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UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION Vienna International Centre, P.O. Box 300, 1400 Vienna, Austria Tel: (+43-1) 26026-0 · www.unido.org · [email protected] Distr. LIMITED 10000 UN I DO/IOD.377/ Add .4 UNITED NATIONS 4 September 1980 INDUSTRIAL DEVELOPMENT ORGANIZATION ENGLISH
ESTABLISHMENT OF A COCONUT PROCESSING TECHNOLOGY CONSULTANCY SERVICE UF/RAS/78/949
ASIAN AND PACIRC COCONUT COMMUNITY
COCONUT PROCESSING TECHNOLOGY INFORMATION DOCUMENTS PART 5 OF 7
"Domestic Coconut Food Processes"
Based on the work of T. K, G. Ranasinghe in co-operation with representatives o f the coconut processing industry of the Asian and Pacific Coconut Community and individual international experts
‘ This document has been reproduced without formal editing. Mention of firm names and commercial products does not imply the endorsement of the United Nations Industrial Development Organization (UNIDO). m Fioar, h y a sdìluihc Cable : COCOMUN ii. Tbamria 12, Jikatta, !adon«sta Mai] : PjO. BOX 34 %
Staton anfc pacific Ccronut Communitp Jakarta — Indonesia <»«ir Nr :
PREFACE
A valid criticism against the poor performance of many agricultural extension services in coconut producing countries is that the services do not have or know what to "extend", A similar analogy can he applied to a consultancy service on coconut processing technology.
"Registering" coconut processes applied in the APCC countries, may he a simple achievement and considered unimportant, when one views the deluge of impressively formulated and identified o b je c tiv e s and programmes pouring out o f in tern a tio n a l agencies and institutions. The fact is, that the disappointments from two UN Development Decades, could be traced to the failure to execute the basic "Home Work" essential for achieving the ultimate objectives.
UNIDO, which concieved and supervised the execution of this project, rightfully owns the entire credit for an important programme o f meaningful b e n e fits to APCC and APCC member cou n tries. UNIDO har provided APCC with a firm basis from which APCC must now build and develop an essential service to those countries and individuals reliant on the coconut for their economic survival®
V - . ■ . » Godofredo P Reyes Jr D irecto r 1 13 June 1980. INT RODUCTIQM The United Natiens Industrial Development Organisation, Vienna, funded and executed ib is project "Establishment o f Coconut Processing Technology Consultancy Servie®" fo r th® Asian and P acific Coconut Community based in Jakarta. The project was in itia te d in 1978 and completed within 18 months.
Coconut Processes, commercial and household, applied in the APCC member countries were documented in individual technology sheets by Consultants fo r specialised areas and by the Project Kanager/Coco nut Processing Technologist. Each technology sheet carries a product code, based on the Customs Cooperation Council Nomenclature (CCCN) which has replaced the Brussels Tariff Nomenclature (BTN). This fa c ilit a t e s easy reference to determine import or export duties, freight rates, etc, as w ell as coding fo r lib ra ry systems. Where there are co-products or by products in a process, only the main product has been taken into consideration for coding.
The immediate objective o f the project is to make the techno logy sheets available to a ll concerned as a "Consultancy Service" in the framework o f technical cooperation among developing countries and others interested in improving the coconut processing d iscip lin e.
The technology documented is not only on major commercial processes but also on the h ith erto, somewhat neglected* rural and house hold processes. These processes offer a large scope for further develop ment with appropriate and suitably scaled technology, in order to bring «bout the canmercialisiation o f new or improved products.
The development o f the Coconut Processing Sector through technical cooperation in existing commercial processes and the improvement of rural ami household products, could mean higher incomes and better living conditions for several hundred million people living in the coconut areas o f the world.
acknowledgement
The kind assistance and co-operation rendered by the counter parts, the national collaborating agencies and the excellent services
given by the APCC Secretariat are gratefully acknowledged. îm t e d МАТжте дш ш ш а, ш т я т т т о ш ю з & и ш sm ASIAN & PACIFIC OOGMIIT OSHMSMIg
CFmjaet UF/lAS/ЖЛМД)
This doeiami is osto of ?П parts? »
Р Ш 2 G000№f Я Ш Ю П Ю АШ Ш Ш , ШШОГАШШ! PAST 11 GOGCM" O IL ШИАСТЕШ
Pâier h i oooomiT o il ж р ш е ю s m ш т ш ш ш
РАЮ I f d e s ic c a t e d о о ш ге ш ш т ш т к
РАЮ f DOMESTIC ШСШШТ FOOD PROCESSES PASS ¥X СОСОШТ COIR РШ ® AND PRODUCTS
р ш m СОСШШ? Ш Ш Ш Ш AMD ОШЕ FROGlSSiS
those feelsaolecgr have Ь®то prepared ty i-
Р«С. Catanaoan, ШПШ GaasmLtmt œ o il esteaetim
H.B.U. Patterson, ОШШ ©CMWltart он o il re iiniqf
Pol» Abacs, ШВДО Goasmltaat ш тм traditional food
Т«1ов» Ш Ю Pttsjoet Ms»ager/GeomH& Processing Tseiumlogiet,
1979/1*0 IV
Consultancy Service on Coconut Processing Technology
UFTDO/APCC P ro je c t UF/RAS/78/049
PART ¥
DOMESTIC COGOMOT FOOD PROCESSES
L iâ t o f Technology sheets
^g§i-BMbg£: Mme o f Technology sheet Î M §L
y/ i detraction of coconut milk in Asian households !
V/2 Extraction of coconut milk in Pacific households 9
' V/3 Stabilised coconut milk » Pilot plant 12 in Thailand.
Ï/4 Coconut cream - P ilo t plant in Thailand 17
?/5 Coconut cream - M alaysia 24
¥/6 Coconut cream - Pilot plant in Philippines 27
-f/7 Coconut cream - CotmaerciAl plant in Indonesia 38
¥/8 Coconut cream - Commercial plant in Western Samoa 41
V 9 Coconut jam processing - Philippines 45
v/io Mata de coco cu ltu re - Philippines 49
¥/11 Yinegar by fomentation of coconut mater - 53 Philippines
¥/12 Yinegar by fermentation o f coconut mater using 56 bamboo generator - Philippines
v /i3 Canned young coconut in syrup - Philippines 63
¥/14 Sweetened Macapuno - Philippines 66
¥/15 Coconut chips - Philippine® 69
¥ / 1 6 Tubo Jam from apple o f gem in ated nut - Philippines 73 V
¥/t7 Dehydrated coconut pith & coconut pith flour 76 - Philippines.
V/l8 Cooking o il using fresh mature coconut - Philippines 81
V/19 Cooking o il using fresh mature coconut - Method A 84 of Indonesia.
?/ao Cooking o il using fresh nature coconut - Method B 87 of Indonesia.
f/21 Cooking o i l using fresh mature coconut - Msthod C 93 o f Indonesia.
¥/22 Coconut Aqueous process - Hagenmaier p ilo t plan t 97 of Philippines.
¥/23 Wet process fay Krauss - M&ffsi/C.F.T.R.I. - 106 pilot plant
¥/24 Wet process by m odified solvol method - pilot plant 110
¥/25 Wet process by Tropical Products Institute 113 (pilot plant)
¥/26 Wet process by Ghayen or Impulse rendering method 117 (pilot plant)
¥/27 Wet process by H ille r (patent process) 120
¥/28 Same patented wet processes 123
1/29 Dry process by Tenko (patent process) 126
¥/30 Integrated dry process fay National Institute 12? o f Science and Technology - (Philippines patent)
¥/31 Tapping coconut sap - Philippines 134
¥/32 Tapping coconut sap - S ri Lanka 143
¥/33 Processing coconut sugar tra m fresh sap - Thailand 158
1/34 Coconut syrup and sugar from fresh sap - S r i Lanka 164
¥/35 Coconut sugar using fresh sap - Sri Lanka 169
1/36 Vinegar from coconut sap - S r i Lanka 177 ¥/37 Coconut Arrack - Sri Lanka» Philippines 198 Product code CCCH 20.0?f technology sheet no» ?
OMZfffi? NATIONS INDUSTRIAL DOTELOPMEMT CBûAMISAtlCS!
AMD ASIAN & PACIFIC COCONUT OCWflMTT
"Coasultagey Service on Coconut Processing technology1*
( P ro ject W /US/W ® k9}
technology sheet for 8 - MtEACtlW 0? COCONUT MILK H ast am HOUSEHOLDS *
Uses of finished products i - i . l the Heist use o f coconut milk i s fo r cooking cu rries.
@•2 Coconut silk is used for preparing various traditional food such as deserts, sveetasats and delicacies.
2.3 Healdue used as aniaal feed.
Country of origin * »
m . LAMIA INDIA (K£EALA fflJÏS ) INDONESIA MALAYSIA PHILIPPINES THAILAND
IsiuiiSBsat t •
l » . l Description of equipaent s »
U . l . l Kitchen knife (heavy type) for splitting the nut into tiro along the 'equator1» See figu re I .
UcX.2 Scraper or grater. See figures H , III and IV. 2
2 •
k «2 Mataríais * -
Mot applicable.
U.3 Cost o f equipment s -
U.3.1 Kitchen knife heavy type mode o f forged steel» about US$ 1 or 2.
1».3.2 Scraper - bench type US# 1 or 2. Scraper - rotary type hand operated - US# 3 or h This rotary type is used in hotels etc in S ri Lanka. Crater - serrated steel plate » about US| 1.
Capacity s -
This does not arise as one or h alf a coconut is grated and M lk e x tra cted by f sadly sseather fo r one house hold for each aain steal. 3 3<»
wmmi жшвш кип (ьм*? «до)
штт и шсожт тот (в®жш tan») иш ш в и ш ь ш ш и ' 1|ф two b u ll ЫшЛщш
eide view show in g till» tw ur blade®
wooden handle
о
A A A AA&AA A A A A A A A A A AA AAA A AAA А А A â> IA A A A ft * “ k k i k к M k ' á A à. A- A & A. â â A 4 A A & ft A A A A A A I ( It i П А A A A A-A- A I J i H H U ¡ а д Ì A & & i j 4 4 * 4 6 *1 & A & A â 4 ¿i U J 1 U J Í
<4* " ...... H»»“ m m if СОРОКИ (ШИВ (Serrated urtai plat®) .. . Ш II SOUTH Е Ш ASIA - 5. Procesa g - £.1 Procesa flew <üag;
gyatsm A » India ani Sri. Lanka
J u st я&Шт9 husked coconut
r > s p lit iurte «long equator and allow water to ши out
Scrapscoeomt toraci wMl®t inali® half вЬвИ
€®e®mt ©eraftíLagS
add li t t lo vatar» squassa ky baisi and strsdn
residuo
eocomit adLlk - firs t « p e U i a g
add acro water» squassa by to d and «trai®
eocomit milk - (d ilu te ) fro® тсшгД foqpalliiig résidu® usad «e ©also, feci gyetew В In Srotb lest Asia
je i t шЬвж®ьЬтк®А mmm%
Шмттш &ШИ lu pieces wit&sttt ÉÊmgiMg krnwml
Break kernel la Ш sbape fer renewing water
gmt® eeeomt kernel . which le in 5 or 6 pieces
grated т т ш Ь
add water, eqaeese bj hand ani stralli
coconut aUk
residen
a id вюге w ater eqaeese b j band and strain
eeeessufe aU k
residue for ш £ш 1 fe e d 7 7.
5«1 Lescrlptian of process t -
Frestalj husked just mature eocomuts are a v a il able in the market.
The husked nut is sp lit open in two along the 'equator1 and water allowed to run out in In d ia and S ri Lanka. The h a lf coconut kernel w ith shell intact is scraped either using the bench type device or the ro ta ry type® I f the coconut is not fresh or if beyond ju st mature, the kernel tends to g e t released fro * the sh ell resu ltin g in difficulty in scraping* The coconut scrapings are squeezed after adding water fo r two separate expelling® (occassionally three).
Owing to the ve ry low efficiency of ex p ellin g ■ ilk by this household method, about kQ% of the milk is lo st in the residue. Where large amounts o f coconuts are consumed as food nuts ($OJf of Sri Lanka's product ion) this wastage is considerable. The per capita consumption of food nuts in Sri Lanka varies between 90 and 120 nuts p er person per year. This figure fo r Indonesia is 60 nuts. The need for an efficient system is obvious.
In Sri Lanka, where food is prepared for commercial purposes, a further amount of milk is expelled from the residue by suitable treatment. Either the residue is pounded or ground using the traditional dose Stic equipment and then squeesed by hand after add- ing warn water.
In South East Asia, the husked nut is first desh elled and the undamaged kernel is then broken to release the water. The kernel i s broken up in several pieces. Each piece i s held by hand and grated on the metal plate w ith serrations. Thereafter, expelling the 8 8.
s&lk is carried oat на menai.
5*3 Product П т diagram s -
le r a s l containing 100 unita и Ц к
V
About 66 unita «s p e lle d
é« Cjfaallty of finished product s -
Coconut silk i « on oil/profcelVmfcer em isión which provides important food intake for people livin g in the ecco m i ядами*
Th® eheadcal cmposltion ( 5) of oocomt milk aeeerd- ing to various sources io given Шот i -
CoHPonanb Clement® and lathana®! P o p p er lathaoael Villacorto (1 9 3 3 ) П >510 i m D СЦ60)
Moisturo 47.0 - 53.0 5 0 .0 54.1 5 2 .0 Fat 39.8 39.8 32.2 27.0
Protoin 2.6 - 2 .9 2.8 4 .4 4.0 S u g a rs 2.8 - 3*2 3.0 » - Total solids 10.3 - 1 0 .5 10.4 « 0» A sh 1.1 - 1.3 1.2 1.0 1.0 Carbobgrdratos » - 8.3 - ftm S i 0.08 - 0.10 0.09 » о
?. Q m rm of infemotion
Observations daring flu id visite to amber eoamtsie».
Î.I.H .I. 1980 9
' Product cedei GCCI 20.0?f Technology sheet no* ? / 2
PMITED NATICHS IMDDSPRIAL DMKLOPMEHÎ OBJAMISATIOi
AMD A SIAM Je PACIFIC COOQMPT CCMMPMITT
"Consultancy Service oa Cocoaut Processing Technology8
( Project KF/RA5/?8/Obÿ)
1. Technology sheet for EXTRACTION OF COCONUT MXLI XM PACIFIC HOÏÏS1HŒJ2S.
2* Pees of finished products t «
The nain use o f coconut milk i s fo r cooking end baking traditional food*
3® Country of origin s «
PAPPA MEM GUINEA SOLDI®! ISLANDS HESTER SAMOA
Equipment * -
Fibrous a a te ria l from sten of a plant belonging to the banana f a n ilj, known lo c a lly in Western Saaoa as Tauaga and pronounced as Tauwanga. 10
2.
5® Precoce s »
Vs&M&m flew diagram i -
satu re е®с@ш%
axed into two longitodinalljr and meat oeeoped «mt
seat broken iato muflí fieoee asá grated or amaebed
First expelling without add ing water and aaing fibrana material
undiluted eoeomt ®ilk
reatine
aeeoiiá expelling with water and using fibrana material
eeoemt milk (dilato) 11
. 3®
Sei Description of prosas» s •
The pices* of iras*»! шт scraped or m M Int* m all ones. Ив* шее of fibrous material i* wasted, cleaned and then placed inside tte bowl with coconut. After some ooooimt got* entangled in the fibrous mass, it is twisted Hke wringing a wasted towel to ш щ ш т out tte water, fte milk «spelled at the first attempt is undiluted. The second «s p e llin g is cfter adding water, The undiluted wdik la need for traditional baked items in tte earth ovens.
ÏÏ8© of the fibrous mass appears to parfom a mors efficient «spelling tten the use ef hand only as in the Asian reglen. ¥te level of o il remaining in tte residue is spilt® acceptable for une a* pig feed in this region where copra cake etc. is not available dae to tte absence ef coco nut ®il M ils.
It is to be noted that in tte Pacifie region tte per capita consumption of ©©mimi in a ll ferns is between 300 to |0© salts per person per pear.
1.3 Product flow diagraa s -
Coconut kernel w ith 100 unita milk
About 70 u nits of milk espoliad
6. Quality ef fia i abed product г «
Coconut m ilk is an oil/prteein/water «asíale® Which provides Important feed intake fo r tte pople.
7. Hoarse of information s -
Observations during field visite t® amber countries in tte Pacifie regie®.
f .1.0 .1. 1980 12 Product cods CCCM 20,0I t ftm h m lm g j «boot m .W / J
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT CQMMUNITf
" Consultancy Service on Coconut Processing Technology"
(P r o je c t UF/RAS/98/OU9)
1. Technology sheet fo r i - STABILIZED COCONUT MILK (Pilot Plant)
2« Uses of finished product i - Culinary purposes
3* Country o f o r ig in THAILAND
Equipment : -
U.1 List of equipment
Pinned roller grater hand feed , | hp motor Coconut presser hand operated, vertical cage press with pressure applied by a mechanical screw advancing the pressure plate from above
Aluminium K ettle with steam in je c to r Autoclave standard Equipment Ointment m ill BrevettatOj UOO w, maximum r.p.m . 10,000 Soft drink bottles 230 ml capacity with crown caps hand capping stand
M aterials 30 liters coconut milk Benzoic acid
!w U»2 M aterials fo r construction: - Not applicable
lu3 Cost of equipment : - Approximately US$2,000
U.U Capacity * - 30 liters per day 13 2.
$« Proceaa
Water
Water
Benzoic aeid u» 3.
Put aluminium k e ttle inside autoclave
Autoclave at 117°C fo r 3 minutes
Turn o f f autoclave & cool for 30 minutes
Run tap water into autoclave
Remove aluminium pot from autoclave
Scrape sides & bottom o f pot
Homogenise
Bottle milk at 70 - 0O°G
Seal with standard crown cap
Inspect & put expiry date
Bottled stabilized coconut milk 15 U.
5.2 Process description
Coconut kernel free from testa is cut into pieces & coimninuted in a locally made coconut grater machine. Weigh comminuted coconut meat. Add ^ of its weigh of water. Extract the milk. Repeat procedure. Sat aside milk (milk 1).
Weigh the residu e. Add \ its weight of water. Press until flow abates. Loosen the residue k press until flow abates (milk II). Pour milk I & II into one dontainer.
Strain coconut milk in a cheesecloth. Put coconut milk in an aluminium pot f i t t e d w ith a steam in je c to r . Add 0.1$ benzoic acid. (This w ill act as preservative). Put the aluminium kettle in sid e the au toclave, Autoclave a t 117°C fo r 3 minutes with steam injection. Turn off autoclave k cool to atmospheric pressure. This takes about 30 minutes. At this point the temperature of the milk is about 100°C. Run tap water into the autoclave to cool the milk in the pot qu ick ly to 80 •» 85°C. Remove aluminium pot from autoclave.
Scrape sides 4 bottom of pot to dislodge any adhering ourd. Homogenize for 5 minutes or until a ll the curd is thoroughly dispersed. Ther8after« turn on homogenize? intermitently to keep milk uniform during fillin g. Bottle milk at 70 - 80°C into 230 ml sterilized soft-drink glass bottles. F ill bottles V in headspace or 200 ml. This is approximately the amount of milk obtained from half a coconut by hand squeezing. Seal bottles with Standard crown cap immediately after fillin g shelf-life of the product in 7 days.
5*3 Product flow diagram
30 liters diluted coconut milk
Y
# 30 l i t e r s canned coconut milk 16
$•
6* Quality of finished product» -
Stabilized coconut milk has the same .appearance and. quality as fresh coconut milk.
7a Source of information « -
Technological Research Institute Applied Scientific Research Corporation of Thailand Phahonyothln Road Bang Kehn, Bangkok Thailand
«
P.M.A. 1979 17 Product code: CCCM 21.0? Technology sheet n».¥ / k
UNITED MUONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCON’JT COMMUNITY
"Consultancy Service on Coconut Processing Technology"
(P r o je c t UF/RA3/76/OU9)
1• Technology sheet fo r COCONUT CREAM - F ile t plant ia Thailand
2. Uses of finished product : - Culinary purposes
3 Country of Origin THAILAND
It* Equipment t -
U.1 List of equipment
Knives - for removing husk Desh ellsrs Knives - Sharp for scraping testa Grating machine (please see illu s t r a t io n ) E xpeller Steam jacketed k e ttle w/ ro ta tin g blade.
U.2 Raw materials
100 pcs mature coconuts 11-13 month old Sodium metabilsulphite 150 gms (soaking medium) Anthracine U ml Pectin 2U0 gm3 Sodium metabisulphite 600 ppm
U.3 Sketch of important equipment :
Steam - jacketed kettle Coconut Shredder 2.
500 to 1000 rpH
SKETCH OF COCONUT SHREDDER wooden s tirre r 20 rprt
SKETCH OF STEAM JACKETED KETTLE 20 go Process U. $.1 Process flow diagram s -
Extract T 21 5. I Extract
Preah coconut Coconut residue milk (5 k l i t e r s ) (26 kg)
Pour in steam jacketted kettle
T Evaporate moisture at 60°-70°C w/ constant stirringifor Uj - 6 hrs)
Sodium me ta b i sulphite I (600 ppm) Coconut milk concentrate (17 kg)
Pectin t (2U0 gms) Pasteurize at 70 0 for 1 to 2 minutes >t Pasteurized concentrated coconut cream
Pack in s t e r iliz e d lacquer Pack in s te riliz e d cans a t 70°G aluminium tube at ?0°C
Close caps tightly Seal
’ t ... r Cool for 10 minutes in Cool running water
Put inside box Dry & lafeel F Cecenut oream in Cecenut cream i n cans ini»® ' 22 6.
5.2 Process description s
Dehusk 100 pieces of 11-13 month old coconuts, weighing 130 kg. Deshell. Waste materials from this process are coconut water & coconut shell. Scrape o ff the testa or paring using a sharp knife. Soak the white meat in a sodium - m etabisulphite fo r 1 to 2 hours o r overnight. Use 1 gm o f sodium m etab isu lfite fo r every coconut. D&lssolve in water. Wash & drain white meat for several times in order to remove any trace of sodium metabisulphite which was added to prevent spoilage & discoloration of the meat. Orate the coconut meat. Extract the milk using an expeller or screw juice extraction in this requence t Pour the coconut milk in a steam - jackebted kettle equipped with a blade, rotating at 20 rpm. Evaporate moist'ire at 60°-70°G with constant stirring for Ug to 6 hours. Add 600 ppm sodium metabisulphite and 21*0 gms pectin to the coconut milk concentrate. Pasteurize at 70°C for 1 to 2 minutes.
To produce concentrated coconut milk in tubes, pack the sterilized aluminum tube at 10°C. Close the cap tightly. Let cool. Put inside box.
If concentrated coconut milk is desired, pack in sterilized lacquer cans at *10°C. Seal the can. Cool for 10 minutes in running water. Dry & label.
In both cases f ill without head space. Met weight of both products are 160 - 170 gm.
5.3 Product flow diagram
Whole mature coconuts - 100 coconuts * 130 Kg ------=ir------6
r—#U 0 kg husk
*—#17.5 kg shell
2.5 kg coconut-water 5U-55 kg whole.e meat
h ,S kg parin g 50 kg whiteF meat l 200 tubes/cans at 160 gms each or 3,200 gms or 32 kgs 23 7.
6. Quality of the finished product :
I t i s a th ick , cream colored emulsion, with very strong coconut flavor. Its proximate composition is 10-11 % m oisture, 76-80/6 fa^ & 6-7 protein.
Add 3 times water i f an undiluted coconut milk is needed in the food preparation; add > times water to produce diluted coconut m ilk.
7. Source of information s -
In s titu te o f Food Besearch and Product Development Kasetsart University Bangkok, Thailand.- Product coda: CCGM 21*07 Technology «heat no* IT
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
^Consultancy Service on Coconut Processing Technology"
( P ro je c t UF/RAS/78/0U9)
1» Technology sheet for i - COCOHUT CREAK - Malaysia
2» Uses of finiehed product * - Culinary purposes.
3» Country of origin * - MALAYSIA
U. Equipment *
U.1 L is t o f equipment
Deshelling tools Standard equipment Paring knives Standard equipment Cooking pan To be used fo r s t e r iliz in g coconut meat D isin tegratin g machine To be used fo r comminuting coconut meat Presser To be used for extracting coconut milk Steam jacketed k e ttle Standard equipment Laddie ' To be used for stirring coconut milk Containers Cans or plastic pouches
2l«2 Materials for construction i - Not applicable.
U.3 Cost of equipment t - Approximately US$ 150.00
lull Capacity * - 30 liters coconut milk 25 г . 26
3..
5.2 Process description *
Dehusk whole coconut» Remove the kern el» Coconut water is thrown away as waste. D eshell. Coconut s h e ll i s used as domestic fuel. Pare the whole coconut. Wash the white meat & then s t e r iliz e in b o ilin g water fo r 1 to minutes.Comminute sterilized coconut meat. Extract the milk.
Concentrate the milk by heating in steam jack etted k e ttle at 80° C for about U hours with continuous stirring. For purposes of extending the shelf-life of the product add 600 p.p.m. o f sodium metabisulfite.
Concentrated coconut milk can be canned and kept a t room temperature or packed in plastic pouches & immediately frozen & kept a t a l l times under fre e z in g temperature.
The shelf-life of canned concentrated coconut milk is approximately six months while that of frozen coconut milk is appreciably longer.
5.3 Y ie ld :
It has been calcul_____ j oz of concentrated coconut milk is approximately equivalent to three tiross the weight of unconcentrated fresh coconut milk.
6. Quality of finished product !
Very thick coconut cream with 1&0 - U5£ fa t.
7. Source of information *
Agricultural Product Utilization Division.
Malaysian Agricultural Research St Development In s titu te (MARDI) P.O.Box. 202 UPM Post Serdang, Selangor Malaysia
P.M.A. 1979 27 Product cedes CCCN 21.07 technology sheet n®. V / 6
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN k PACIFIC COCONUT COMMUNITT
" Consultancy Service on Coconut Processing Technology"
( P r o je c t UF/RA3/78/0U9)
1. Technology sheet for COCONUT CREAM - P i l o t plant in P h ilip p in e
2. Uses of finished product Culinary purposes » 3* Country o f o r ig in PHILIPPINES
U. Equipment
U.1 Description of equipment
Coconut meat grinder Made of cold ro ll steel with a hopper» screw conveyor St two corrugated disc plates. Cut pieces of the coco meat are dropped into the hopper & by conveyor the coco meal are caught in between the teeth of the two disc plate where they are crushed into uniform s izes o f around 16 mesh. It is operated by a 1$ horsepower e le c tric motor*
Screw press (expeller} s Made of cold ro ll steel and could expel maximisa: amount o f coconut m ilk from the i’ coconut meat at optimum pressure & tem perature» in order to protect the oooonut milk from dénaturation prior to process in g . It is operated by a £ horeepower gear type electric motor Centrifuge 8 Stainless steal Be Laval type separator» It can separate coconut m-Uk into 3 portions, namely coconut cream (fatty portion), skimmed milk (watery portion) and protein solids (solid portion)
Prooassi&g tank s Stainless steel, steam-jacketed tank standard equipment with a stirring rod and a discharge valve located at the bottom of the tank where the processed coconut milk can be tran sferred ascep- tica lly to the next processing equipment by means of stainless pipes.
Homogenises 8 Stainless steel standard equipment with an operating pressure range of 0 to 500 kgVam2.
Can sealer $ A standard equipment adopted for sealing 1C oz cans.
Autoclave ’ 8 A standard equipment made of steel, c irc u la r in shape operated between 10 to 1;1 psig from 30 minutes to one hour* ,
U*2 Materials for construction 8 Not available
U*3 Cost of equipment Coconut meat grinder P 29,000 * 3,972,60 Screw press 20,000 2,139*72 Centrifuge 5o,ooo 6,81*9.31 Processing tank 80,000 10,958.90 Homogenizer 100,000 13,698.63 Can sealer 10,000 1,369.86 Outoelave 10,000 1,369.86 P299,000 «1*0,958.88 k »k Capacity t Coconut meat grinder - 1 tor\/hour of fresh coconut meat
Screw press - 1 ton/8 hours of f r e & coconut meat
Centrifuge - 200 litres/hour
Processing tank - >00 litres of ooconut milk
HotaogsnLzer - 200 gallons/hour
Can sealer - 23 sans/minute U. зо Propesa г
Oanmd e©eо o n a 31 5.
5.2 Description of processt
Sound mature coconuts are selected & d esh elled. Coconut water is collected 4 made into nata de coco or vinegar. The meat with paring is washed, weighed& ground. The ground meat i s mixed with \ to 2 times its weight of water & passed through a screw press or expeller to extract the coconut milk. The residue is used for animal feed. The whole coconut milk is transferred to the centrifuge to separate the cream from the watery (skim m ilk) p o rtio n . The skim m ilk is used fo r making nata de coco or coconut syrup. The cream is mixed with J to 2 times its weight of water and pasteurised for about 25 minutes. Ih@ pasteurized cream is mixed thoroughly with a stabilizer & passed through a homogenizer. The homogenized mixture is heated almost to boiling, fille d hot in tin cans, sealed immediately 4 processed at 6 to 10 psig for U5 to 70 minutes in the autoclave. From the autoclave, the cocomilk in tin cans are cooled immediately by submerging in a cooling tank with running water, dried & packed in cartoon boxes of 2k cans per cartoon.
6. Quality of finished product t
Export q u a lity coco cream „
7. Source of information s
Engineering Research Department
Industrial Research Osnter NIST, P .0 . Box. 77U Pedro Gil St. Emits, Manila Philippines.-
FJU A. 1979 32
Product code: CCCN 21.07 Technology sheet no: V /7
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
"Consultancy S ervice on Coconut Processing. Technology"
(P r o je c t UF/RAS/78/049)
1. Technology sheet for : - COCONUT CREAM - Commercial plant In Indonesia. 4 2. Uses of finished product : -
For culinary purposes in Indonesia and for export,
3. Country of origin : -
INDONESIA. This process uses desiccated coconut for manufacturing coconut cream. The process was developed by the manufacturers whose main a c t iv it y is manufacture of desiccated coconut. The plant is located in North Sulawesi^.
4. Equipment: - m
Special grinding machine and packaging equipment for small plastic bags and tin cans.
Details of equips eat, costs etc are not a v a ila b le . 2
5. fesgegg: -
5.1 Process flow diagram: -
desiccated cocdnut
grinding
packing and sealing
coconut cream (300 gm cans) 3'L>
- 3 -
5 «.2 Description of process : -
Desiccated coconut is subjected to grinding by the use of special equipment. Details of the complete process ace not known.
After grinding» the material is packed into p la s tic bags or " l i f t tab" cans o f 300 ¿pa n e tt.
5.3 Product flow diagram: -
fields are not known
6. Quality of finished product: -
The cream upon dilution in hot water reconstitutes coconut milk similar to the original milk.
The local restaurants preparing typical food of West Svnatra (Padang) have found this product very acceptable.
7. Source of information: -
Observations during plant v is it.
T.K.G.R. 1980 35
Product code: CCCN 21.07 Technology sheet no: ¥ /8
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
"gO Tg^affcx,^„rylce £n„Cocpnut ,Processlgg
ffl/»AS¿Z 8 / £ № )
1. Technology sheet for s - COCONUT CREAM - GoBmsrcial plant in Western Samoa.
2. Uses ftf ^n^,shed,.par9duct : -
Exported for culinary purposes
3. Country of origin : -
WESTERN SAMOA. This plant uses an adaptation of the process invented by the Tropical Products Institute o f England, end was set up with their assistance.
4. Equipment: -
Bush knives for deshelling Paring knives for removal of testa Tanks fo r washing kernels Rotary grating machine with stationary and rotating discs Screw type expeller Stainless steel containers Jacketed kettle of stainless steal for sterilisation Hom.ogenizer Canning equipment
The details of equipment, costs, capacities etc are not available.
The capacity of the plant is 7000 nuts per в hr shift « 4200 cans o f 15 ounces
Capacity per year on the basis of 250 working days is about f m illion вше o f 15 ounces each. 36
- 2 » f. Procesa: - 5*1 Process flow diagrms: - mature coconuts picked from the tr e e and husked a t the fa ra
inspection at re c e iv in g sto re.
temporary storage maximum 3 days
deshelling with bush k n ife
'
paring testa ZZI ' t cut open kernels and wash parings sold as animal feed
grating by rotary- disc type machine
expelling by screw expeller without adding water «
milk (undiluted)
residue sold as dilute 2 of milk animal feed with 1 part of water
sterilize in jacketted kettle
homogenise while < hoi
canned and sealed while hot I canned coconut era 37
Description of the process: -
Picked, mature coconuts are dehusked in the farms and brought into the plant within a few days. It is usual to allow nuts to f a l l naturally in Western Samoa but, such nuts are dry and hence not used fo r the process. At receiving, the nuts are inspected so as to reject any nuts under mature, over mature or those not freshly harvested and husked. The nuts are kept in the stores and stocks rotated to ensure that no nuts are held for more than 3 days.
The nuts issued for the days production are deshelled by piece rate workers using bush knives. Thereafter the kernels are pared, cut open and washed thoroughly in fresh water.
The washed kernels are grated by a rotary device which has a stationary disc and a rotary d is c . Thereafter the milk expelled by a screw expeller. Occassionally when the axpeller is out of commission, the tradition al ex p ellin g by the use of squeezing with banana type fib re is adopted (See technology sheet fo r "EXTRACTION OF COCONUT MILK IN PACIFIC HOUSEHOLDS")
The parings e a rlie r removed, and the residue a fte r expelling die sold as animal feed.
The coconut milk is diluted 2:1 and sterilized in a jacketted kettle for half hour, boiling of the contents taking place during the la s t 5 minutes. The cream is homogenized while hot. The canning and sealing operation is also carried out while hot. The cans contain 15 ounces (425 gm) each. 38
4 -
5.3 Product flow dlagrmi: -
500 coconut» (400 lb before paring) < i
> r i
M lsm .siLl^.m ssssL
6. Quality of finished products; -
The coconut cream has e x c e lle n t consumer acceptance by the Asian population in the msay countries to which the product is exported.
7. Source of information; -
Observations during plant v is it . i
T.K.G.R 1980 r;<
Product code: CCCN 20«05 Technology sheet no. V / 9
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION AND ASIAN & PACIFIC COCONUT COMMUNITY "Consultancy S ervice on Coconut Processing Technology" (P r o je c t UF/RA3/76/0U9)
1» Technology sheet for s - COCONUT JAM PROCESSING (Home Industry)
2. Usee o f fin ish ed product * - Dessert
3» Country of origin Philippinea li« Equipment
U.1 Description of equipment & ingrediente
Equipment:
G rater metal sheet with serrations for grating Basin 2 sets» round 12" diameter
Cheesecloth £■ yard
Cooking pan Round 12" diameter Casserole Round 12® diam eter w/ rack Laddie wooden
B o ttle s Six pcs 8-os capacity with caps
Tong 1 sats medium size
Weiging scale : for kichen use
Ingredients Proportion Coconut milk 100$ Brown sugar 10.25$ of weight of coconut Glucose 5.5$ of weight of coconut Citric acid 0.25$ of weight o f coconut
U.2 Materials for construction: not applicable Uo
2.
U.3 Coat o f equlpnent t P 100 # 13.98
U.U Capacity * Six S-os bcttlea
Process
5.1 Process floe diagrea Cook in lo v boat
yt
Pour in sterilised c o n t a in » »
Seal, coal & labal
Coconut Jam
5*2 Description of process t -
Dehuaked mature coconuts (12 pcs) are opened & grated. Lukewarm water is added to the freshly grated coconut in the proportion of 1 part grated coconut to 1 part water. Extract & strain the milk using a cheesecloth. Weight the coconut milk & the other ingredients to be used. Jet aside | c* of coconut milk.
Pour the remaining coconut milk in a cooking pan. Add p reviou sly measured sugar & glucose in the cocomilk. D issolve the mixture by stirring constantly while cooking over low fire (approximately 20 minutes). Strain mixture in & cheesecloth to remove fo re ig n p a r tic le s . ¡42
k.
Boil the milk over high heat to evaporate water content. S tir constantly. Cook for approximately UO minutes. When the mixture i s almost thick add the coconut milk - citric acid mixture. Citric acid w ill prevent sucrose crystallisation during storage. Cook in low heat (for approximately 25 minutes) until the mixture thickens.
Sterilize bottles by boiling them in a casserole completely submerged in water for 10 minutes. Remove bottles, using a tong & put them on the tab le up-sids'^dotra to dry.
Pour hot coconut jam in ste rilize d b o ttle s while hat. Cover tightly cool & label.
5.3 Product flow diagram
12 pcs grated mature coconuts
v Water, sugar O glucose, citric acid Six 8-oz bottles coco .jam
6. Q uality of finished product
It is a creamy, free - flowing, sweetened product, prepared from coconut milk & sugar with an average moisture content of 25%, h% fa t , 6% protein & 75% total solids.
7» Source o f inform ation s -
Food Research & Development Division
Philippine Coconut A u th ority Diliman, Quezon City Metro Manila Philippines
FJt.A. 1979 H3
Product coda I CCCN 20 ©Ok
Technology sheet no! 7 / TO
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION «anBHMHMMMaraMMMHMaMaHnunMBMHMHnHMBnMnBB
AND ASIAN & PACIFIC COCONUT CCfriKPNITT
aCensultancy Service en Cocemt Processing Technology*
(Project UF/RAS/78/OU9)
1* Technology sheet fori MATA DE COCO CULTURE (Home in du stry) from coconut «s t a r or alternatively coconut milk»
2» Uses of finished product! • Dessert.
3a Country Of O rigin ! PHILIPPINES
W Equipment
Ual List of equipment and ingredients
Basin 12 cups coconut water or milk Laddie 1 cup sugar Cup for measuring 2 cups mother liquor 3 cu lture ja rs J cup glacial acetic acid Casserole dish sugar syrup (2 cups sugar and 1 cup w ater) Sterilised bottles
iu2 Materials for construction! Not applicable
ii»3 Cost o f equipments - About 9 50 (US* 6.73)
ii»U Capacity s ® 1 Kg raw Nata de Coco every 15 days with above set of equipment» HU
- 2 -
5e Process
5*1 Process flow diagram! -
b o ttle d líate de Coco in sugar syrup. b5
5*2 Description of process
The coconut water is boiled and cooled* Mix well the sugar, mother liquor and acetic acid in the coconut water. Alternatively an equivalent quantity of coconut milk made from milk of 1 grated coconut in 1 2 cups of fresh water can be used instead of coconut water. Pour into culture jars to a height o f 60 mm ( 2^ inches), cover the jars with clean paper and incubate a t 28°C (82° P ), the temperature most favorab le fo r the growth o f the nata© The jars are le ft undisturbed or else the nata being formed at the surface w ill sink to the bottom. After lir days when the nata is about 25 mm (o r 1 inch) thick, pick the nata with a clean fork taking care not to contaminate the liquid below the nata formation. This liquid w ill be used again to culture nata and is called the "mother liquor"*
Remove the cream formation at the bottom of the nata. Cut the nata into squares of about 25 ®m (1" inch). Wash and boil fo r 1 minute in an open pan, drain, soak in water constantly changing the water. Repeat the procedure until all the acid taste is removed. Drain the nata for 2 hours. For every part of nata add 1 part of sugar. Colouring may be added if desired. Leave overnight. Cook until gummy texture is removed and nata is transparent. Add flavouring. Prepare syrup. Pack nata in jars f fu ll, add syrup to \ in headspace, seal cups tightly, process in boiling water for 30 minutes. Dry, cool and store.
5*3 Product flow diagram
3 Kg (12 cups) coconut water 2 cups ^ cup glacial 1 cup or coconut milk mother liquor acetic acid sugar <» * * > ' Ì_____ J
> 1 Kg raw Nata de Coco
Sugar syrup (2 cups a»» ■ ■ i>. Sugar & 1 cup w ater) 6« Quality of finished product
The fin ish ed product has no h am fu l in gredien ts and i s su itab le for edible purposes»
7« Source of infomatiom
Philippine Coconut Authority DUlimanj wueson C ity Metro Manila Philippines»»
«
P. M..A. I979 1*7
Product coda : COSSI 22®1Q Tedinolo©- sheet nos V / U
UN IIE P NATIONS INDUGEUAL DKViuLOFI-lillT ORGANIZATION
AND AdIM & PACIFIC COCONUT CO?J UNITY
wConsultanqy Service on Coconut Processing Technology*
(Project UF/RAS/76M9)
1» Technology sheet fort VINEGAR BX FERMENTATION OF COCONUT WATER (Heme Industry)
2» Uses of finished products Cooking purposes and smkin^ pidd.es®
3® Country of origin: PHILIPPINES
U® Equipment:
U» 1 Description of equipment and ingredients
Cheese cloth for filtering 16 cup6 coconut water K e ttle i f cups sugar Laddie 1 teaspoon yeast * Jars (wide mouth) f o r fe rn eating Bottles for packing
U®2 Material for construction: Not applicable
U.3 Cost of equipment: » About 9 50 (US$6-70)
U®U Capacity: About U®5 litres (1 gallon) Vinegar every h weeks w ith 1 s e t o f equipment® Process
5*1 Process H a s diagrams
coconut water
yeast sugar o strain (filte r), boil and cool
mix w e ll
store fo r 5 days (Alcoholic fermentation)
Sipboa d ear solution into widemoutfa Jars» T store fo r 3 weeks (Acetic fermentation)
raw vinegar 1 pasteurize and cool Heat at 60° to ?0° for 20 minutes (lii0° to 160 F)
coconut vinegar H9
® 3 -
5*2 Description of process
Strain (filte r ) coconut water through a cheese cloth» B o il fo r 10 minutes and cool» Add sugar and yeast and mix w e ll» Four into jars with wide mouth, cover with cheese cloth and store for 5 days for alcoholic fermentation. Siphon the clear solution and pour in to ja r s with wide mouth, cover and again store fo r 3 weeks for acetic fermentation» Strain the contents and pack into b o ttle s with narrow mouth» Seal t ig h t ly and pasteu rize by heating at 60° to ?0o C (lljD0 to 160° F) for 20 minutes and cool»
5*3 Product flow diagram
16 cups coconut water i f cups sugar 1 teaspoon yeast
v
lu5 litres (1 gallon) vinegar
6» Quality of finished product:
Coconut vinegar is suitable for edible purposes* It contains not less than k% (g / 1 0 0 ml) acetic acid and usually about 6#« The vinegar is derived from alcoholic and acetic fermentation t&nd contains no foreign matter except caramel»
7 • Source - of informations
- P h ilip p in e Coconut Authority Diliman, wezon City Metro Manila Philippines*®
P.M-A. 1979 50
Product oad® * GOGH 22.10 Teeh&elegy shoot no. 7 /12
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION AND ASIA & PACIFIC COCONUT COMMUNITY ^Consultancy Service on Coconut Processing Technology*1 ( Pro.leot UF/RAS/78/OU9)
1. Technology shoot fog * - VINEGAR BT FERMENTATION (F COCONUT WATER USING MHBOO QSSSSAtOBL
2® Uses of finished produot ; « Cooking purposes, p ic k le making.
3. Country of origin s - KiXXJP FINNS lie Equipment : -
U.1 Description of equipment and ingredients
A single bamboo generator is composed of upper & lower compartments, each fille d with packing materials one meter high. The lower compart ment contains the packing support &. assembly, thermometer & a ir in let & glass product collector. The air vents, vinegar stock inlet, viewing glass & packing support make up the upper compartment.
Construction of Bamboo - Generator
( 1 ) Use two dried straight bamboos of about 9k cm and 121+.5 cm long with 9 cm outside diameter. Remove the nodes and smoothen Inside wall with sandpaper. (2 ) Upper compartment - The upper end o f the upper compartment is f i r s t covered with a superimposed air vent. The air vent is a circular wood cover with a hole in the middle through which a bamboo 12 cm long and li cm in diameter is inserted. Before the bamboo is insert ed, cover the hole w it| * "ainamay" cloth. Two k cm square openings are out on both sides of the bamboo protruding above the wooden cover. An 8 mm circular hole is bored in between but below the U cm square openings. The bamboo and the wooden cover are glued together and sealed w ith paraffin® 51
8 IS! CIRCULAR HOLE
FLOW-RATE METER h MM SQUARE OPENING AIR VENTS k [NEGAR STOGI r INLET AIR VENTS AND VINEGAR STOCK INLET VINIGAR STOCKv g L Ü DISTRIBUTOR,/
PACKING MATERIALS i ì l VIEWING GLASS
•VIEWING GLASS -PACKING SUPPORT PACKING SUPPORT
0 PACKING SUPPORT assembly
PACKING MATERIALS j|| &
.AIR INLET GLASS-PRODUCT COLLECTOR PACKING SUPPOR' ASSEMBLY GLASS-PRODUCT 0- COLLECTOR OUTSIDE VIEW SECTIONAL VIEW
THE BAMBOO-GENERATOR WITH ITS ACCESSORIES An empty bottle of 9 a outside diameter is cut at both ends and fitted at the lower end of the bamboo. This is called the view ing glass. The viewing glass oonneots the upper and the lower compartments.
Lower compartment - Reduce the thickness o f the low er end o f the lower compartment to f i t in the glass product c o lle c to r . The glass product collector is a bottle of 9 cm diameter with the bottom cut and removed. Sotos 15 om from the lower end of the bamboo tube a 5-cm hole is bored; this is the air inlet. A piece of bamboo tube of the same diameter is inserted to this hole. This bamboo tube must be inclined upward to prevent spilling of the solution. Another piece of bamboo is glued around the in let and covered with "sinamay® cloth . Place one packing support in the upper compartment a t the bottom part above m e viewing glass. Another packing support and assembly is inserted from the bottom and placed just above the air inlet of the low er compartment.
It is then filled with packing materials, coconut coir fibers washed with water and soaked in vinegar. These packing materials, with a wet weight of 650 gms, are equally distributed in the upper and lower compartments.
The two compartments are join ed in the view ing glass section with plastic tape. The joint is further sealed with paraffin to avoid contamination.
Equipment :
Bamboo generator 10 liters capacity
Casserole b ig enough to contain 10 liters liquid of any shape Vessel for feeding generator U000 ml Erlenneysr flash with removable plastic sideara on side near the bottom in line with tbs section connection Vessel fo r fermentation ary wooden or glass container big enough to contain 15 liters liquid, 1 vessel must be filled only § full.
Vessel for collecting vinegar Glass gallon jar 53
u«
Muslin cloth or coarse fabric for filtering Cooker or fire place
Ingredients:
10 l i t e r s ( 2 .2 gn) coconut water 1 .$ kg sugar (white or brown) 5 gm. Fleisohmann' e
Mother vinegar for innoculation to be used only oncej the firs t tine the bamboo generator is used.
U.2 Materials for construction: : -
Dried straight bamboos of about 9k cm & 12U.5 cm lon g w ith 9 cm diameter
U.3 Cost of construction : - P800 (#110) for four column
iuli Capacity : - 10 liters per oolunn 5. Process i
5*1 Process flo w diagrams
filtered coconut water
sugar (brown or white) d isso lve
pasteurize by heating at 60°C (11aO°F) lor 20 minutes, cool and transfer to fermentation v e s s e l.
yeast mix
store fo r (alcoholic fomentation)
decant or siphon alcoholic solution and transfer to feeding vessel
alcoholic solution reacjy for feeding generator
trickle down previously innoculated bamboo generator at | to 1 litre per hour
pasteurise
store for ageing
B o ttlin g
t l negar 55 6.
5*2 Description of process:
Filter 10 litres of fresh coconut water through muslin cloth o r coarse fa b ric to remove d ir t and suspended p a r tic le s . D issolve 1*5 Kg of white or brown sugar, Pasteurize by heating at 60°C (litO°F) for 20 znLnutes and cool» Transfer to the fomentation vessel and add 5 gra of Fleischmann's yeast. Allow the solution to ferment until vigorous bubble fermentation stops. Decant or siphon the upper layer of the alcoholic solution without disturbing the sediment at t he bottom» Transfer to feeding vessel above the bamboo generator. Now the alcoholic solution is ready for feeding into the generator which is previously innoculated®
Trickle down the alcoholic solution at the rate of f to 1 litre per hourr Recycle the solution in the collecting vessel until an acidity of about 6$ is obtained. The air vent of the bamboo generator must be kept fu lly opened during this operation* The vinegar finally collected is pasteurized, cooled and stored to age (mature). Thereafter the vinegar is bottled.
The innoculation of the bamboo generator is necessary for
the first batch only. This is carried out as follows: » Close the air inlet of the bamboo generator and trickle down it litres of fermenting vinegar for 3 days. Fermenting vinegar is made by mixing 1 part of mother vinegar to it parts of alcoholic solution*
5*3 Froduct flow diagram:
10 litres coconut water 1.5 Kg sugar (white or brown) I I
5 m y e a s t» -
10 litres vinegar 56
7®
6 » Quality of Vise gar
Coconut vinegar is suitable for edible purposes. It contains not less than k% (gny'lOO nil) a c e tic a cid and u su ally about 6%® The vinegar is derived from alcoholic and acetic fermentation and contains HO foreign matter*
'4 7® Source of information:
national Institute of Science & Technology Pedro Gil Street KanUa Philippinee®-
IVH.A 1979 Product codes CCGH 03.01 Sdehnology sheet no. f / 13
UNITED NATION3 INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
"Consultancy Service on Coconut Processing Technology"
1, Technology sheet for s - CANNED I 0UNQ COCONUT IN SIRUP (Research & Development)
2. Uses of finished product s - Dessert» baked products
3* Country of Origin t - PHILIPPINES li« Equipment : -
U.1 List of equipment
Compact canning line - Ball
Can slioer - Automatic
It.2 Cost of Construction : - Not applicable
U.3 Cost of equipment 5 P 170,000 - ©$23,287.67 5* Proce aa
?«1 Proce ea flow diagram
Store in cool, dry Csnnad young plaoe. coconut. 59 3
5.2 Process description s -
Scoop out meat of young coconut (8 te 10 months age). Remove paring using sharp knife. Wash the white coconut meat in tap water. Cut the meat into strips thick 3" long. Pack strips in 2T cans a t 200 + 5 grams/can. Add 50° Brix syrup w ith 0.01;? sodium metabisulfite. Exhaust at 180°P (76°C). Seal. Process at 250°F (15 lbs) for 20 minutes. Cool, dry & label. Store in a cool dry place.
5.3 Process flow diagram * -
2500 m s white meat from 10 coconuts I lit cans young coconut in syrup
6. Quality of finished product
Cream colored, sweetened young coconut strips.
7. Source of information t -
Food Resaarch & Development D ivisio n
Philippine Coconut Authority Diliman, Quezon C ity Philippines 6o
Product code * CCCN O0«O1 Technology sheet no* ¥ / 11*
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN Sc PACIFIC COCONUT OOItlUMITY
" Consultancy S ervice on Coconut Processing Technology"
(Project UF/RA5/78M9)
1® Technology sheet for s - SWEETENED MACAPUNO (Coconut Sport) (Home Industry) A coconut tree that produces macapuno usually y ie ld s 1 to 2 macapuno nuts per bunch of ordinary coconut. The entire cavity of the macapuno is filled with s o ft \ tender je lly - like endosperm, which is considered a delicacy in the Philippines. ,
2. Uses o f fin ish ed product s - Dessert
3® Country of Origin : PHILIPPINES
Bquipmsnt : -
U.1 List of eguipment
Cooking pan S tain less Wooden laddie steel blade measuring cup Scraper (for young coconut) Preserving bottles w/ caps.
U.2 In gredien ts : -
1 part coconut sport to 1 part sugar SCRAPER
U.3 Cost of equipment i - p 100 DS# 13.98 Ргосааа
5*1 Ргосеза Пои <11&£гат %
Botfcla¿ Зиее1дапе<1 Масарто 62
3. f>.2 Process description
Dehusk macapuno. Open the nut. Scrape o f f white creany meat using young coconut scraper. Measure the white meat. For every part of macapuno meat add a corresponding amount of refined sugar. Put the mixture is a cooking pan. Stir to partially dis solve sugar. Cook in low heat until sugar is totally dissolved (this takes approximately 30 minutes i f only 1 nut is being cooked) Hot pack in sterilized bottle. Close cap tightly. Cool & label.
6. Quality of the finished product
It is a dessert product very similar to young coconut meat but has a very soft je lly - like endosperm .
7® Source of information t -
Food Research & Development
P h ilippin e Coconut A u th ority Dlliman, Quezon City Philippines.
PJ1.A. 1 >79 63
Product code t GCCN 08/01 Technology sh e e t ns. 1 /1 5
UNITED MATIONS INDUSTRIAL DEVELOPMENT ORGANISATION AND ASIAN & PACIFIC COCONUT C0Ü4UNITI
" Consultancy Service on Coconut Processing Technology”
(P ro je c t UF/RAS/78/OU9)
1» Technology sheet for I - COCONUT CHIPS (Home industry)
2® Uses of finished product I - Snack item
3. Country of origin : - Philippine s
U® Equipment
U.1 List of equipment t
Baking oven 1 unit Potato peeler 1 dozen Mixing bowl 1 large Callander 1 large Laddie 1 large Tray I; pcs. aluminum baking trays
U.2 In gredien ts :
6 mature coconuts (1 £ month old) Soaking media ;
Sugar Barbe qua fla v o r S a lt
li.3 Capacity : - 6 Nuts every batch
U.U Cost of equipment t - P2,190 US$300.- 2 Pro casa
5»1 Process flow >diagram
Label 3.
5*2 Process description t-
Open 12. month old coconuts in to two. Coconut water can be collected & be processed to produce coconut vinegar or nata de coco. Put the coconut inside the oven & bake at 176°C for 15 to 30 minutes or until the meat can easily be taken out of the shell. Scoop out the meat. Remove the paring using a sharp kniv®. Slice the white meat thinly with the use of a potato peeler, long. Season the sliced meat by soaking in the solution of desired flavoring ;*
Flavor Concentration Soaking t i tm
S a lt 2% 2 hours Barbeque h% 2 hours Sugar $0% U minutes
The proportion of the soaking solution to the sliced coconut meat is 2 s 1. Drain in a collan der fo r approximately 20 minutes. Spread thinly on a baking sheet & put in pre-heated oven (300°G). Toast while drying. Bake for 30 minutes or until desired brown color is obtained. Cool for 10 minutes. Pack in cello/foil/PE bags. Label.
5.3 Process flow diagram
\97h gms fresh sliced white meat from 6 coconuts - j
967 gms coco chips
6® Quality of the finished product
It is a golden brown crunchy snack item with a critic la l moisture content of 3 %» Source o f information t
Food Research & Development D>Wisicm
Ph ilippin e Coconut Authority Diliman, Quezon City Philippines
Comment : «
This product is also being commercially produced by some desiccators in the Philippines. The meat is mechanically sliced & its moisture content is evaporated by passing through a conveyor type of dryer.
P.M.A. 67
Product code s CCCN 20*05 I Technology sheet noi ? /16
UNITED NATIONS INIÆSTRIAL DEiTELOMiENT ORGANIZATION AND ASIAN AND PACIFIC COCONUT C0MMJWP1T
"Consultancy Service on Coconut Processing Technology8
(P r o je c t UF/ftAS/78/0U9)
1» Technology sheet fori TUBO JAM FROM APPLE OF GERMINATED COCONUT (Home Industry)
2® Uses o f fin ish ed product» A nutritious dessert as well as a bread spread*
3* Country ef origin» PHILIPPINES
U* Equipment i
li*l Description of equipment and ingredientst
Bowl for mixing 1 Eg of tubo Pot Cooker 1 Kg o f white sugar Jars for packing Yaailla flavouring
U*2 Materials for construction! « Not applicable
U*3 Cost o f equipments About 9 100 (US$ 13.UÔ)
lull Oagtaeifjrt About 1*25 Eg per batch* 68
- 2 -
5a Process
5*>1 Process flow diagram
sugar
▼ardila to ta s te
tubo j 69
3 -
*>®2 Description of process;
fake 1 Kg o f clean tubo® Tdbo if the apple (hanstoriua) inside the coconut that has begun to germinate. Shred the tubo to a very fin e mesh and add the sugar® Mix w e ll while cooking to a sticky consistency. Allow to codL, Add vanilla to the desired ta ste and mix w e ll. Pack in to clean preserving Jars, sterilize by boiling fer 20 ad nates and seal.
5*3 Product flow diagram
About 1»2$ Kg of tubo Jam
6® quality of finished products
The finished product does not contain any harmful in gredien ts and i s su ita b le f o r ed ib le purposes®
7® Source of informations
Ph ilip p in e Coconut Authority Diliman, Quezon C ity Metso Manila Philippines®»
P.M. A. 1979 70 Product code s CCCM kk Technology sheet a»« ¥ / If
UNITED NATION 3 INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
" Consultancy Service on Coconut Processing Technology*1
(P ro je c t UF/RA3/78/0U9)
1» Technology dheet for * - DEHYDRATED COCONUT PITH & COCONUT PITH FLOUR (Terminal Bud or Cabbage) (®98»arch & Development) < 2« Uses o f the product t - Culinary purposes
3® Country of origin i - PHILIPPINES
U« Equipment : -
U.1 List of equipment
Cabinet dryer locally fabricated Grinder Almeda rice/corn grinder Steamer Standard equipment P a il 1" high, plastic Kni ea 3 Pieces Collander P la s tic < Plastic sealer Standard equipment
Ua2 Materials for construction :
Cabinet dryer
U.3 Cost o f equipment ’ $200
Usli Capacity : 5 Kyraw coconut pith/bateh 71 2
5.1 Procesa flow diagram t 72
3.
Bone d ried coconut pith
Cool
F&ck & Seal
Dehydrated Coconut Pith 5.2 Process description s -
Wash thoroughly head part or leafy portion of fresh coconut pith. Remove rough, highly fibrous portion.
Cut the edible portion 1^" long % 3 ran thick (head part) or slice thinly (leafy part) 4 put them in a pail of water to prevent browning of the pith. Drain in a collander. Blanch in boiling water for 5 minutes. Drain.
Thread th in ly the blanched coconut p ith on the dryin g rack of the cabinet dryer. Dry at 100 - 120°F for approximately four hours or until ine product becomes bone-dry.
Cool head p a rt. Pack in polyethylene bags 4 s e a l. Alternatively if the end-product is ubod flour, cool the bone dried leafy portion, grind, s ift using 80 mesh sieve. Pack 4 dry.
5.3 Product flow diagram % -
5 Kjedible fresh coconut pith
1.5 dehydrated product
6. Quality of the finished products : -
Dehydrated coconut pith strips are bone dry 4 cream colored. Its rehydration capacity is h.9. Rehydrate by boiling for 10 minutes.
Ubod flour is a high fiber, highly hygroscopic wheat flour extender.
7. Source o f inform ation : -
Food Research 4 Development Division
Ph ilippin e Coconut A u th ority Diliman, Quezon C ity, Philippines.- Corroient i »
There has been no research activity undertaken before to preserve coconut pith since one has to k ill the tree in order to get the pith. However, a lot of coconut pith w ill be avialable in the Philippines starting thé middle part of 1980 when the Philippine Coconut Authority starts its ’ 20-year nationwide re p lan tin g programme.
Re commandation i -
I f the product is to be commercially produced the use of mechanical cutter St commercially available forced-draft oven are highly recommended. 75
Product code t COON i Technology Sheet not ¥ / 1 8
UNITED NATIONS INDUSTRIAL DETOLOMEM ORGANIZATION
AND ASIAN & PACIFIC COCONUT C(M1UNITI
«Consultancy Service on Coconut Processing Technology11
(P r o je c t UF/RAS/78/Qiiy)
1« Technology sheet fort COCKING OIL USING FBSSH MATURE COGCSIUT (Traditional home industry)
2. Usee o f -finished product! Home cooking o il is used by the rural population in remote coconut areas as edible o il. This is being rapidly replaced by industrially processed and refined o il. By product ® residue used as chicken feed.
3. Country of origins PHILIPPINES
U. Equipment:
iul Description of equipment:
Grater
Pots and pans Strain er Glass container Cooker or fire place
U*2 Materials for construction: « Not applicable
Cost o f eqiilpment: About 9 100 (USI 13.U8)
ll.it Capacity: Nominal capacity per family engaged for 10 hour working day is estimated at 20 Eg o il. 76 * s • 5. Procesa
5.1 Process flow diagram: mature cocorat (husked)
sto re undisturbed for 3 hours (d en sity separation) Z decant to separate cream f1 cream milk (top layer) skimmed m ilk (w aste)
moderate heating with continuous stirring until colour tends to turn brown
filte r using cheese cloth
cooking o il protein T7
- 3 -
5.2 Description of process:
The husked nuts are deshelled and water allowed to run out to waste. The white meat i s grated and fresh water added. After macerating by hand, the milk is squeezed. The first residue is treated similarly for a second expelling. The milk is collected into a large glass container and allowed to stand undisturbed for 3 hours. The cream milk s e ttle s a t the top w hile the skim milk comes to the bottom® Separate the top layer by decanting or by gravity separation i f there is an outlet and tap at the bottom of the container.
The cream is tra n sferred to a pan and heated g en tly with continuous stirring to avoid burning the protein content. Burning of the p ro tein can be observed when i t turns from white to brown colour. When the p rotein i s ju s t beginning to turn brown, stop heating and let the oil cool down. Filter the oil on a cheese cloth. The protein w ill be retained on the filte r whilst the clean white cooking o il w ill collect into the container.
5.3 Product flow diagram:
10 Kg white meat from 30 coconuts i > ...... V
2 Kg cooking o il
6. duality of finished product:
Analysis of coconut o il not available, The o il has been used by the rural population as edible o il for generations®
7. Source of information:
Philippine Coconut Authority Dillman, Quezon C ity Metro Manila Philippines.
TJtUQ*® 1979 Product code : CCGN 15*07 i ffeohnoilogf sheet aoi' ? /15
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC SQCCKUT COMMUNITY
w Consultancy Service on Coconut Processing Technology"
(P r o je c t UF/RAS/76/049)
1. Technology sheet for s - COOKING OIL ( "KLENTIK OIL”) USING FRESH MATURE COCONUT - METHOD A (Traditional home industry)
2. Uaea of finished product : - Cooking oil is used by the rural population in coconut areas. Ejy-productss- The cake is rich is protein. It is mixed with sugar and eaten as sweet meat. The residue o f white meat i s used as chicken feed.
3. Country of origin INDONESIA.
4. Bquigaent
4.t Description of equipment
Kitchen knife for splitting nut and deshelling. Thick metal sheet witn serrations for grating. Pots, pans and stra in er. Traditional fireplace or Kerosene cooker (2 Units) • Funnel, deep spoons, empty b o ttle s fo r o i l .
4.2 Materials for construction : - Not Applicable.
4.3 Cost o f equipment : - About Rp 15,500 (US$ 25)
4.4 Capacity t - Nominal - say 100 coconuts giving about 15 litre of o il per working day f o r one fa m ily. 79
- 2 -
5® Procesa : - 5.1 Process flow diagram : -
^ ) mature coconut (husked)
splitting, removal of water and deahelling
coconut shell & coconut water (waste)
water, preferably warm
squeeze and strain
milk water
squeeze and strain 3 milk water
squeeze and s tra in
m ilk _ ^ residue a ft e r 3 ex p ellin g s heat boiling for (chicken feed) 2 hours
s tra in r t squeeze and strain
------y ------T Cooking o il Cake (e d ib le ) 8o
- 3 -
5«2 Description of process : -
The coconut is cracked using the kitchen knife and as the husked nut splits in two, the water runs out. The kernel is forced out of the shell. The white meat is then grated by moving the pieces against a serrated metal p la te by hand.
Water (p refe ra b ly warn) is added to the white meat and then squeezed by hand. The m ilk is strained using a kitchen strainer. The residue is similarly treated for two more expellings. The milk from all 3 expellings is collected together into a large pan and cooked (boiled) over the fire for two hours until all the water has escaped. The contents are strained to remove any residue which passed through the earlier strainers and the o il is collected. The brown coloured cake le ft in the strainer is squeezed by hand to ex tra ct more o i l .
The cake after expelling oil is rich in protein. It is eaten as sweet meat a fte r mixing with sugar. The residue is used as chicken feed.
5,3 Product flow diagram 5 -
White meat from it to 5 coconuts
Note: 5 coconuts o 1 kg copra. 650 ml cooking o il
6, Quality of finished product : -
Analysis of oil not available. However, this is one of the tr a d itio n a l methods fo r preparation o f cooking o i l and lias been consumed by rural population for generations. The oil is coloured light yellow. The characteristic odour and flavour is desired by the people,
7. Source of information : -
Observations during field visit to East Java,
T.K.G.R. 1979, 8l
Product code •: CCGN 15.07 i Teohnologh sheet no: 1 / 2 0
UNITED NATIONS INDUSTRIAL DEVSLOB'IfiftiT ORGANISATION
AND ASIAN & PACIFIC COCONUT CCMKUiilTY
" Consultancy Service on Coconut Processing Technology”
( P ro ject UF/RAS/78/049)
1. Technology sheet for l - COOKING OIL ("KLEUTIK OIL") USING FiiESH HATUKE COCONUT-METHOD & (S n a il Scale industry).
2. Uses of finished product : - The cooking oil is used by the. rural and urban population in coconut areas. The cake is used as (a ) cattle feed, (b) other animal feed after further processing or (c) exported for use as animal feed.
3® Country of origin * - INDONESIA
4» Equipment
4.1 Description of equipment : -
4.1.1 gutter : - Two units of locally manufacutured rotary knife cutters to reduce the kernel into small particles.
4.1.2 Cooking utensils : 6 Units cooking pans. 6 Half barrels with strainers. 2 Stirrers. 2 Pouring devices 2 Sieve strainers.
Uiese utensils are locally made. See page 2 for sketches and other details.
4.1.3 Fire alace i - 6 Unite for heating the 6 cooking pans.
4®1*4 Im pellers i - 4 units small expellers, Handar type. These are of Japanese design with capacity 120 kg/hr copra basis. 82
2.
Strain er
DQQ-J&r?)
Sieve Strainer 83
- 3 -
4.1.5 Oil Sump : - Oil collection tank of 3000 litre capacity which con hold about 2.5 Tonne o f o il»
4 .1 .6 O il Pump : - for pumping o il fraa the strap to the overhead tank»
4 » I .7 Overhead o i l tank s - This has a capacity o f 2«5 Tonne»
4.1.8 Other items such as weighing machines, piping etc.
4.2 Materials for construction : -
The building requirement is about 1000 square meter (About 10,000 square feet).
4.3 Cost o f Equipment and construction : -
Cost o f equipment Not available Cost of Installation Not available Cost of building (1000 m^) Not available
4.4 Capacity i - Capacity o f the plant for 8 hour working day is 25000 nut8 giving 3 Tonne cooking o il» 8*1
- 4 -
5. Process s -
5«1 Process flow diagram : - 5»2 Inscription of process i -
Fresh mature husked coconuts are purchased on a quantity basis regularly»
The nuts are cracked, dewatered and kernel removed from the s h e ll»
The kernels are manually elevated to a wooden loading platform above the two cutting machines and then fed into the machines a t a regu lar ra te . The coconut coming out o f the cu tter is similar to the manually grated coconut»
About 70 kg o f cut kernel is loaded in to each pan and heated fo r one hour u n til a l l the water has escaped. The f i r e is obtained from firewood lo g s . Sometimes th e . raw coconut sh ells are used for firing. In this case the fuel requirement just balances the shells separated. During the heating process the pans are stirred now and then. Vihat is le ft in the pan is coconut o il and brown coloured cake. Each half barrel with strainer is placed adjascent to one cooking pan with one outlet returning the o il into the pan. Using the sieve strainer the cake soaked with o il is loaded onto the strainer of the barrel. The soaked o il strains and collects in the barrel while the cake remains on the straiher» The cake is then removed fo r e x p e llin g using the screw type small expelíers. The o il (and some cake) in the barrel is returned to the pan and this straining procedure repeated two more times. The oil collected in the barrel after the 3 straining is discharged into the o il sump through a piping arrangement fcy gravity flow.
The o il coming out of the expeliera is also allowed to flow into the same o il sump by gravity through a piping arrangement. At the pipe outlet into the sump a sieve strainer is fixed to trap any cake in the o i l .
The o il is pumped into the overhead tank the following day. This allows any cake particles s till mixed with the oil in the sump to settle at the bottom. The cake le ft at the bottom of the o il sump is then collected for recycling in the expeliera» 86
- 6 -
5.3 Product flow diagram i -
1000 kg fresh kernel (2250 to 2500 nuts)
1 1
6® Quality of finished product l -
Analysis of o il not available. However, this is one of the tr a d itio n a l methods fo r preparation o f cooking o i l and has been cosuned by rural population for generations. The o il xs coloured light yellow. The characteristic odour and flavour is desired by the people,
?* Source of Information s -
Observations during field visits to West Suwtra and North Sinatra provinces of Indonesia.
T.X.Q.B 1979. Product sod® •’ ?5«07 i Technology shoot not 1 /21
UNITED NATIONS INDUSTRIAL DSVELOKffiKT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
"Consultancy Service on Coconut Processing Technology"
( P ro ject UF/RAS/73/049)
1 • Technology sheet fo r : - COOKING OIL ("BACING O IL") USING FRESH MATURE COCONUT - METHOD 0 (T ra d itio n a l home industry),»
2® Uses of finished product t - Cooking oil is used by the rural population in coconut areas as edible o il. Due to the dangers of the decaying action and ra n c id ity , th is method is being done away with. However, steaming the grated coconut is an interesting technique in promoting the release of o il from the white meat. % product - residue used as chicken feed.
3. Country of origin INDONESIA
4. Equipment
4*1 Description of equipment
Kitchen knife for cracking nut and deshelling Thick metal sheet'with serrations for grating Pots, pans, and strainer Steamer (kitchen type) Traditional fireplace or Kerosene cooker Funnel, deep spoons, and empty bottles for o il.
4*2 Materials for construction : - Not Applicable.
4»3 Cost of equipment ; » About Rp, 18,500/- (US $ 3 0 ).
4®4 Capacity s - Nominal - say 100 coconuts g iv in g about 15 litre of o il per working day fo r one fa m ily. 89
- 2 -
Process : ~ 5.1 Process flow diagram : -
mature coconut (husked)
splitting, removal of water and deshelling. Coconut s h e ll (domestic fuel) Coconut water White meat (w aste)
Grating
•t
Steam Steaming (| hour)
Cooling after spreading (15 minutes)
'f Stored in a tightly closed container such as a big biscuit tin after covering with banana leaves (2 days & 3 nights).
Dry (in the sun a fte r spreading ______fo r 6 hours) 'f
Cooling (in the shade)
Pressing by hand or wooden device and straining.
Cooking o il Residue used as chicken (••Basing o il") feed 89
- 3 -
5.2 Description of process s -
The coconut is cracked using the kitchen knife and as the husked nut s p lits in two, the water runs out, and the kernel forced out of the shell. The white meat is then grated by moving the pieces against a serrated metal plate by hand.
The steamer i s f i lle d with grated coconut and heated for half hour. Thereafter, the steamed coconut is allowed to cool fo r 15 minutes by spreading evenly on banana leaves. After cooling, the coconut is packed into a metal tin such as large biscuit tin, using banana leaves as a lining. The tin is closed firm ly and left for 3 nights and 2 days. During this period decaying takes place by bacterial action. Thereafter the contents are dried in the sun after spreading evenly for 6 hours on the 2*d 3 day. After drying, the material is cooled under the shade.
It is then pressed by hand or by the use o f a wooden device to expell the o i l. The residue is used as chicken feed.
5*3 Product flow diagram : -
White meat, from 4 to 5_ coconuts
Mote: - 5 coconuts ■ 680 ml cooking o i l 1 kg copra.
6. tttality of finished product: -
Analysis of o i l not available. However this is one of the traditional methods for preparation of cooking oil and has been consumed by rural population for generations. The oil is coloured light yellow. The characteristic odour and flavour of the oil is desired by the people»
Due to the bacterial action causing the decay o f the white meat, the product can cause stomach disorder. The high FFA content would also bring about similar adverse affects. This method therefore is 90
- 4 -
being done away with gradually. However, steaming the grated coconut is an interesting technique in promoting the release of the o il from the white meat.
7. Source of information * -
Investigations during fie ld v is it to East Java Province, This process is traditionally practiced in the Centra Java Province,
«
T.K.G.R. 1979. 91
Product code * COCH 15®0?i Technology abeet V / 22
UNITED NATIONS IND'JSmiAL DEV.SLOPMEMT ORGANISATION
AND ASIAN & PACIFIC COCONUT GOHITTrilTY
"Consultancy S ervice on Coconut Processing Technology*1
( P ro je c t UF/RAS/78/OU9)
1 • Technology sheet fo r : - COCONUT AQUEOUS PROCES JING - HAgemaier p ilo t plant of Philippines
2. Uses of finished product : - Beverage, baked products, meat extender
3. Country of origin s - PHILIPPINES
U« Equipment t «
Description of equipment :
Specifications for processing equipment are designed to produce sanitary protein end-product, with the versatility to pre pare the main product either as a spray-dried powder or as an intermediate moisture syrup.
The indication "stainless steel" means that the material of construction should be stainless for those parts of the equipment which come into contact with the product. Other alloys may be used where stainless steel is not suitable, but these other alloys should never be copper or brass, because of their propensity to catalyse degradation of the oil.
The designation "sanitary design" means the equipment should be polished and so designed as to minimize dead spaces, where the product can hang on and stagnate. The equipment sho aid be designed instead, sc that any new product entering' in to the machine w ill displace the aid product already inside.
Only one unit o f each item is required unless otherwise stated. Motor sizes are given in metric units, where 1 hp equals 0.75 kw. Please note that only important equipment are included in the l i s t 92 2.
Equipment for the receiving Section * »
Weighing scale Two units automatic weigh punch-out, drive fo r truck on type. About 15,000 Kgs. capacity.
Conveyor s Three units, approximate dimensions: l i f t U meters, width 30 cm, length 20 meters, speed 20 m/min, 1 kw. motor, about 25 tons/hr capacity.
Yard Vehicle 1 unit, three ton capacity, with fork lift .
Meat Preparation Equipment :
Maat Preparation * 1.5 meters wide, consisting of storage spaoe for 100 nuts, a shelling k paring bench and space fo r accumulation & nanual collection of shells. Stations are joined side-by-side to form two rows of 50 stations each.
Belt conveyor Through-put capacity about 6.5 tons/hr or 210 nuts/ system min. B elt speed about 30 meters/min, width 15 m, length 85 meter with negligible in clin e, motor 0.5 kw. This is used for carrying whole kernels away from paring benches to the cutter.
S h ellin g tools 300 pieces standard equipment
Paring tools 300 pieces standard equipment
Cutter t Sanitary design. Stainless steel with 1 kw motor to reduce kernels approximately in quarters.
Conveyor : 5 ton/hr. 'Jhrough-out capacity, 12 cm longest dimsnsion with semi-automatic weighing device, UO cm conveyor width, length 30 meters. Rise 6 meters, motor 0.5 Kw. Sanitary design.
Extraction Equipment :
Wadge-and-di®- Through-put capacity 5 tons/hrj 33 mm oil-plate p la te m ill holes. Cutter blade speed 2,900 rpm, motor U5 Kw. 2 Die-plate areas about U,000 cm . Stainless
S i so a ttritio n Throegk-put capacity 5 tons/hr. The grinding disc m ill should rotate about 1,800 rpm. Stainless steel. Sanitary design. 93 3.
Mixes* 1 i Continuous, cylin d rical mixer with v e rtic a l a x is . Seed material consists of 5 tons/hr. of comminuted meat and 3 tons/hr o f diluted milk mixing chamber 1.2 m inside diameter & stand k.l* m ta ll, 5 cubic meters capacity. Ribbon type agitator rotates at 15 rpm powered by 5 kw. rating. Stainless steel sanitary design.
Mixer 2 1 Cylindrical mixer similar in design to mixer 1 except that it should be smaller & be equipped with a horizontal screw-conveyor to extract the mixed m aterial from the bottom o f the mixing chamber. The mixing chamber l*as 0.8 meter inside diameter k stand h meters t a ll, 2.0 cubic meters capacity !< powered by 5 kw motor. Stainless s te e l. Sanitary design. Insulated to lim it temperature drop to 5°C.
High-pressure t u.1 MT/hr input capacity, compression ration of screw press about 12j 8 rpm screw speed & 10 kw motor, S tain less steel. Sanitary design.
Hammer-mill 2 1 ton/hr through-put capacity.
Equipment fo r Liquid Processing :
2 Vibrating screen t 1.3 m screen area, 150 mesh, 6 kw motor, Stainless steel. Sanitary design.
Holding tanks s 3 units, each equipped with a low-speed mixer, 0.5 kw motor.
Total capacity, 3,600 liters
Evaporator % Total evaporative capacity % 3*5 to U.O MT o f w ater per hour, U to 5 MT/hr rate of evaporation.
Spray dryer for % Product feed rate of 0.8 MT/hr of concentrated coconut dehtnddifler skim milk containing 55? moisture, air outlet 70°C. Stainless s te e l. Sanitary design, Spray dryer for t 130 kg/hr. feed rate. Production rate is 50 kg/hr. 70°C Cocota in outlet air temperature. Stainless steel, .Sanitary design. Au xiliary Equipment :
Elictrical generator: 600 Kw output capacity; diesel- powered w/ d iesel - fu el storage tank - 5 50,000 liters capacity.
Steam b o ile r • 1 Shell-fired. 5*000 kg/hr o f steam. 10 atmosphere operating pressure.
M r compresser: 10 cubic feet per mix ate of air, with a pressure o f 7 atmospheres. Water softener re s in type, through - put capacity of 1,000 liters/hr
Water-cooling tower s 85 metric tons/hr» throu^i-put capacity 50°c in le t temperature & 30°C cool water temperature.
U.2 H&terlals for construction %
Buildings P i*,000,000 US# 5U7,92i5.20 Materials for electrical installation 700,000 9&690.M Piping, values and f it t in g s 350,000 U7,9U5.20 Concrete substructures & foundations 50,000 6,8U9,31
Miscellaneous installation & construction materials 200,000 27,397.20
P 5,300,000 US# 711,U09.36
U.3 Cost o f Equipment ! : P 17,000,000 ÜSI 2,281,879.19
Please note that prices given are supplies prices as of April 1977. Currency exchange rate used was USfl.OO to P 7.U5* lull Capacity: 100T/day working at three shifts. 95 5. 5» Process
5.1 Process flow diagram:
Fresh, husked nuts
coconut sh ell
Hot W&tOT
Pasteurise for 1 hour a t 60 C oak®
I Osntrifuge 96
6.
unpareà neat 97 7.
5.2 Description of process;
Fresh dehusked mature coconuts are used as n w m a teria l. They are opened & the meat is removed» The coconuts water is discarded. The coconut shells are made into charcoal except for about 2Q% which used as b o ile r fu e l. Whole coconut meat may be used depending on the desired end product. I f the paring is removed, this meal i s d ried St expelled to get paring o il & paring meal.
Fresh meat, (pared or unpared) is milled to reduce particle s iz e , St extracted with water to separate the coconut milk from the residual solids. This procedure is repeated twice. The two materials resulting from the pressing operation are the liquid filtrate (coconut milk) and the solids (residue) the residue that comes from the press is dried in a rotary drier, pressed with an expeller to obtain expelled o il & residue presscake.
The coconut milk is filtered through a vibrating screen (12# mesh) to remove the last traces of residue. The pH of the filtered milk is raised from 6.3 to 7. The milk is pasteurized for one (1) hour at 6#°C, then centrifuged in a cream separator to obtain: (1) the lightest phase, usually called coconut cream which contains approximately 6$% of o il on a wet basisj (2) the aqueous phase, usually called coconut skim milk which is a solution of the soluble components o f the coconut, with some suspended p a r tic le s . With counter - current washing of the residue, the aqueous phase would contain approximately 9*5% solids as it comes from the separator; and a solid phase, consisting mostly of insoluble protein. Hie coconut cream is an o i l in water emulsion. Hie emulsion is d ilu ted with o il to reduce the moisture content, then heated to.agitated & centrifuged to recover its oil. This all is in turn extracted with water & dried to produce a high quality o il product called natural' o il.
The coconut skim milk St the insoluble solids are combined; their water is removed in two steps, namely, vacuum evaporation St spray » during to obtain a high-proteia product. The spray-dried prod oat is called cocopro 1 or cooopro 3 depending on whether the 98 8.
Meat was pared or not before the coconut milk wag extracted.
In an altern ate method o f processing, the coconut skim milk & insoluble solids are not mixed, instead they are processed separately. The coconut skim milk is concentrated by vacuum evaporation to produce cocopro syrup and the insoluble solids are spray-driad to obtain cocotein.
5.3 YIELD From 1000 kg. of husked coconuts (wet weight basis)
Mass o f ]Protein in O il in Product product product product
Residue U3.0 k g» 1.5 kg 10.0 kg Insoluble protein 5.7 3.6 0.7 Skim Milk hU.O 11.8 0.6 O i l 1U2.0 0.0 1U2.0
Totals 23U.O 16.9 153.0
All results are on a dry weight basis
Quality of finished product Composition of Oil Products
Free Fatty Acids Color Value {% calculated Iodine Value ------as Laurie) Red Yellow Natural Oil 0.05 6.U 0.2 0.9 Expelled Oil 0.05 - 1.6 1.6
Composition o f Cocopro Syrup
Syrup 1 Syrup 3
Crude Protein 2? (N itrogen content ij.6.25) Ash 8.2 O il 7. Crude Fiber 0.0 Carbohydrate by difference 58
a ) Because o f i t s high and variab le m oi3tirs content, the composition of the syrup is shown on a dry basis, whereas other product com positions are reported on a wet basis, or !,as is”. The moisture content of the syrups averaged about 28% (wet basis),' with a standard deviation of about 5 units. 99
9®
b) Calculated here and elsewhere as 100 - (protein + ash + o il + moisture). Naturally, the moisture content is zero here, since the results in this particular table are on a dry weight basis®
Composition of Cocotein
Cocotein W. Cocotein D.
Moiâture 6 6 Crude P rotein 58 h£> Ash 9 8.9 O il 2.U 9 Crude Fiber 0.3 2.8
Carbohydrate by Difference 25 30
Composition o f Spray - Dried Cocopro
Cocopro 1 Cocopro 3
Moisture U.3 U.o Crude P ro tein 32 32 Ash 9.3 h O il 8 1 Crude fib e r 0.2 2 Carbohydrate by difference U6 hS
Packaging Materials
The following packaging materials have been found acceptable :
Spray-dried cocopro - Laminated fo il, metal or glass Polyethylene Cocotein bags, laminated fo il h glass or metal Coconut Residue or - Fiber sacks (lines with polyethylene bags, Residue Presscake food grade) Natural Oil » Glass or metal
7® Source of Information
Hagenmaier, R. 1977. Coconut Aqueous Processing® San Carlos Publications, Cebu City, Philippines.
P.M.A. 1979 100
Product OGGI 15.0? i foolmology m s ? / 2 3
qfigBD MTidis awsm i&L BgmopMBiT Q8MM.rn.nm
MD A3XMI & PACIFIC GC-CPHUT CWOTITT
wQoa®ultanoy Sand to on Oooonut Processing tfeehnology”
(Pro.leot UF/B13/?8/0li9 )
1* Iteehnology sheet for I*» WET PROCESS BT SB àim ® MAPFBI / C«F»T«E>1 9 (pilot plant)
2* lQfaas o f finished products *«■
The uses on an oaqperinentiil basi® ara s®
t«1 Glean coconut o il « aditalo us® 2«2 Residual o il - «rada o i l 2®3 P ro te in coagulato « edible purposes foil Coconut honey « food preparations
3® Counter of o rig in s « INDIA
Original process by Krauss - H affei, who gifted a plant to India» the plant was installed at th® Central Food l&chnological R®s®arbh Institute at Mysore* Th® original process was nodifiad by CFTRI to MadLnis® the o i l y ie ld .
U. gqaipasnt
0» tolls of «quipnent etc not oraUablo Process; - 5.1 Process flo w diagram; -
coconut honey 102
3
5*2 Description of proeess t-
Modlfioetlocs vmm introduced by C1TRI in order to recover the maxima quantity o f o i l from the kernel.
Scoop oat neat without subjecting the nuts to heat treatment. M ill. Squeese Billed meat in a dewaterer under a reduced pressure (2:1) & then feed into the K.M. press (12:1). With this two stage extraction methods roughly 93 per cent o f t he o i l i s extracted & the final protein recovery is l$%, Dry residue after milk extraction k feed into sa expeller to extract the residual o il.
5*3 Product flow diagrm t-
Results of a trial™
220 kg wet meat 103
k
6« Quality of finished produots
The coconut o il is of high quality edible oil®
The Consumption o f other Products,percent * «
Product Moisture P rotein Pat M inerals Carbohydrates (Nx6.2£)
Coconut Uo.o 15.6 2.0 6.8 35.6 honey (6Cr B riy
A d d ooa- 6.0 71*. 3 3.1 6.1 10.5 guL&ted p rotein s
Residual 8.1* 66.1 3.U 8.2 13.9 B S il
7® Source of information;
The coconut palm and i t s products by PK Thaapan, In dia 1975»
P.MJU - % m 10U
Product code CGGM 15.07 i Technology riieet nos T / 2 k
IWITED HATEOHa INDUSTRIAL DEVEhQPMMT ORGANISATICM
AMD ASI&H & PACIFIC COCCWOT COMMUNITY
" Consultancy Service on Oooaaut Processing Technology"
(Project UF/H4S/78/0U9)
1. Technology aheet f o r e WET PROCESS BT MODIFIED SCLftiL METHOD ( p i l o t p la n t)
2. Osss o f fin is h e d prodnatas-
A ll the products «re edible
2.1 dean oil
2.2 Protein sugar ¡algors »
2.3 Cooonnt H o u r
3® Qoffittrr o f origlffi i«
HIDIAs In the early 1570 s, tie Chemical Construction Ckaapany Prim t© Ltd., developed this process and Installed a p la n t a t Faridabad, near Hew Delhi.
ii. Eoiaioaant s«
Details of equipment etc are not available Ю5
5> « P; осeзз : - >rl Procesa flow diagram: - 106 3
5*2 Description o f process j-
Cut husked nuts in to halves. Collect water in a filte r for use in subsequent operations. Sooop out neat. Remove testa. Keep testa in a separate container for separate oil extraction.
Slice pared neat & shred into a pulpy nass. Centrifuge to separate ooconut adlk from the meal. Add coconut water to the meal & press in a continuous screw to recover more milk. Repeat this procedure twice. F ilter the milk & vacuum dry at low temperature to remove moisture. Centrifuge the resulting o il - protein - sugar mixture to separate the o il from the protein St sugar. Solvent e x tra c t p rotein sugar mixture to remove the o il adhering to the mixture.
In the same manner» solven t e x tra c t the meal & the parings after drying to remove & recover a l l the oil present. Desolvent!ze thoroughly oil extracted tram the meal St parings. Add to the oil recovered directly from the milk.
Pack resulting products - coconut o i l , ooconut protein sugar mixture & coconut flour for marketing.
5.3 Product flow diagram
Yields from the pilot plant are as follows
100 kg wet kernel
t 1 5.81 kf coconut flour
6® Quality of finished products
All products of edible quality.
P.MJU - 1979 107
Product cod» CGCN 15*07 i Technology sheet not T / 25
TOTED NATIOMS INDUSTRIAL DEVELOPMENT CBGANISATIQf?
AMD ASIAN & PACIFIC COCONUT COMMONUT
"Consultancy Services on Coconut Processing Technology”
fProject TIF/RAS/78/0U9)
1. Technology sheet fo r WET PROCESS B I TROPICAL PRODUCTS HSTITUTR (pilot plant)
2* Uses of finished products i-
2.1 Coconut o i l - e d ib i» purposes
2.2 Protein isolate - has teen successfully used fo r fortifying composite wheat Hour breads.
2.3 Residue
3* Country of o r ig in I -
UGLAND
Uo Rquitsaent %-
Details of equipment etc not available 1)8 ~ 2 ~ 5. Process: - 5.1 Process flo w diagram:
husked coconuts
split in two, dewater, scoop out kern el, remove te s ta and wash
white meat
e lìc e r
mince In wedgemill (5 «m)
Add half it's weight of water and mix in the slurry vessel
mince in second wedgemill (1 am)
vibrating sieve
milk
residue 3 09 - 3 -
o il 110 k
5® 2 Description of process s«
Slice fresh kernel & adnee in a 5 mm wedgemill d ie p iste. Mix the misused mass w ith h a lf Its weight o f water & pass through a im Jal&te assembly on a second wedgemill. Pass resulting slurry through the plate assembly o f the second wedgeraUl. Ihe resulting emulsion i s passed through a v ib ra tin g sieve to remove the coconut residue under a higi velocity overhead water spray. This facilitates the washing of the traces of o il & protein contained on the surface into the main emulsion. Press the residue again & add extracted milk to the main emulsion. Dry & hag the final residue to be used as raainant feed or in an expeller m ill to extract the residual oil.
Adjust emulsion pH o f 3.5 to U.O & allow to stand for six hours. Remove lower water phase by gravity flow o r by siphoning. Centrifuge cream phase a t a temperature o f 35°C to separate the o il & protein. Vacuum dry protein component a t 55°G to 80°C. Extract residual o il with iso- prapanol. Desolventise defatted protein by vacuim drying for one hour at 60°C. H ill protein isolate to a powder. The o i l yield is SO to %$% and powder contains 80£ protein.
6. Quality of the finished product
Main product - edible o il with CXI to 0.2 FK&. Other products - composition by percent s-
Crude Crude Carbo Product Fat Moisture Ash P ro te in Fiber hydrate
P rotein is o la te 7.2 82.0 U.9 0.6 lw95 0.35
Besidm or Meal 36.U U.8 5.0 U3.6 o.t* 9.8
PJU . - 1979 I l l
Product code ССШ, 1 ¡?®0? i Technology sheet noi ? /26
UNITED NATI OHS INDUSTRIAL DEVELOPMENT ORGANISATION
AMD ASIAN & PACIFIC COCONUT COMM WITT
"Consultancy Service on Coconut Processing Technology88
( P ro je c t UF/RAS/78/0U9)
1« Technology aheet for MET PROCESS B I CHAIM OR t IMPULSE RENDERING 1 Ш Ш ( p i l o t p lan t)
2* Uses of finished products»-
2.1 Coconut o i l - e d ib le uses
2.2 Oil / protein complex.
3* Gomitar of origin »-
ENGLAND. The process was originally developed by British Glues and Chemicals Company L td . (now Groda In tern a tion a l L td .)
Ц. Equipment *-
Details of equipment » not available 2
5* Proce 33 :
5.1 Procese flow diagram*
Whole nuts I / Y Dashell S h e ll . ( f u e l K . •T : c „ : Comminute 0.1 sodium hydroxide _ 1 _ Comminuted coconut
Vibrating screen
______!______” ¡ Residue
Press
+ Meal Skim
Precipitation tank
Centrifuga
O il
Oil/protein emulsion
D rier
Oil.protein compisse 113
3
S»f Description of process *-
Impulse rendering is described as "a mechanical rupture of the membramoss o f the fat containing cells by a series of high-speed inpulses transmitted through the meditBB of a liquid, whereby the fat in the cells in liberat ed and is removed by the liquid in violent movement® - ( Cttayen and Ashworth 1953)
The fresh coconut kerm is axe fed into a hasmsar m ill with ten tines their weight o f 0,15 percent soditra hydroxide solution» The fibre fraction is then removed on a vibrating screen, and to© emulsion which passes through the screen is centrifuged to separate the free o il from the l i p id - p rotein oomplex#
Typical re c o veries are 60$ o f o i l and 70$ o f p rotein »
6» Q u ality of finished products?-
toe main product o i l i s hig$i q u a lity ed ib le grade, toe other products have the following composition on percent basis s-
Carbohy B iologi Net Diges Produst O il Protein Ash drates cal prptein t i b i l i Falus u t ili t y zation
Oil/proteim 3$ 6 0 2»5 2.5 60 50 75 complex
Meal 20 1.5 75 3.3 -
- • llU
Product coda s COCN 15-07 i Technology ehoet no- V / 2 ?
UMITED KATIOKS INDUSTRIAL DEVELOPMENT ORGANISATION
AMD ASSAM & PACIFIC COCOHUT COHMUNITE
BConsultancy Service on Coconut Processing Technology"
( P ro je c t Of/MS/78/Qb9)
1- Technology aheet fo r t - WET PROCESS BI hH-T-EP
(patented process) 1
2- Osee of finished product * -
This patented process i s reported to produce i
2.1 Coconut o il fo r edible purposes
2.2 Coconut flour for edible purposes
3- Country of o r ig in i -
UMITED STATES OF AMERICA t - D.S. Patent 2583 022 (1952)
PHIUPPISES t - Phil. Patent 186 (195U)
U- Bqujpaenfe i -
Details of equipment etc not known, m ч
115
ï>. Process 5 И Process flow diagram
O il 116
3.
5*2 Description of process t -
Mature, dehusked nuts are placed in a cooker to fa c ilita te removal of the kernel from the shell. Slice the kernel & vacuum, dry* at 60°C & extract the o il using a conventional expeller. The cake i s ground to produce coconut flo u r. The oil is allowed to settle in a settlin g tank, filte re d & deodourised. The processing time i s about three hours. 4 5.3 Product flew diagram i -
Details of yields are not available* However high yields of protein flour are reported.
6. Quality of finished products s -
The coconut o il is of high quality edible grade.
The composition o f the coconut flo u r by percent s -
O il content 12.2 Protein 18.2 Moisture 6.2 H Crude fib re 20.0 Ash U.9 Carbohydrates 20.1*
P.M.A 1QVO 117
Prodact cods CCGN 15®0? 1 Technology sheet no. V /28
MIXED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITT
* Consultancy S ervice on Coconut Processing Technology*
(Project UF/RAS/76M9)
1. Technology sheet fo r *- 30Mi PATENTED MET PROCESSES
2, Uses o f fin ish ed products i -
2.1 Coconut o i l f o r ed ib le purposes
2.2 Protein for edible purposes
fixe advantages of the net processes art «-
(a) By-passing copra stage and thus avoid da terioration and losses
(b) Avoids solvent extraction process.
Ba® disadvantages are s-
( i ) Uses h i# i le v e l technology (ii) Oil recovery not as high as through copra process despite losses in the latter, (iii) The protein product though edible grade has not yet found steady outlets for marketing, (iv ) Ike process^have yst to demonstrate economic v i a b i l i t y .
3e Country of origin i-
See Description of process.
Us Equipment s« D e ta ils n ot known. 2
$• Propesa s-
5*1 Propesa flow diagram f o r the gem r e i set process
Cooonat o il CoQonub p ro tein 3 119
5*2 Description of the prooess
5,2.1 Iraaag - Maffol process (Fat no, 1.031.912 - 1958).
Steam hashed note in an autoclave a t a pressure 2 Of 3 kg/cn for 10 minutes* Open the nut, scoop out meat» pass thru a cutter* Comminute further by passing through a roller m ill. Screw press to extract the milk* Centrifuge to separate the o il phase from the water phase. Heat o il phase to ?2°C, & filter to get good quality oil* Heat water phase to 9S°G in a flow heater to coagulate the protein which is separated by centrifugation. Dry. Con centrate le ft - over whey under vacuum to a syrupy product called eoconut honey* Coconut residue is dried in a drier & powdered to get edible quality coconut meal*
5*2*2 Boblsdana - Lusurlaza (Phil. Pat. 1 19k8)
Grind fresh coconut meat & press to get solid residue & emulsion. Subject emulsion to controlled enzymatic action» freeze & thaw to separate the o il by centrifugation* Heat the water phase to get protein concentrate (6o£ protein)* The residual meal is suitable for direct human conscaption*
5*2.3 Qcnzaga process (Phil* Pat 3 - IASI
Grate coconut meat* Press. Put the coconut milk in a settling tank. Isolate protein by heat coagulation (100°C)*
5*2Ji Mokno process (Phil. Pat. 7.67li - 1960)?
Three fractions are obtained by centrifuging the eoaninuted meat namely coconut o il, protein rich solids and skim m ilk.
5*21 process iBri. Pat 505.211 ^ J J 2.101*371-1937).
Extract o il from freshly grated coconut meat by water extraction & subsequent separation of o il from the protein* The by-products are the press cake with 8% protein, dried protein concentrate containing 75% protein in fa irly pure state & m aqueous sugar « mineral sciatic®*
p*m.a. - 121
Product cod-?: GCCN 15.07 1 Technology sheet no: V / 2d
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
" Consultancy S ervice on Coconut Processing Technology”
( P roject UF/RAS/78/049)
1. Technology sheet for : - DRY PROCESS £7 XENKO (patented process)
2. Uses of finished product : -
2.1 Coconut o i l fo r e d ib le purposes
2.2 Coconut flo u r f o r ed ib le purposes as p rotein
3. P^Qt|x.Qf..grifiin; -
PHILIPPINES
Phil pat 187 (1954).
4. Equipment: -
Details of equipment etc not known 123 - 2 -
5* Procesa t
5.1 Procesa flow diagram
Coconut o i l Coco flo u r 1 22
» 3 -
5.2 Description of process: -
S p lit open dehusked coconut. Scoop out meat. CoRsninute & heat in a chamber at 80 to 100°C u n til the moisture content of the meat is reduced to 4 - 8^. Press. Grind the cake into coconut flour. Filter o il for further processing.
5.3 Product flow diagram: ~
Details of yields not available.
6. Quality of finished products
Coconut o i l - high q u a lity ed ib le grade
Coconut flour - edible grade protein content
P.M.A. 1979 123
Product cod® CCCN 15.07 i Technology sheet no.! 7 / 3 0
H IT S ) NATICKS INDUSTRIAL DEVELOPMENT ORGANISATION
AMD ASIAN k PACIFIC COCONUT COHMUNITI
"Oansultanoy Service on Coconut Frees a slag Technology*
( P ro je c t qF/BA3/?8/08t9)
1. Technology sheet fo r I - INTEGRATED DRT PROCESS BT VaX.S.T. (Philippines Patent)
2. (Face of flnidied products *-
2.1 Coconut o i l •» e d ib le uses
2«2 Coconut flo u r - ed ib le uses as p rotein
2*3 Coconut c o ir fib r e
2eU Coconut s h e ll charcoal
3. Coratry of origin i-
PHXUPP1NB3 - National Institute of Science and Technology
S M I patent 208*1 •
U. laaiinwnt *®
See figure See section 5.2 « description of process and equipment. 12h
Patented July 22, 196$ Patent Wo. 0M-3Wi JESUS QÜ2MHN ALCANTARA ET AL FLUIDIZED BED DRIER FOR COCONUT PRODUCTS AND THE LIKE
1 a b e t Filled June 26, 1961*
Figure 1
JESUS G. ALCANTARA PLARJDEL H. RECATO TEODORO T. GARCIA Co-Makers
Byi FELIPE LL. 3ANTILLAN Patent Engineer Agent 125
3 .
£• Process :
5T.1 Process flow diagram
Oehusked matured coconut
S p lit open
«aioli
Charcoal Grind in a Coco c o ir colloid mill
Dry in fluidized bed dryer
E xpelí
i O il
Equipment
U.1 Equipment for drying 1 2 6 u. £u>2 Description o f process and equlpamt
The fluidized Bed Dryer is specially adapted for drying comminuted coconut meat and similar fin ely ground material with high moisture contents
Generally described, the dryer* aa shown in Pig. 1, is made of stainless steel plate formed into an upright cylindrical chamber (1) having a perforated bottom plate (5), an inlet for the material to be dried with screw feeder (11), an inlet for hot air (U ), an outlet for the discharge air and dried fine material (15)» an outlet for the coarse dry material with screw type conveyor (16) and (17), and a rotating scraper rake (6) on the top face of the perforated p la te . The conical bottom (2) has a glass window (3) and duct extension underneath (U) for the entrance of hot air admitted at controlled volume* pressure and temperature, and blown through a heat exchanger by an electric centrifugal blower.
The perforated bottom plate is made of stainless steel plate of sufficient thickness and fits snugly right where the bottom edge of the upright cylindrical drying chamber meets the top edge of the conical bottom. It is being continuously surface-scraped by the rotating scraper rake which is driven by an electric motor (9) through the vertical shaft (7) and worm gear assembly.
The drying operation of this fluidized-bed type dryer is simply described as follows: The finely ground wet material is fed from the hopper (10) and is conveyed into the drying chamber by the rotating screw feeder (11) which is driven by an electric motor (12).
It is discharge at the open end of the screw feeder (13) located at the center end of the screw feeder (13) it is spread over the spikes (6) of the rotating rake. The hot air current coming from the perforated steel, plate causes the fine material to be p a rtly suspended and a t the same time heat exchange between the ma terial and hot air takes place. The water content of the material is evaporated and carried by the hot air current and out to the exhaust air duck. 127 s .
-When the m aterial lo s e s enough water i t becomes lig h t e r than when originally introduced. The dry fine granulated particles are carried by the hot air through a collecting cyclone, where the air is separated from the dried fine material. This is finally collected into plastic bags and scaled for the market. The moisture content of the product varies from 1-3§$ - the range acceptable to the market.
In the process of drying, the coarse particles are not carried by the outgoing air. These are discharged at the side of the drying chamber by the screw conveyor (17) and collected and bagged as another grad® of the final product. I f the moisture content is higher than 3 - 3% the material is passed through the secondary fluidized dryer for further drying until the desired moisture content is obtained.
The spikes of the rotating rake serve to break up any lump pieces of wet material. They also stir and agitate the material in the drying chamber. The qu an tity o f d ried fin e m a teria l, ca rried by •toe hot air and collected by the cyclone collector, and the amount of coarse material discharged at the side are continuously replaced by wet material through t hm screw feeder so that there is a constant predetermined quantity of materials in the drying chamber. There is no accumulation of material inside the chamber. The operation is continuous. *
M A *090 1 2 8
Product cod® s GCGN 22,07 Technology stoat nos V / 31
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
HConaultancy Service an Coconut Processing Technology*8
( P ro te c t UF/RAS/78/Q49)
TAPPING COCONUT SAP (LOCALLY CALLED TUBA)* (Cottage Industry), 4 2, Uses of finished product Sweet_S5B$ “ Before fermentation i t is used as a beverage. This is also called tuba.
Fermented sap After natural fermentation and addition o f Ceriops tanbark for colouring an alcoholic beverage called Tuba is obtained. When natural fermentation is allowed to take place for 5 days (without adding Ceriqps tanbark), it is distilled and the distillate i s known as Lsmbanog 4 (also called Arrack, Uraca) which is used as a strong alcoholic drink.
3. Cçuntrx ?f, orlfdfl PHILIPPINES
4® jouiraient i -
4 «f Description of equipment: -
The fo llo w in g simple equipment is used for the tapping process: - - 2
Hardwood m allet
Bamboo receptacle
Bamboo vessel for tanbark fFTil !i
i t I« l i I I? I i
Collection bamboo Bamboo brush
A ll dimensions in mm
EUUIPMBNT FOR TAPPING COCONUT SAP 130
- 3 -
Sharp k n ife ( * Sanggot•) Hardwood mallet for tapping Bamboo receptacle ( 'Sahod') Small bamboo vessel for carrying ground tanbark for tuba Collection bamboo ( ‘Kawit’ ) with a wooden hook for the shoulder.
Bamboo brush ( fPitlagonge) 5 ga llon (27 l i t r e ) t in can or p la s tic Jerxy container Fomentation vessels for Tuba,
4*2 Materials for construction: - Not applicable
4*3 Cost of equipment : -
Sharp k n ife 5 gallon can Fomentation vessel Other items at no cost
Total estimated cost 9 200 (US$ 30/«)
4,4 Capac ity / Y ie ld : - The average d a ily y ie ld o f sap per palm ranges from 360 to 1030 ml with an overall average of 650 ml. Thus the average per palm per year on the basis of 12 months continuous tapping w i l l be 237 l i t r e s . Each spadix produces sap only fo r about two months.
I t must be noted that the y ie ld o f sap has a considerable variation from spadix to spadix, palm to palm, day to day and season to season. Further, a greater flow of sap occurs during the night than during the day. The yield also varies on the variety of the palm, its age as well as the duration for which the palm has been continuously tapped.
The capacity of a tapper per 6 hour working day is 30 to 40 palms when gathering tuba. When gathering sap fo r making Lambanog, the capacity is 100 trees per working day. 131 - 4 - 5* Process; - 5»1 Process flow diagram: -
selected coconut tree
Fully fermented sap for distillation into lambanog 5*2 Description of process: -
The ta ll variety of coconut generally starts to bear fru it upon reaching 8 to 10 years and keeps bearing up to 60 years or more. Coconut trees which bear very well and are not too young or old are selected for tapping.
The tuba gatherer cuts V shaped notches onto the coconut trunk to serve as steps in climbing to the crown. The notches are large enough to accomodate a toe-hold. One side of the notch is parallel to the ground. At the crown, the dried leaves, weakly attached senile leaves, the stipules or "guinit" and the aborted spadices are removed.
The xoan gathering sap fo r making Lamb&nog does not climb each tree but moves from tree to tree by the use of bamboo poles connecting the palms. Two mature poles are securely tied to two adjascent palms ju st below the crown a t a le v e l that a man can stand conveniently when tapping and collecting sap. One pole serves a® the foot bridge and the other as a hand ra il. The palms are spanned by p oles. The man climbs up the lea d palm, walks across the bamboo bridges to the other palms and comes down the la s t palm.
A fu lly mature spadix w ill soon have its spathe burst open and when 'tapped' produces a reduced yield of sap» A spadix younger than this is selected for tapping and is indicated by a swelling at the base of the spadix due to the development of the female flowers. The spadix ceases to elongate shortly before the spathe splits open. This usually occurs from 75 to 90 days after the first appearance of its tip. The total length of the spadix i s 700 to 900 mm. When suitable for tapping, the spadix w ill be about 600 mm lon g. A palm produces about 10 spadices per year. The msaber o f spadices on any one tr e e a t any tim e w i l l be 2 o r 3. 133
- 6 -
The selected unopened spadix i s wrapped w ith abaca string or rattan strip along its length to prevent it splitting open. The spadix is gen tly tapped using a hardwood m allet so as to carefully bruise and rupture the tender tissues of the floral branch. The spadix is gradually bent downward without breaking the stem. The tip is tied down with abaca string to a nearby petiole (leaf branch). This bending procedure is repeated daily for one to two weeks until the spadix droops. When the bending down is more than h a lf done the t ip is cut open with a sharp knife ( 'Sanggot*). Three days later, the sap flows out. The daily slicing of the tip of the spadix allows the sap to flow continuously and the drooping position prevents the sap from entering the inflorescence and enables a bamboo receptacle (*Sahod') to collect the sap. The slicing is done once in the morning and once in the evening. The finer the slice, the longer is the life of the spadix. The bamboo receptacle is Kept in position by fastening it to the spadix through two small holes at the top rim of the bamboo receptacle with the use of abaca string. The mouth of the bamboo receptabie is covered with a piece of fibrous network of light brown stipules locally called ’guinit’ . This keeps out rain water, insects, mice and lizards.
A tuba gatherer handles 30 to 40 palms d a ily . The palms are climbed twice a day to tap and slice the spadices, each palm taking about 5 minutes. For a morning tuba collection, the Ceriops tanbark is added in the afternoon and for an afternoon collection, i t is added the follow in g morning. The ground tanbark ( •tungog') is carried up the palm in a bamboo about 120 mm diameter and 150 nm length. It is tied round the waist of the climber like a canteen. A pinch of tanbark which iMparts an astringent taste to tbe sap is dropped into the bamboo receptacle for the purpose of colouring the tuba red. During collection, the tuba is transferred to the collection bamboo called •Kawit1. With the wooden crook near the neck of the collection bamboo, it is hung on the back of the climber while moving up and down the palms. After transferring the tuba, the sediment in the receptacle is removed using a bamboo brush locally called 'pitlagong', while on top of the palm. The sediment adhering to th is brush in turn is removed by beating it on the petiole. The collected tuba is filtered through a sieve of stipules or abaca fiber into a 5 gallon tin can or a plastic jerry container. The tuba is then reac^r for transportation to the market.
A man gathering sap fo r making Lambanog tends to 100 palms a day. The lead palm is climbed in 10 seconds. During collection, the receptacle is untied, contents stirred with a bamboo stick and the sap poured into the collection bamboo * Kavdt'. It takes about 9 fu ll receptacles to fill up a collection bamboo. A 5 g a llo n t in can in to which the sap in the c o lle c tio n bamboo is transferred is pulled up by means of a rope. It takes 1 to 2 minutes to complete collection from one palm. The movement from one palm t o another takes 1$ seconds. The spadices are s lic e d morning and afternoon. The sap fo r making Lambanog is brought to the distillery. 135
- 8 -
5*3 Product How diagrams ~
One avernffw t a l l nalm
650 h»1 sweat aao per day
650 ml sweet sap A pinch 1 o f tanoark T 650 ml tuba
650 ml sweet gap
650 ml Fermented sap Bay yeast fo r lambanog 136
- 9
6. of .finished product! -
6.1 Sweet sap : » This is sweet, oyster white and transluseent. Highly susceptible to fermentation due to inositol content which is an essential growth factor for certain yeastss - Sugar content - 12 to 18# Cg/lOO ml) as Sucrose Specific gravity - 1.07 value - 6,2 to 7.2 with 6.7 average. A c id ity less than 0.1* (g/100 ml) as Acetic
6.2 Tuba i - This is red in colour due to the effect of the ceriops tanbark addedi - Sugar content 0.3* (g/100 ml) Specific gravity 1.01 A cid ity 0.5* (g/100 ml) as Acetic Alcohol 5* (g/100 ml)
6.3 Fomented sap s - This is oyster white in colour and less transluseent than sweet sap: - Sugar content 0.3* (g/100 ml) Specific gravity 1.01 A c id ity 0.5* (g/100 ml) as A cetic Alcohol 7.5* (g/100 ml)
7. Source of Information : -
University of the Philippines Los Banos, Central Experimental, S tation , No. 76 - 149. Los Baños, Laguna Philippines.
T.K.G.R 1979. 137
Product code • CCCIi 22*07 Technology sheet no* V /32
UNITED NATIONS INDUSTRIAL USViaLOa^ENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
MConsultancy Service on Coconut Processing Technology**
( P ro ject UF/RAS/78/049)
1. Technology sheet fo r : - TAPPING COCONUT SAP (TODDY) - (Cottage In d u stry).
2« Uses o f fin ish ed product : - Sweet toddy? -
Sweet toddy (before fermentation) Is used as a beverage, or used for processing into syrup (Treacle) and sugar (J a ggery).
Fermented toddy (Palm wine)
After natural fermentation it is U3ed as an alcoholic drink. The sediment when separated iron the liquid is raw yeast and this is occassionally used for baking traditional rice flour preparations. The fermented toddy is distilled to manufacture Arrack which is a strong alcoholic drink. The fermented toddy can also be fu rth er fermented into Vinegar,
3. Country of origin : - SHI LANKA,
Very similar techniques are engaged in INDIA, MALAYSIA and THAILAND fo r tapping sap.
4« Equipment : - 4*1 Description of equipment : - Details of the following Implements are given in page 2® 138
TAPPING XMPUMMTS
1. Tapping Knife 2. Box (Hanna. P e ttiy a ) 3. Earthenware Pot (Unglazed) 4» Wooden M allet 5. Cleaning Knife.
See Section 4.t 139
- 3 -
4*1*1 Tapping knife which is a broad blade razor.
4*1*2 Light weight box (locally called "Manna pettiya") for carrying the implements. This is tied round the waist
4*1*3 Earthenware pot (unglazed) with capacity ^ to ^ gallon (2 to 3 litre).
4*1.4 Hardwood mallet with a smooth egg shaped head and a tapered handle. The hardwood commonly used is tamarind.
4.1.3 Cleaning knife with a curved blade.
4*2 Materials for construction - Not applicable.
4*3 Cost o f equipment : -
The cost of the equipment is estimated at Rs 100/» (o r US$ 6.50 1 US$ - Rs 15.50.
4*4 Capacity/yield : -
The average yield per palm per day with 8 months tapping per year can be taken as 2 b o ttle s (1500 ml)* Thus the average per palm per year (on the basis of 8 months tapping per y ea r) w i l l be 81 gallon or 370 litre. The average daily yield for typica x puraila F hybrid palm based on 12 tre e s over a one year period was found to be 3 bottles or 2250 ml per day (Ceylon Coconut Quarterly 1975 Vol XXVI Nos 1/2). The y ie ld o f toddy depends upon the s k ill o f the tapper. It must be further noted that the yield of sap has considerable variation from spadix to spadix, palm to palm, day to day and season to season. Further, a greater flow of sap occurs during the night than during the day. The yield also varies on the variety of the palm, its age, as well as the duration for which the palm has been continuously tapped.
The capacity of a tapper is 25 to 30 palms per working day when he has to climb the trees Individually. In tapping groves however, where the palms are coupled with aerial ropeways, a man can manage 75 t o 90 palms in a day, provided that he has an assistant on the ground to bulk the toddy that is collected and
low ered down by ropes* 5. Process ï -
5*1 Process flow diagram
Selected coconut tree »
Preparation of palm
Preparation and tapping o f spadix (unopened flo w e r) daily tapping
Collection of sap and tapping spadix
Coconut sap
Distillation for Further fermentation saking arrack into vinegar ll»l
» 5 -
5.2 Description of process ; -
5*2.1 Meaning o f tapping : -
The tem "tapping" itself collectively denotes a rtificia l extraction and the various processes of stimulating the d iffe r e n t types o f toddy y ie ld in g palms to exude ju ice (sap) from a selected part. Toddy is an exudate of plant sap, but in the different palm types employed for tapping, it is not necessarily drawn from the same region or portion of the palm.
5.2.2 The spadix
In the coconut palm, i t has been found that the tender spadix (floral branch or inflorescence) at a particular stage of development is best suited for tapping purposes. The spathe is the bract enveloping the spadix. In general, at any one time, if an average healthy coconut palm is stripped in to i t s components, i t should be possible to is o la te about 44 developmental stages of the floral branch. These would range from the rudimentary in itials to the cluster of r.' oe drupes as harvested. The figure in page 6 illustrates that the development stage 27 indicated with *T' is the most suitable stage for tapping. The location of the spadix and it's details are also given in this page.
The spadix that i3 ready for tapping generally averages about 2.5 feet (760 mm) in length and about 3 to 5 inches (75 to 125 mm) diameter in the region of maximum girth.
5.2.3 Selection of palm
The selection of the palm for tapping is more a matter o f in s tin c t than communicable knowledge. The fo llo w in g characters however may serve as a guide in the pre-deteraination o f su itable palms : - Ib 2
- 6 -
THE STAGE »T» AT WHICH THE DEVELOPING SPADIX IS SUITED FOE TAPPING
LOCUICH AMD DETAILS OF SPADIX
See Section 5.2.2 l h 3
- 7 -
( i ) Palms with long inter-nodea ( i i ) Palms bearing the f u l l compliment o f drupe developmental stages (usually 14)» (iii) Relatively thin inner bract.
Judging from records in S ri Lanka i t would appear that coconut palms could be tapped fo r an in d e fin ite number of seasons as long as the rainfall is satisfactory and the palms are rested fo r 4 months in the yea r. In the dryer areas, the spadices after 3 to 5 consecutive seasons may propressively diminish in size and eventually abort. For best results it is always essential that the palms should be adequately manured. The p ra ctice o f tapping a ltern a te spadices though done in other countries has not be followed in Sri Lanka.
5*2.4 Preparation o f palm s -
The preparation of the palm involves the following operations : -
(a ) T© climb the palm the t o d d y tapper generally makes use of segments of coconut husk fastened previously at convinient heights a ll the way up the trunk of the palm in the form of a ladder. This is illustrated in the figure. lU4
« 8 -
When he has to climb palm6 that have not been prepared this way, he passes a girdle or loop (of soft rope, coir fibre or coconut leaflets) round his ankles to hold his feet close together and onto the trunk. With this simple contrivance he works his way up the palm like a looper caterpillar holding the trunk with his arms. When he reaches the crown o f the palm, he s e ttle s him self on one o f the larger fronds. (b) While at the top of the palm, the tapper cleans and clears the crown with the deeming knife.
( c ) When groves o f palm are to be tapped, the palms are in te r connected ju st below the crown with strong c o ir ropeways. Two ropeways are used for each pair of trees. The lower one to place the feet and the upper one to hold by hand. With this arrangement the tapper needs to climb up only one tr e e , attend to a ll the palms in the grove by moving from palm to palm using the ropways and fin a lly climb down. This method which is much faster (See section 4.4 for capacity) however needs an unskilled assistant on the ground to bulk the collected toddy which is lowered in the pot by the use of a coir fibre rope.
5.2.5 The tapping process: -
The tapping process is essentially an art and the results therefore depend principally on the skill of the tapper. In essence the technique consists of carefully bruising and rupturing the tender tissues of the floral branch by gently hammering and pounding the spathe, without reducing the flower buds within to a pulp. These operations tend to direct the sap to the wounded parts through conducting elements within the stalk (peduncle) of the inflorescence.
Actually a variety of techniques are being used in S ri Lanka and elsewhere fo r achieving th is but the method described in this document is the one that has been evolved and adapted at the Coconut Research Board. This method has been found satisfactory in most respects, including yield coupled with rate and duration of flow of sap. It is recommended for the ta ll (typica) variety of coconut, which is grown extensively on plantation and commercial scale in many coconut growing countries.
The tapping technique described does not aim at "slaughter tapping" whereby the palm is forced to maximum yields but aims at a practical and logical technique for promoting even production over a long period of time.
Apart from natural fluctuations in yield, contingent possibly on lim iting and stable environmental factors, this method o f tapping has been found to g iv e economic and productive yields without causing any adverse symptoms on the pals».
5*2,6 The tapping technique
The various techniques described in this section on a day to day basis are illustrated in the figures given in page 10,
DAI 1 The operation on the first day (morning) in initiating the process of tapping, consist of binding the pre-selected spathe firmly all along it*s length at intervals of £ to 2
inches with fibrous strands. The strands are leaf stalks t to 4 | inch (6 to 12 mm) width stripped o ff from tender green fronds available at the crown of the palm. The binding prevents the splitting of the spathe (inner bract) due to expansion of the flo r a l components that are contained w ithin. The outer surface of the spathe is then "tapped" or "beaten" a ll round with the hardwood (generally tamrind) mallet. In addition, the pointed apex of the spathe is also gently pounded using the tapered end of the mallet.
DAI 2 The tapping and pounding operations are repeated in e x a c tly the same manner. 1U6 - 10 -
STAGE DAY ( a p p r o x ) CRUSHEDTIP** **’
BOUND SPATHE | S f
CRUSHING
C U T SURFACE1 11 , / * > , PETEOLE STRANDS ¿ ¿ f \ J f M m / / POUNDING № * -f r H j
1,1 ^ F R O T H Y 6 ^ . SUI CINS ! J k Y e x u d a t e l\ M&
! I V I k 1 5 * TAPPING
i/f- NNCISION ONG FOURTH ( approx) • — SEMI-DRY * ■ ER BRACT
v i4« a 30‘ ^ HALF ------LEAFLET STA/ ( a p p r o x ) v i THREE fOURTH (^yaox) v " ¿ P © f i n a l .* s t a g e & FULL % (WPPX)
PK0G1ESS1VE STAGES IM TODDY TAPPING
See Section 5.2.6 11*7
» 11 -
DAY 3 The tapping and pounding operations are followed by cutting off transversely a length of about 2 inches (50 mm) of the composite apical tissues with the tapping knife. The cut end with the exposed flower buds is then carefully pounded with the handle of the mallet. This last operation is very essential and is restricted to the tip of the bound spathe only. The idea is to cause the crushed floral tissues to pack snugly at the apex thereby preventing the sap exuding from the terminals of the spikelets from running through the interstices and collecting within the body of the spathe. I f this happens, the spadix may have to be discarded as spoilage would invariably set in consequent on heat and other fermentative changes.
DAY 4 & 5 Once each day, the operations of day 3 are repeated in the mornings preferably before 11.00 o’ clock. The apical tissues however are not cut on day 4 & 5.
DAY 6 onwards to flo w o f sap From day 6 onwards t i l l about day 12 or until the flow of sap commences, a slightly different technique is introduced. After the usual tapping and pounding operation, a very thin slice of about 2 mm from the apical tissues is pared off with the tapping knife. The slicing in done twice each day (before 11.00 am and about 4.00 pm) but the tapping and pounding operation is carried out only in the mornings until the flow of sap commences.
Though the tapper knows through experience the proper time when the toddy begins to ooze, yet the appearance of ants, bees, wasps and flie s around the spathe and the characteristic smell of toddy are good indications of the time of exudation.
DAY 12 to 46 Once the sap begins to drip, (usually Day 12 to 15) the tapping and bruising operations are discontinued, but the exposed end of the inflorescence is shaved o ff afresh twice a day as usual. ik Q
- 12 -
At this stage, the earthenware pot is slipped over * the free end of the spathe, supported in position by i t ’s own weight or stay be tied to a nearby frond. The figure in page 13 illustrates the original and tapping positions ef the spat he. In the natural position, as the distal (far) end of the spathe is considerably higher than the proximal (near) end, there is every chance ef the Juice flowing from the cut end trickling dowi along the spadix into the leaf axil. This could cause spoilage at the base. In order to avoid this, the free end of the spadix is gradually bent down t in it slopes at an angle of about 23° to the horizontal, and its tied down with coir rope to the frond directly beneath it. To facilitate this flexure, a long&itudinal incision about 4 to 5 inches (100 to 125 mm) in length near the base of the spadix (above the point of i t ’s isaimwith the stma) splitting the outer and inner bracts alone may be made witheub injury to the stalk of the in flo rescence itself,
A device to direct the sap into the pot is to pin- on to the cut end of the spathe an improvised fluted spout. The spout is made from a 2 inch (50 im ) strip of the V-shaped green coconut leaflet with the ventral side upwards. The pinning-on is done using t&e midrib know as "eekiln. The diagrams in page 13 gives details of this improvised spout.
Using the above technique, regularly paring the spadix and collecting the sap twice daily, it is usually possible to continue tapping a single spadix t ill it is reduced to a stianp about 4 to 6 inches (100 to 150 am) in length. Regarding the duration of tapping for a single spadix, an experiment has shown that from the onset of exudation the period is in the regies 31 days f®r the typica variety of the coconut palm.
To prevent any break in continuity, about three weeks prior to the anticipated time of cessation of tapping ¥
lA
- 13 -
ORIGINAL POSITION
BENDING SPADIX (AND SPATHE) FOR TODDY CQLBCT1QN
See Page: 12. 150
- 14 -
on a spadix; the next younger spadix in the crown is gradually prepared for tapping. Zt has been found possible to continue this sequence without a break for a period of one year in good palms»
The interval from the commencement o f tapping te the dripping of the juice would depend on the sk ill of the tapper, the seasonal conditions prevailing and the nature of the palm» In the literature available on this subject, 10 to 35 days have been quoted by different writers. Employing the above method on selected palms, the time interval has been rarely found to exceed 12 to 15 days»
For the first few days, only a meagre flow of juice could be anticipated. Thereafter, as the flow increases, the sap is collected twice a day (morning and afternoon), the tapper pouring o ff the contents in the pot into a bigger one which he him self ca rries on h is v is it s from palm to palm. When the tapper deals with groves of palms which are joined togeth er w ith c o ir ropeways, the f i l l e d pots o f toddy are lowered using a rope. An assistant bulks the toddy on the ground while the tapper draws the emptied pot up for further collection.
When the sole purpose of collecting toddy is for processing into syrup(treacle) or sugar (-Jaggery), the earthenware pots vised for collecting toddy are treated with lime to prevent alcoholic fermentation» The toddy collected in pots without such treatment undergoes fermentation due to the culture of yeast found in the environment»
5»3 Product flow diagram t -
One average Hypica” tall palm
1500 ml sat> per day i fo r 8 months o f 1 year 151
- 15 -
69 Quality of finished product : -
Unfemanted coconut вар is sweet, oyster white and transluscent* The average composition. o f S r i Lanka toddy (Nathaneal - 1956) is given hereunder : -
Fresh toddy Fermented toddy Stale toddv
Total solids (gn/100 ай) 18,7 4.5 4.4 Sucrose(gm/lOO m l) 16.5 » - Ash (gn/100 ml) 0 .4 0.4 0.4 A c id ity (да Acetic/lOO ml) tra c e 0 .6 1.6 Alcohol (v/v) n i l 7.5 6.5
7* Source of information : -
"Toddy Tapping" Leaflet No i - IS (1967) issued by the Coconut Research Board, Lunuwila, Sri Lanka,
T.K.G.R 1979, 152
Product code : CCGN 17*02 Technology sheet nos V / 3 3
UNITED NATIONS INDUSTRIAL DEVELOFMHJT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
MConsultancy Service on Coconut Processing Technology11
( P ro ject UF/RAS/78/049)
1. Technology sheet for i - PROCESSING COCONUT SUGAR FROM FRESH SAP (SWEET TODDY) - (C ottage Industry)
2* Uses of finished product : - Edible purposes and for preparation of traditional dessert.
3. Country of origin % - THAILAND
4» Eauirment s -
4e1 D escription o f equipment : -
4*1*1 One horizontal fireplace with provision for two cooking vessels and chimney. See diagram in page 2 for details. This is inside a temporary shed for shelter.
4*1.2 Two Cooking vessels of steel each 70 litre capacity. See details in page 2.
4*1*3 Two baskets of woven bamboo strips. See details in page 2*
4*1.4 Stirring device with spring coil. See details in page 2.
4*1.5 Bamboo vessels for sap collection
- 1.5 litre capacity for day collection.
2*0 litre capacity for night collection, Square * ------> up Wooden handle \ t *' 111 I l l llleiufirm r : n ! n r ! L
Jt ~ “T T Coil of ^ “ 0 spring steel ¡n r & T m T Stirring device with vessel
r I 3 X J L R - i ~ r - f r
\ I ! e' /
/ I) - y/— - - - .
/
S'
15" Square fo r charging Sectional elevation 12" Sqi firewood inlet for air. End elevation U) 151»
- 3 -
4.2 Materials for construction : -
Ordinary bricks for foundation, side walls and chimney-quantity not known.
Fire bricks (large) of special shape for arch of horizontal portion of fire place. The weight of the cooking vessels is taken directly by the side walls.
The en tire f i r e p lace, and chimney are housed in sid e a temporary shed of about 10* ft width x 16ft length. This provides for a little working space for crystallization of the sugar and packing the finished product. The shed is constructed entirely of local materials which would keep the cost very low. The chimney ris e s above the r o o f f a c ilit a t in g exhaust o f smoke.
4.3 Cost of construction & equipment s -
The cost details are not available.
4.4 Capacity: -
The output per vessel in 2| hours cycle time is 7.5 kg sugar. The fireplace with two cooking vessels working for a 8 hour day with two members of the family can produce 45 kg coconut sugar per day. 5. Procesa î " 5.1 Process flow diagram : -
Sweet teddy
Wood chips or chemicals (preservative'D
Temporary storage in bamboo collection vessels
Lard or coconut o il/ ‘~ '\ _ _ Calcium Itypochloride (antifoam agent) ( (bleaching agent)
1 r ' f yt Heating for 2\ hours in Heat CH vessels/with basket
Cooling & Stirring I Simultaneous crystallization I Packed in to k ga llon tincans I Coconut sugar (packed) 5.2 Description of process : -
Fresh sap (local name "Maprau") is collected on the tree into bamboo vessels. See technology sheets on tapping aap for details. The collection during tne night is in 2 litre vessels while during the day, the collection is in 1 .5 litre vessels, 3 to 5 p o f hardwood chips is added in to the bamboo c o lle c tio n vessels vhile at the top of the tree to preserve the invert sugar content from fermenting into alcohol. There are two varieties of wood available for this purpose. The local names are nKiumn and “ Payom". Care must be taken to ensure that not too much is added or else the toddy w ill become too bitter (astringent). The preservative is effective upto 6 hours at room temperature. A lte rn a tiv e ly , chemicals can be added to perform th is function. They are either 0 . 2* sodivm Benzoate or 60 ppm o f Solfanilam ide.
About 50 to 53 litre of toddy is poured into each 70 litre steel cooking vessel. Three or four drops of lard oil or alternatively coconut o il is added as an antifoam agent. One teaspoon of Calcium Bypochloride is added as a bleaching agent to improve the colour of the finished sugar. For each vessel, a basket made of bamboo strips is placed to contain rising foam during the heating process.
The fire is started and maintained for about 2\ hours u n til foaming ceases when the water content has evaporated. Coconut fronds, dried coconut leaves etc are used m firewood, Bapid boiling is avoided so as to minimize carameLization®
The vessel containing the thick liq u id is now removed from the fire place and placed on tbs floor. Is the cooling, proceeds, the contents .are stirred by the device^ When the contents start to thicken further, the stirring device is dipped, lifted and rotated, between the two palms o f the worker* This throws out. the material radially onto the walls of the vessel* This rapid cooling cm stirring action prevents any isolated crystallization. Towards the end af this operation, there is eiaultaneous cxystallis&tdan 157
- 6 -
throughout the entire contents; giving rise to regular shaped m a ll cry s ta ls . The colour o f the sugar is lig h t brown such as the colour’ of pine wood. From one vessel, about 7»5 kg of sugar is obtained per cycle.
The sugar is emptied from the vessel into 4 gallon tin cans and lidded.
5.3 Product flow diagram : -
¿3q i t r e . t,odds m ,i,k g)
''
A 7.5 kg coconut su^ar
Estimated yield is y or 14. 3# on weight to weight basis.
6® Quality of finished product : -
This edible sugar consists of regular shaped small crystals. The colour is light brown (pale brown) similar in colour to pine wood. Jus there is no removal of molasses, the sugar is neither a hard nor a granular substance but a very coarse semi-solid material.
The sugar is very sweet and has a characteristic flavour due to the raw material used.
7® Source of information : -
Observations during a field visit to a cottage industry on the ou tsk irts o f Bangkok,
T.k.G.K. 1979. Product code i CCGN 17,02 Technology sheet nos V / 3 4
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGaNIbATION
AND ASIAN k PACIFIC COCONUT CCHHUNITY
“ Consultancy S ervice on Coconut Processing Technology"
(P ro je c t UF/RAS/78/049)
1 , Technology sheet f o r s - COCONUT SIRUP (TREACLE) AND COCONUT SUGAR (JAGGARI) FRQ4 FRESH COCONUT SAP (SWEET TODDY) - (Cottage In d u stry),
2, Uses o f fin ish ed products s - Coconut syrup is used as a sweetening agent for many traditional food preparations including dessert.
Coconut sugar is used fo r e d ib le purposes as well as a sweetening agent in many traditional food preparations,
3, Country of origin s - SRI LhKKA. These products are also made in INDIA, MALAYSIA, INDONESIA and THAILAND. For Thailand, see separate technology sheet. As regards Indonesia, tapping coconut sap and manufacture o f these products is confined to West and Central Jawa provinces. In other coconut provinces the Aren (Arenga) palm is p referred . Syrup and sugar are not produced in the Philippines and the coconut sap is used only as a beverage.
See separate technology sheet CCCN 17,02 for the camuercial process in S ri Lanka fo r sugar manufacture. 159
- 2 -
4. Equipment : -
4.1 D escription o f equipment
An open steel cooking vessel of about 5 gallons (22 litre) capacity Stirrer (wooden) Traditional fire place Bottles for packing syrup and or clean coconut shell halves for cooling and crystallizing the sugar.
4*2 Materials for construction : - Not applicable.
4.3 Cost of equipment : -
Estimated cost of cooking vessel is Ra. 100/■ or US;p 6.40 ( Rs.15/60 per US$). Other costs donot arise for household process.
4.4 Capacity % -
For the home process using a cooking vessel of about 5 gallon capacity and utilizing say 2j gallon of it's capacity, the capacity per batch is as follows : -
For treacle (syrup) - 4 lb (1.9 kg) in about 3 hours
For sugar (Jaggary) - 3.5 lb ( 1.6 kg) in about 4 hours JS
5. Process : -
5«1 Process flow diagram : -
Sweet toddy collected in sterilized earthenware pots, each containing 5 gm o f "Hal" I bark chips.
Treacle Treacle (for sugar preparation)
Allow to cool; Continue to heat gently bottle and fo r another hour fo r close tightly further evaporation
Bottled Tread Pour into clean cocomit shell halves for cooking and crystallization
Crude sugar (moulded) 1 6 1
4
5.2 Description of process : -
Sweet toddy is collected on top of the palm in sterilized earthenware pots. Sterilization is carried out by holding the pot to the naked flame. This destroys all the micro-organisms which cause ferm entation. About one teaspoon (5 gm) o f fin e ly cut "H al11 bark (v e te r ia acuminata) chips is added to each pot and this acts as an antiferment. For the treacle and sugar industry, the toddy must be collected twice a day (morning and afternoon) and then processed without delay to avoid losses due to fermentation action caused by the bacteria in the air»
The sweet toddy is filtered by cloth and poured into an open vessel for evaporation. The vessel is filled to only half capacity because, space is required for foaming which takes place during application of heat. A few drops of castor o il is added to reduce the foaming action.
Heating must be so controlled as to avoid excessive foaming and spill over. The contents must be stirred steadily. After about 3 hours heating, the loss of water content tran3fo m s the material into one of thick consistency. The syrup is now ready. It is allowed to cool and carefully poured into clean bottles and closed tightly after some time. The pouring should be gradual along the inner edge of the bottle to avoid aeration (bubble formation). The bottles have to be kept tightly closed to avoid mould attack.
'When sugar is the desired end product, the material is heated with occasional s tir r in g fo r a fu rth er one hour beyond the treacle stage for near complete evaporation of water. Heating should be done slowly so as to avoid caramalization of the sugars. When the material is very thick, it is poured into olean «oconut s h e ll halves fo r cooling and c r y s ta lliz a tio n . The moulded sugar i s removed from the sh ells and wrapped in sp ecia l v a r ie tie s o f dried leaves. 162
- 5 -
5«3 Product flow diagram : -
6® Quality of finished product : -
Treacle : - This is a very sweet, thick syrup. It has a characteristic flavour due to the starting material being coconut sap. The sugar content is about 722*
Sugar j - This is a crude, dark brown sugar in a moulded form. It is coarse and the crystals are in varying sizes. The characteristic flavour (due to the starting material) is enjoyed by the people in coconut areas. The sugar content is about 80.2 ,
7® Source of information : -
Observations made in Sri Lanka by the writer.
T.K.G.R. 1979 163
Product code : - CCCN 17*02 Technology sheet noi V /35
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION
AND ASIAN & PACIFIC COCONUT COMMUNITY
"Consultancy Service on Coconut Processing Technology11
( P ro je c t UF/RAS/76/049)
1* Technology sheet fo r : - COCONUT SUGAR (JAGG&tf) USING FRESH SAP (SWEET TODDY) - (Saail Scale Industry)
2* Uses o f fin ish ed product i - Coconut sugar i s used fo r ed ib le purposes as well as a sweetening agent in traditional food preparations.
Molasses This by-product is also used as a sweetening agent in traditional food preparations.
3* Country of origin l - SRI LAMA
See technology sheet for preparation of coconut sugar at the cottage industry level in Thailand. See technology sheet for toddy tapping in Sri Lanka.
4* Equipment; -
4*1 Description of equipment end chemicals
4.1.1 A set of about 300 unglazed earthenware pots vf 1 gallon (4*5 litre ) capacity and specially treated as detailed in section 5.2 (Estimated Cost per pot Rp 3/*)*
4*1*2 Muslin cloth for filtering toddy. Three square yards adequate for 6 months use. Cost per square yard Rs 25/“ (estimated)* 16k
- 2 -
4*1.3 Three settling vessels of capacity 35 gallons (160 litres) Rs 1200/* each,
4*1*4 Three deliming vessels of rectangular shape and capacity 35 gallons, Ha 11QQ/« each.
4*1*5 Four concentration vessels of galvanised iron and 12 gallons (55 litre) capacity. Rs 300/» each,
4*1*6 Four stirrers and scraping devices (a ll wooden)
4*1*7 Two crystallizer vessels of capacity 30 gallon (135 litre ) Rs 1400/» each*
4*1*8 One centrifuge, pedal operated (locally fabricated)* Rs 7000/» each,
4*1*9 Two furnaces costing Rs 3000/ » each.
4*1*10 Packing material for sugar and empty bottles for molasses*
4*1*11 Building o f semipermanent construction and area 700 square feet. Estimated cost Rs 35,000/» at Rs 50/» per square foot.
Chemicals and laboratory equipment required
Lime (Calcium Carbonate) 2 Bushels for 5 days at Rs 16/» per bushel. Trisodium Phosphate 500 lb s fo r 6 months at Rs 0/60 e ts per lb . P^ indicator paper fo r 6 months use 3 units at Rs 50/« each
Thermometers (Q-2Q0°C range) - 2 Nos at Rs 100/» each. Measuring cylinders (1 litre)*» 2 Nos at Rs 48/» each.
4*2 Materials for construction i - Not applicable. 165
3
4*3 Cost o f equipment and chemicals
Cost of building Es 35,000/- Cost o f equipment 24, 000/ » Cost of chemicals etc for 6 months 1,900/-
T o ta l cost Rs 6|,000/- US4> 3910
4,4 Capacity/yield The average yield of today per palm per day is 2 bottles (1500 ml), Tne yield depends upon the skill of the tapper. It must be fu rth er noted that the y ie ld o f todcty has considerable variation from spadix to spadix, pain to palm, day to day and season to season. The average yield of toddy from a grove of 80 palms is 26,6 gallons per day. One gallon of toddy yields J lb sugar ana 1 bottle of molasses. The capacity per day for the industry having a grove o f 80 palms w i l l be 13*3 lb (6 kg) and 26.6 b o ttle s (20 l i t r e s ) of molasses. If the sugar is not washed, the yield per gallon of toddy is ^ lb sugar {¡aid bottle molasses but the sugar is dark brown. 166 - 4 - 5. Process 5,1 Process flow diagram O Sweet toddy in limed pots Filtered into settling tank Allowed to settle for £ hour, t o separate suspended lim e . Clear solution siphoned into de-llming vessel Heat a 1 Heat to 45 C with constant T r i Sodium stirring and add Tri Sediun phosphate a phosphate. Continue heating slow ly to 100V%®n C and A»,] b o il fo r few minutes. Filter through cloth into concentration vessel to ive precipitates J l Fow drops of Add caster seed o il and boil castor seed vigorously until syrup reaches o i l o 110*C. (Antifoam agent) I Transfer into crystallizer and allow to cool for 2 t o 3 days. Centrifuge te separate sugar frem molasses. Wash sugar with water to improve colour i f desired. Sugar lasses 167 - 5 - 5.2 ©ascription of process 5 .2 .t Toddy tapping The technology sheet for tapping toddy in S ri Lanka g ives d e ta ils o f the process. The c o l l e t i o n pot however has to be treated to prevent fermentation of the sugar into alcohol. The gave of palms is interconnected by ropeways to facilitate tapping and collection of toddy. 5.2.2 Treatment of collection opts One gallon capacity unglazed earthenware pots are washed, dried and held to the naked flame to remove any live bacteria which causes fermentation of sugars into alcohol. Tnis procedure Is carried for a ll pots every twe days. Freshly burnt lime (Calcium Carbonate) in the fom of a paste is applied to the interior of the pot. The dosage per pot i3 9 to 13 ga to § ounce) which is 0.2 to Q,% by weight of sweet toudy held in the pot. Due to the liming of the pots, tr.e sweet toddy collected is . . maintained alkaline (P above 7) so that the inversion of sucrose does not take place due to the culture of bacteria found in the air. 5.2.3 Collection of sweet toddy Every morning the tappers climb the palms and lower tne pot containing tne toddy usang a coir rope. A fresh pot is immediately hoisted up the palm and placed in position for collection luring the next 24 hours, Whilst on the palm during th~ morning, the spadix is pared (sliced thin) to promote flow of sap. The paring is carried out again in the evening but collection of toddy is done only in the mornings. Any fermented today is detected by it's smell, as well as by the bubbling of gases. This is confirmed by the 1 6 8 - 6 - indicator paper. Fermented teddy is net used far manufacture e f sugar. The average yield ef teddy per palm per day i s 2 b a ttle s (1500 m l). 5*2*4 Filtratien ef sweet teddy The sweet teddy is filtered (through muslin elath ta remove resins, insects, ants etc) into a settling tank of 35 gallon capacity. This is allowed to stand far half hour to s e t t le any excess lim e suspended in th e toddy. The c le a r solution is siphened out far the de-liming process. 5.2.5 De-liming process The de-liming vessel is of rectangular shape and e f capacity 35 gallons. The vessel is gradually heated with constant s tir r in g using a wooden la d le u n til toddy reaches a temperature of 45*0. At this point 10$ tri-sodium phosphate solu tion i s added slow ly to precipitate the calcina salt as insoluble calcium phosphate. Usually 1 to l£ lb s of 10$ solution required per gallon ef sweet toddy. ïhe addition o f phosphate solution is stopped when the F^ value drops to 6.8 to 7 as tested with indicator paper. Thereafter the temperature is slewly raised to 100®C with occassional stirring. After a few minutes of boiling, the solution is carefully transferred to a 35 gallon settling tank to remove the precipitates by straining through a filte r cloth. The dear filtra te free from lime is now ready for concentration and c r y s ta lliz a tio n * 5*2.6 Concentration and crystallization The dear solution is boiled vigorously after sprinkling a few drops of castor seed eij. as an antiloam agent. The syrup is continuously stirred while boiling to prevent caramélisation» Gradually the syrup thickens into a sead-selld state. 1 f>9 - 7 - When the temperature ef the syrup reach 110*0, it is lowered inte a 30 gallon crystal User and allowed t® cool slowly at room temperature with intermittent stirring for 2 te 3 days. Thereafter, the crystallised syrup is centrifuged in a pedal operated locally fabricated centrifuge. A spray of water is given to obtain a whiter colour sugar which is desirable. The yield of sugar is normally £ lb (22? gra) with 1 b o ttle (750 ml) of molasses from 1 gallon of sweet toddy. If however, the water wash is not carried out, the yield per gallon of toddy w ill be ^ lb (340 gm) sugar and ^ bottle (560 ml) o f molasses. This however gives & sugar which is not quite suitable. 5.3 Product flow diagram : - One average coconut palm 1500 rJ, sweet toddy, per day Î gallon (45¿0 ml) sweet toddy 170 - a - &• teU.ty. ^fin ish ed product g - The cooenut sugar is 52©arse and ferswi in e®l®«r* It is very sweet and has a c h a ra c te ris tic ¿l&veur due t® th e seurce being from cecomxt sap. 7. Ssurce tf informations - Study carried eut by UNIDO Industrial Ecenamist attached « t® APGG - Reference Report e f Oecetech inserting 13 " IS Oeteber if?5 in Jakarta» Decwent Ns» ACG/CCOOTBCH - 75/IXX-B/2* « T.K.G.R 1979 171 Product cod®< CCCN 22®10 Technology sheet no: V /36 UNITED RATIONS INDUSTRIAL DEVELOPMENT ORGANISATION AND ASIAN & PACIFIC COCONUT COMMUNITY «Consultancy Service on Coconut Processing Technology* ( Project UF/&AS/76/OU9) 1, Technology sheet for * - VINEGAR FROM COCONUT SAP (TQDDI) USING QENERATQE PROCESS (Snail scale industry) 2® Uses o f fin ish ed product s - Household and commercial uses in preservation of fruits, vegetables, preparation of pickles, sauces, chutney* and oth er manufactured products. 3* Country o f o r ig in - SKI LANKA k® Equipment * » l*.l Description o f equipments - The p rin cip a l components o f a generator assembly comprise o f a feed (o r supply) vat, an acetifier and a receiving trough. For a diagram of the assembly see Figure 1, page 2. k.1.1 Feed vat; - This is a simple conical wooden vat with a capacity slightly exceeding 150 gallons. To minimise evaporation losses, it is preferable to make this a closed covered vessel with a 16 inch square opening on top (lik e a man-hole) with a su ita b le l i d . ' The vat should be provided with a gauge (to indicate liq u id l e v e l ) and a glass tap (som asted by rubber tubing t® the acetifier) to regulate the feed rate. For details see Figure II, page 3. ii.1.2 Acetifier: - This is tbs v it a l part, e? the assembly. I t i s a ta ll conical wooden vat (about seven feet high) with three superimposed compartments, separated by perforated shelve®. - 2 - 172 FIGURE 1 COMMERCIAL SCALE VINEGAR GENERATOR « 1. Feed Trough 2. Acetifier 3. Receiving trough. FlGlJK k il (scaie 1 un h to a ro >ti 1. Gauge [>• ubber Bung fìias!» Tube 2. Fastener (tie .s Tap Groove to Fit in top ini io Generator 3. Hoop (Irriti) i< abber T ubc Rubber Bung. IT1* MCCUONAL ELEVATION OF ACETEFILR SHOWING IN DETAIL EACH COMPONENT PART (Scale i iodi to a Foot) 1. See detail No. 6. (Tipping Trough and Stand) 7. See detail No. 5. (2nd. Perforated 3/4* Thick wooden partitii 2. Iron Hoops. 11* x l ' 8. See detail No. 4. (2nd. Frame for support of 2nd Wooc 3. See detail No. 8. (100° C Thermometer and its fixture.) Partition.) 4- v^«£p^dtiOT) iN°' L Fiame forSupport 0f Perf0iated 9. See detail No. 3. (Perforated 1' thick Wooden Partition.) 5. 2 |'x i r Truss. ’ 10.' Rubber Bung. 6. See detail No. 7. (2* Thickwooden Top Lid and Inlet). 11. See detail No^ 2 (Air Veal S in all). 12. 3/4' diameter Exit 1 FIGU RE IV SECTIONAL ELEVATION OF RECEIVING TROUGH (Scale one inch to a Foot.) 1. Iron Hoops. V FUJI SECTIONAL ELEVATION OF I I HMIN TATION VAT 1. Iron Hoops 2. 4‘ diameter Feed Vent 6' from edge with wooden Plug. 3. Exit Tap or Faucet. 4. Exit Tap or Faucet for Dregs FIGURE VI FACTORY HOUSING . SECTION A. B. PLAN (Scale I inch to 8 feet) 1. Ground Level 6. D.F.C. 2. Ridge Tile 7. Filling 3. 6' x 2* Ridge Plate 8. Cement Floor 4. 4 'x 2* Wall Hate 9. Work Bench 5. 8' x 3/4* Valaoced Boar 10. Conrolidated Rammed Floor DETAIL NO. I I ' FRAME FOR SUPPORT OF PERFORATED WOODEN PARUTION !. Supporting Frames 1' x 1 |' 2. Cross Beams 1}' x 2$' 3‘ Trusses 2 5 'Long 2 |'x IJ' DETAIL NO. 2 CROSS SECTION OF AIR VENT SHOWING AIR PASSAGE (Scale I full size) 1. Rubber Bung 2. Moulded Teak Air Vent. 3. 1 * diameter Air Passage. 4. Stainless Steel Mesh. PARTITION DETAIL NO. 3 1' THICK WOODEN (Scale 1 inch to a foot.) a to inch 1 (Scale as required. as ERFORATED ERFORATED P o o Note :—This partition will be fitted in 9 Nos. and trimmed to size to trimmed and Nos. 9 in fitted be will partition :—This Note I. I ' Diameter Perforations at 3' centres in 9 concentric rings. concentric 9 in centres 3' at I. Perforations I ' Diameter DETAIL NO. 4 2nd FRAME FOR SUPPORT OF 2nd PERFORATED WOODEN PARTITION EAL OF ACETIFIES DETAILS Note Sizes of members are same as in frame No. 1. -4 (Scale one inch to a foot) VO 1. Fitted in two pieces 2. Fitted in one piece. DETAIL NO. 5 2nd PERFORATED 3/4' WOODEN PARTITION Note The perforations are at 3' centres but unlike in Partition No. 1. the diameter of each perforation is only l (Scale 1 inch to a foot) DETAIL NO. 6 TIPPING TROUGH AND STAND \ i r DETAILS OF ACETIFIES (Scale 1 inch to a foot) DETAIL NO. 7 V THICK TOP IJD AND INLET (Scale 1 inch to a foot) 1. Clamp. 2. 2 " diameter Hole to take in inlet tube mounted on rubber bung 3. I ' diameter Hole covered with stainless steel mesh for passage o f Air. DETAIL NO. 8 100°C THERMOMETER AND ITS FIXTURE DETAILS OF ACETIFIES • 1. Rubber pressure tubing 2. 100°C Thermometer 3. Rubber Bung 182 » 12 » Tha upper compartment (o r Dispersion Chamber) contains the distribu tion apparatus which insures even application of the vinegar stock over the generator packing material. The central compartment (o r packing chamber) contains the supporting medium which offers the necessary surface area for the active growth of vinegar bacteria and their contact with a ir . The lower compartment (o r collectio n chamber) serves as a sump for the collection of the vinegar. It also contains 8 ports for the admission of air, and a exit cock or* faucet for drawing off the vinegar. The acetifier is shown in figure III, page U. See also details Mo. 1 to 8, pages 8 to 11. I*. 1.3 Receiving Troughs - This is an open wooden vessel fo r collecting the vinegar that is run off from the acetifier. This receptacle is only for temporary storage, and is parti» cularly useful during the recirculation operations of the vinegar stock. For details see Figure 1?, page 5» ii.1 4.1.5 Accessory Equipments » In operation, the vinegar stock has to be distributed uniformly and intermittently over the generator medium in snail but constant amounts. An automatic feeding device therefore becomes essential. Though a stainless steel revolving sprinkler (or sparger) is ideal, an automatic wooden tilting trough located in the dispersion chamber and resting on the top perforated sh elf i s good enough. The construct ional d eta ils o f a suitable tipping trough are given in D etail Mo. 6, page 10. 183 - 13 - A thermometer graduated to 100°C and fitte d by means o f a rubber bung into the packing chamber, is useful, especially «hen the generator is being seeded and started o f f . See D etail No. 8, page 11. Thermometers fit t e d in to the dispersion and collection chambers are also useful but ndt essential. Though a stainless steel centrifugal pump for recycling the vinegar stock is the best arrangement, this operation could also be done manually. For th is purpose stain less ste el (o r aluminium) receptacles alone should be used. Six pot shaped vessels with a capacity o f about a gallon each would be required for working a single generator. For checking the quality of the raw material and the efficiency of acetification some form of analytic control is essential. For th is purpose simple titra tio n apparatus comprised o f a 2$ (o r 5 0 ) ml. burette with stand, a 5 or 10 ml. pipette, about 6 x 250 ml. titration flasks, and a wash-bottle would be required. An alcoholmeter (or ©bullíosteter) with a stainless steel boiler and inner condenser tube, covering a range o f 0-12 per cent alcohol by volume, is also an essential prerequisite. A suitable type of instrument could be procured from Messrs. Joseph long Ltd,, 181*, Station Road, Harrow, Middlesex, England. There are also many other suppliers o f such equipment. U.1«6 Aging casks or barrels: - These are wooden caske or barrels for aging the vinegar for periods of 3 to 6 months© U.2 Materials of construction U.2.1 D etails o f the equipment have been given under section U.1 U.2.2 Building/factory requirements; » To house a single generator assembly and equipment (including a work bench for analytical operation) a building 35* long X 20* broad, with side walls 15* high would be convenient. Dwarf side walls 5* 6" high along the length of - 1U - the building with a mounted t r e l l i s reaching to roof level would be ideal. See Figure VI, page 7. The roof of the building should have ctilin g to keep the atmosphere cool and su bo to prevent contam in& t i un fr o » duet and fa llin g d eb zir. In conformity with present excise regulations the flo o r o f the factory would have to be a permeable stratum, dean white riv e r ©and is generally used which would readily soak up any splashed liqu id s. Provision should be made fo r entry of diffused day lig h t, and ample natural ventilation to facilitate removal of stagnant air and fermentation gases. Trellis work on two sides o f the building (as suggested above) should be suitable. When a factory i s being b u ilt, ©very source of in fe c tio n ,,such as manure heaps, decomposing materials and rubbish heaps o f debris, should be avoided, as they can act as source o f wild organisms which can infect the raw materials and vinegar in the factory. Cleanliness i s o f prime importance; fo r, the generator® provide an excellent, breeding place for flie s and £ other vermin which is unhyginic and can reduce yields and capacities to a very marked degree. A supply o f fresh potable water should be always available m ar the factory s ite . U.3 Coat o f equipment & constructions Ttes® details are not available ii»U Capacity! - 150 gallon (680 litre) per batch with one generator a s M B b lj* 5® Process $.1 Process flow diagram Sweet toddy F ille d into fermentation vats a fte r filt e r in g through wiremesh & then through cheese cloth. —— Stored fo r 2 to 3 days fo r fermentation o f sugars into —.— alcohol Removal o f yeast cells etc. through progressive sedimentation 1 r i{------Stored fo r 2 to U weeks for i settling (vat tigh tly closed under I anaerobic conditions) Vinegar stock (clear fermented toddy) S®circulais until. 6£ a cid ity Gradual circulation of vinegar stock through generator which has been seeded Aging fo r 3 to 6 months in wooden casks or barrels B ottling Ì Bottled winegar 1 8 6 - 16 - 5.2 Description of process $.2.1 What is vinegar? In general terns vinegar my be defined as a condiment made from watery solutions of sugar or starchy materials by two separate microbial processes. The first is an alcoholic fermentation of naturally securing (o r converted) fermentable sugars by certain species of yeasts called Saccharomyces. The second i s the so called oxidative fermentation of alcohol so produced, by species of bacteria called Acetobacter. Owing to the fact that a wide variety of sugary or starchy substances can be used fo r the production o f vinegar, its exact composition w ill depend on the raw material that has undergone these fermentations apart fro® the actual conditions of manufacture, aging and storage, Essentially however, the finished product is a d ilu te solution of Acetic acid containing salts and extracted matter from Hi® source m aterial and certain aromatic minor const!tutents produced during the fermentations. The term vinegar i t s e l f i s of French derivation sign ifyin g «sour wine®. $•2.2 Coconut toddy as raw materiali «> Coconut toddy by i t s e lf is an excellent raw m aterial fo r Hie manufacture o f high grade vinegar. I t needs no fo r tific a tio n with adventitious sugar or salts and possesses the overriding advantage of being a w ell balanced medium containing su fficien t nutriment fo r the growth and activity of yeasts and bacteria. $.2.3 The "Generator Process* The vinegar generator is designed to provide the maximum :-uri>ice exposure fo r a volume o f vinegar- stock (vide infra) in order to supply enough a ir fo r -'he acetic 187 œ* 1 7 «* Mid bacteria to affici ently and quickly oxidise the alcohol to acetic acid* A &army o f tbs existin g iw k etsy lue shorn that 'Generators’ with a collection climber capacity o f 150 gallons would be an appropriate and convenient else for most vinegar makers to in stai* Whilst in certain factories a single generator o f th is size would be adequate, others would need to operate batteries o f two or more o f th is size, depending on the quantities of toddy handled. In essence the generator is a countercurrent gas absorber wherein the acetic bacteria, cause the oxidation of alcohol to acetic acid. A ir fo r the alcohol oxidation i s admitted to the generator below the fa lse bottom through the eight air vents and it circulates naturally owing to the heat o f oxidation in the packing. The vinegar stock from the feed vat is uniformly sprayed over the surface o f the in e rt porous medium or packing material (maize cobs in th is case) at the surface o f which the oxidation takes place. The stock which drains o ff £Tom the packing by gravity into the base o f the generator is nan out and pumped (o r poured) back into the feed vat, fr m which i t i s recycled t ill acétification is complete. The ordered sequence o f processes in the manufacture o f vinegar from coconut toddy are relatively simple and can be operated at low cost. The re c irc u la tin g generator has several economic advantages. It nay be operated at low cost, and i s re la tiv e ly simple and easy to control. There is a distinct saving of factory storage space, and equipment. A generator assembly described above could replace about 9 x 1000 gallon vats. The process i s continuous and provides a means o f steady and e ffic ie n t production of vinegar with low working lo sses. The process ccmUmM speed o f action 188 - 16 - with high fermentation efficiencies resulting in higher acid strengths of the finished vinegar. The packing material used i s Inexpensive and e a sily procured» It would not require renewal for at lea st a year» $o2ak Vinegar Stocks « The preparation and (if necessary) blending of a suitable alcoholic liq u o r ( fermented toddy in this case) constitutes the f ir s t stage, in the process. The tern ** vinegar stock1» is popularly assigned to this alcoholic wash. 4s the quality and composition of the todd^r used are as important as the details involved in the manufacturing process, it is important that care should be exercised in its collection and handling. 4 system of graduated straining is useful to remove suspended impurities. Wicker baskets may be used at the tapping stopes* for removing the grosser foreign matter (includ ing bees, wasps and other insects) from the toddy, before i t i s bulked in casks. On reaching the factory the finer suspended matter w y be removed, by passing through ’staybrlte' steel wire meshes of different gauge, and ultimately through cloth, into the fermentation vats. Toddy filte r e d th is way w ill be found to be agreeable in taste and smell and w ill also be quicker and smoother in fermentation than the unstrained m aterial. To ensure an economic conversion o f sugar to alcohol and to obtain a better quality vinegar stock, control of the alcoholic fermentation is desirable. If acetic acid is produced in any quantity, the fermentation may cease before all the sugar has been converted. 4 concentration o f 0.5 per cent acetic acid markedly dimisbes the ac tiv ity o f the yeast and higher concentrations w ill completely in h ibit the alcoholic foment ation. The use of conical rate of graduated sises (depending on the volume o f toddy to to fomented) of the type shown in Figure V has been found to to tto tost way o f limiting the air supply, thereby discouraging th® development o f «idity and obtaining a satisfactory fermentation. The vats should to kept 189 - I f - nearly fu ll awl only loosely covered in order to facilitate the e x it o f the carbon dioxide gas produced. The yeasts naturally present in the toddy can produc® a rapid clean and fairly satisfactory alcoholic fomentation without the v m material having to be seeded with say selected yeast starter. I t w ill he found that fom entation w ill he ©caplet® within U8 to 72 hours* a fte r which the yeast c e lls and other debris should be removed by progressive sedimentation. After a storage period of 2 to I» weeks is allowed for settling* the supernatant stock May fe® drawn o f f (racked) and i s ready fo r acétification. I f the vinegar stock is to be stored i t i s important to place i t in casks under anaerobic conditions. I f stored in the open?the stock is subject t® serious loss of aloohol by evapora tion as well as by metabolise by oxidative yeasts. The un protected stock w ill also attract Hies and vermin and i s objectionable from the stand-point of sanitation. 5>.2«j> Seeding the Generators « When a sufficient quantity o f vinegar stock has been, accumulated the a c e tifle r may be seeded with vinegar bacteria® To do th is* mM.ee cobs (a fte r removal o f seeds) which have been previously cleaned* washed and dried are soaked in good unsterilized vinegar fo r about 6 hour® and .packed fa ir ly lo o sely in the packing chamber o f the a c e tifle r between the two perforated shelves. I t i s a good plan to pack the bigger robs at the bottom and the s w ille r ones near the top. th is arrangement would fa c ilita te the fre e circu lation o f a ir even after the growth of bacterial film over tbs cob®. learly eight thousand selected robs w ill be required in a ll for on» acetifler. About 150 gallons of fresh* sound* unsterilised* unverified incompletely oxidised vinegar in active acétification* dram from a high production efficiency vat (not maturation cask) is placed in the feed vat* The best suited Maples for use is a starter 190 - 20 • n i l l b@ found to analyse above 3.5 per cent o f acid and above 2.5 per cent ?/f o f unotodised alcohol. This fresh vinegar is sickly re-circulated through the generator for ?2 to 120 hours or nor® with a ll the air went® closed. When the temperature of the interior of the generator starts to increase the generator may he regarded to to seeded and ready fo r operation. 5®2®6 Operation after Seeding? - Once the generator is seeded* it s operation consists in recirculation at a regulated rate of flowj each batch of vinegar stock through the packing* and controlling the air supply by opening one or more «dr vents* until* the alcohol is oxidised, if too much air is allowed to oitsr* there can to ©verwexldatioa o f the alcohol resulting in wasteful loss o f acid. For w & a d m m efficiency, certain optimum conditions of flow and a ir supply could to worked out through experience. In general the rate o f flow from the feed vat may to so adjusted that i t would take about s ix hours fo r the 150 gallons to run out into to® collection chamber. It is Important to remember that just after seeding* i t would to injudicious to pass rm vinegar stock through the generator. The f i r s t batch should preferably be a blend of 2$ per cent vinegar stock and 75 per cent of the starter that has gone through the generator fo r seeding. The subsequent batch could to a mixture o f 50 percent vinegar stock and 50 per cent o f to® firs t batch after acei ill cation® In the third and subsequent charges to® percentage o f vinegar stock could to gradually increased but mixed with reduced quanto ties o f acetified vinegar from toe immediately preceding batches* t in toe generator settle* down to mood operation. €ma» this happens toe vinegar ' stock could to used without blending with acetified vinegar. In newly constructed generators* toe raw unseasoned timber in contact with todd^y attracts toe development o f worms and maggots. For a period of about a »Bth, at in terva ls ®£ 3 d^r® 191 -SU i t is absolutely important to remove the lid of the geaerator sad clean the dispersion chamber with a d e w damp cloth. The tiltin g trough cradle and top perforated shelf should be taken out a flushed with dean water and put back. Qmi the generator sh ell is seasoned and soaked with acid there should be no further trouble and the washing and cleaning operations could be discontinued» $.2»? Aging? - When the vinegar has reached its maximum strength it must be aged before i t is bottled, and i s at its best quality for table use. The aging is dons in wooden maturation casks or barrels that are kept fu ll and dosed, so that destruction of acid by oxidation by the vinegar bacteria does not occur» During the period of aging which could range between 3 to 6 months, a certain amount of sedimentation takes place which improves the appearance and c la r ity o f the vinegar. 5.3 Product flow diagram fie ld s etc. are not available. 6. Quality of fin is h e d product? - The s- oreqgth o f the vinegar is about 6% (gpas Acetic acid per 100 ml. of solution). The Quality o f the vinegar produced is good and uniform and the process is hygienic as it takes place in a closed acetifier whereby insect and putrefai'wive organism aro excluded. I a® i analytical characteristics of coconut toddy vinegar manufactured hj this pro* css compare favourably with reputed imported bs&nds o f vinegar. ? * ? •. : .ire s o f 1 . '>mation Leaf- * no. 22 (1971) iestud ty Gocoi t Research Beard, Lunut-.il a, Sri Lanka.» . & & a n!9 19? Product Code: - CCCM 22.09 c Technology Sheet Mb: V /37 UNITED NATIONS IMPJSfPJAL DEVELOPMENT ORGANISATION AND ASIAN & PACIFIC COCONUT COMI-EJNI IT №Consultancy Service on Coconut Processing technology" ( Project UF/RAS/78/OU9) 1® Technology sheet fo r : - COCONUT 2® Uses o f finished product : - Alcoholic drink 3® Country o f o r ig in : - Sài LAMICA AMD PHILIPPINES U® Equipment iut List of equipment Glass container - 1 gallon capacity Kitchen Thermometer - Fahrenheit reading Cooking vessel Hydrometer U®2 Cost of construction : - Not applicable U®3 Cost o f equipment : - tS$ 20. 193 - 2 » £. Process 5»1 Pro08sa flow diagram Water Arrack 19*+ 5.2 Process description D is t ill fermented toddy by boiling. Fermented toddy begins to b oil between 200°F & 20fJ°F. The d is tilla tio n is stopped when the hydrometer reading o f the distillate records three per cent B o ilin g poin t a t th is stage i s 211°F. Reduce strength o f the distillate by adding water. D istill again. Repeat process. D istilled arrack may be bottled & sold, or bottled St matured o r aged.to improve the taste.. Length of ageing process varies. After ageing, bottled arrack is ready to toa sold or for consumption. 5.3 H e ld The range of recovery is from 11.5 to 25 per cent of the original toddy. 6. Quality of the ‘finished product The reported analytical valued of the arrack (parts/100,00 absolute alcohol) ares - Esters 165* to 258 Total acids - 116 to 158 Fixed acids - 6 to 13 Volatile acids- 105 to 152 Furfural 0.H5 to 1.32 1 PJI.A. 1979