniques using which your edible oil processing plant can make gains in terms of yield, energy efficiency, product safety and utility, and, of course, revenue generation.
Why your vegetable oil refining machine will eventually need upgrades
Seed oils are a powerhouse of nutrition. They contain fatty acids, lipid-soluble phytochemicals, and bioactive compounds like tocopherols, phytosterols, and phenolic compounds, which are associated with good health. Different seed oils may reduce people's risks of developing hyperlipidaemia, hypercholesterolemia, type-2 diabetes, and inflammation.
However, research has begun to suggest that conventional extraction methods, some innovative approaches, and even processing techniques like bleaching, degumming, dewaxing, neutralisation, and deodourisation may affect the micro- and macro-constituents in seed oils. Further, heating and storage could also degrade healthy bioactive constituents that give them their nutritional edge.
Other research has also indicated that during vegetable oil processing steps, processing contaminants like mono-chloropropane-diol (MCPD) esters and glycidyl esters (GE) may arise. Research is ongoing to develop direct and indirect methods to detect their presence and mitigate their occurrence.
These are only a couple of examples of recent research, but as you can see, our understanding of the quality, safety, and sustainability of traditional edible oil processing technology is constantly evolving. Naturally, the build of your edible oil processing plant will change over time, as innovations keep up with these learnings.
Emerging edible oil processing technologies
Supercritical fluid extraction (SFE): SFE has emerged as a fairly popular green edible oil processing technology. Compared to conventional extraction processes, it offers several benefits, such as higher extraction yields, enhanced selectivity, better fractionation capabilities, and a much lighter impact on the environment. Importantly, SFE products also conform to the marketing and labelling requirements of food safety authorities like the European Food Safety Administration (EFSA) and the US Food and Drug Administration (US FDA).
Instead of commonly used extraction solvents like hexane, supercritical fluid extraction relies on supercritical fluids, as the name suggests. Supercritical fluids are essentially any substance above their temperature and pressure critical points, at which distinct gaseous and liquid phases do not exist. This offers the method an important advantage over liquid-based techniques because the extraction solvent, used under higher pressure, becomes a gas after extraction. This means that post-extraction clean-up steps are eliminated or at least minimised.
Changes in temperature and pressure conditions can also alter the density and other physicochemical properties of the supercritical fluid, making the entire extraction process much more selective and versatile. Carbon dioxide, or CO2, is the go-to choice because of its extraction properties, widespread availability, low critical point of 73 atm and 31°C, and safety.
This process still needs to be widely adopted in edible oil extraction or vegetable oil refining machines. Its higher selectivity limits its applications. Automated instruments to carry out the process are quite expensive. To add to that, developing methods to extract specific oils requires a deep level of involvement. Nonetheless, personally, the prospect of such seed and vegetable oil processing steps is quite exciting. We'll have to wait and see how widely this technology will be implemented in the industry.
Microwave-assisted extraction (MAE): Microwave-assisted extraction uses microwave energy to heat solvents used to extract specific compounds from mainly solid samples. Basically, microwave radiation promotes the evaporation of raw material residual water; it also breaks the plant cell walls to encourage internal diffusion. This edible oil processing technology not only speeds up the solvent extraction process but also reduces solvent consumption. This makes it a fairly green extraction technique. The process' ability to potentially extract multiple samples simultaneously also makes it extremely efficient. Most importantly, from an energy efficiency perspective, the targeted nature of microwave radiation means that energy loss to the surrounding environment is extremely low.
This technique isn't entirely new; it was used in the 1990s to extract organic residues from solid samples. However, the process is more complex and time-consuming than solvent blending. Analyte degradation is a genuine concern, as is safety, because the application of microwaves can generate very high pressures, which could result in explosions if appropriate equipment and precautions are not used. Notwithstanding the challenges, what's most exciting about this technique is its use in separating flavonoids, which are natural substances found in fruits, vegetables, grains, roots, and other plant products and are known for their health benefits. As such compounds become more in demand to meet food security concerns, it's possible that MAE will make an impactful comeback in oils and fats allied industries.
The applications of unconventional techniques in your edible oil processing plant
Above, I've focused on only a couple of potentially transformative technologies. Other processes, like ultrasonic-assisted extraction and ionic liquid-based solvent extraction, could also be game changers for your edible oil processing plant and the industry at large. But where exactly can these techniques and technologies be applied?
Various studies have explored the applications of SFE, MAE, and other unconventional techniques for oil extraction. One of the most notable applications of emerging vegetable oil processing steps is in cocoa butter alternatives - at Kumar, we have already taken steps to incorporate them into our offerings. The problem? High demand, high prices, and limited supply of cocoa butter mean that the chocolate, confectionery, and related industries need alternatives. Our solution? Blending, fractionation, hydrogenation, and interesterification of various vegetable fats to produce cocoa butter equivalent, cocoa butter replacer, and cocoa butter substitute.
Advances in edible oil processing technology have also been applied to processes other than extraction. For instance, research has explored using enzymatic degumming for rice bran oil. A study has attempted to prepare a sauce product using ultrasound-assisted extraction of olive leaf extract. Another study has even focused on the preparation of human milk fat substitutes. Even biodiesel can be produced using unconventional enzymatic processes, which offer more environmental benefits than traditional transesterification.
As our research and innovations come of age, Kumar is on the brink of a technological revolution and we can't wait to take all of you, our customers and partners, along. Over the past 80 years, we've remained at the forefront of edible oil processing technology, and in the years to come, we intend to stay there. Going beyond oil extraction and refining, our current and future customers across the food, fuel, feed, and chemical industries have so much in store for them.
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Choosing the right oil crushing machine for your edible oil processing needs
The imperative to innovate in the edible oils processing industry
Building a resilient supply chain in the oilseeds processing industry
