Ofero A. Caparino, Ph.D. Division Chief, BioProcess Engineering Division PHilMech Philippine Center for Postharvest Development and Mechanization CLSU Compound Science City of Munoz Nueva Ecija Tel: 044-4560-213 68 out of 79 3.61 B provinces are nuts coconut areas 2.7 B nuts 340 M bearing trees 8.92 B 15.31 B nuts/year nuts Reference: PCA, 2013) WORLD TOP TEN COCONUT PRODUCERS (FAOSTAT, 2013) 15.31 B nuts/year 20,000,000 18,000,000 (Average 2007-2011) 16,000,000 14,000,000 12,000,000 10,000,000 8,000,000 6,000,000 4,000,000 2,000,000 ‐ PRODUCTION COCONUT MACHINERY, PRIMARY VALUE‐ADDED MARKET SALES EQUIPMENT for INCOME INPUTS PARTS PROJECT PRODUCT PRODUCTS R&D, COOKING OIL OILMILLS OIL SOAPS PRODUCTION MEAT DETERGENTS RESOURCES KERNEL PROCESSING COPRA LIVESTOCK FEEDS MACHINERY MEAL Nursery/Seed Gardens ROPES, GEOTEXTILES BEATING MACHINE, FIBER DOORMATS, BASKETS HUSK DECORTICATOR, BALER, 1‐ & 2‐PLY ORGANIC FERTILIZER ROPE TWINER, Farmers/ COIR DUST ROOTING MEDIA Planting DOORMAT EQUIPMENT HORTICULTURE POTS DOMESTIC AND …creating new JAGGERY, COCONECTAR, EXPORT TODDY Fertilization SAP COCOSUGAR, LUMBANOG MARKETS WINE, VINEGAR Pest demands in the Management COCONUT Coconut COCONUT JUICE, VINEGAR, NATA emerging markets WATER WaterWATER DE COCO, WINE LATHE, CUTTER, ACTIVATED worldwidePOLISHER, CHARCOAL CHARCOAL SHELL HANDICRAFT Harvest FORMED FASHION ACCESSORIES, MACHINERY PRODUCTS BELTS, BUTTONS, HANDICRAFTS WOOD WOOD, WOOD, HANDICRAFTS, LUMBER LUMBER FURNITURES LEAVES, LEAF SHEATHS, HATS, SLIPPERS, BASKETS, STIPULES BAGS, HANDICRAFTS FRUIT TRAYS, PICTURE INFLORESCENCE FRAMES, PLACE MATS, BLINDS, ARTIFICIAL FLOWERS Flowchart of Supply and Value of Coconut and Coconut Products in the Philippines , Coconut industry strategic plan for Philippine Agriculture 2010 Sources of cocowater – Large desiccated coconut processing plants Some health benefits of coconut water Use for intravenous hydration of patients in remote areas (Campbell‐Falck et al.,2000). Hasbeenusedasalternative fluid for emergency blood plasma transmission to wounded soldiers without allergenic reactions (FAO, 2005). Acclaimed as a natural contender in the sports drink market because of its desirable taste and aroma, nutritional and functional characteristics that normally present in sports drinks (FAO, 2005). It has large amount of electrolytes, which believed to be an important alternative solution for oral rehydration (Sena et al, 20012) Some health benefits of coconut water Intravenous hydration of patients (Campbell‐ Falck et al.,2000). Alternative fluid for emergency blood plasma transmission (FAO, 2005). Natural contender in the sports drink market (FAO, 2005). Large amount of electrolytes (Sena et al, 20012) Coconut water has five electrolytes that human body needs (FAO, 2010) Potassium The most important positive ion (cation) inside the cells; regulates heartbeat and muscle function; coconut water contains 203‐256 mg, which is 15 times the amount in the average sports drink Sodium The most important positive ion in fluid outside the cells, and also the one most depleted with exercise, as one lose sodium through sweat and urine. Magnesium Important for maintaining the electrical potential of body cells, proper muscle function, and preventing calcium overload Phosphorous Plays important roles in bone health, and in transferring energy throughout your body, helping your muscles contract, and regulating nerve function (partners with calcium) Calcium Important for bone health (partners with phosphorous) Chemical composition of young and mature coconut water Components Young Mature Inorganic ions Calcium (Ca), mg/100g 27.35 31.64 Magnesium (Mg) , mg/100g 6.40 9.44 Phosphorous (P) , mg/100g 4.66 12.77 Potassium (K) , mg/100g 203.70 257.52 Sodium, Na, mg/100g 1.75 16.10 Presentation Copyright by PHilMech HOW MUCH potential volume of coconut water from mature coconut left unutilized during processing (e.g. copra and Virgin Coconut Oil, desiccated coconut, etc ) ? Copra processing Unutilized coconut water Harvesting Dehusking Splitting/cracking Drying Scooping dried coconut Copra product Unutilized coconut water Coconut flour Whole nut Coco shell Skimmed Deshelled coconut milk coconut meat Ground coconut meat Coconut milk Virgin coconut oil Processing of VCO, coconut flour and skimmed milk Unutilized coconut Broken shells water Coconut flour Whole nut Pairings Skimmed Deshelled coconut milk coconut meat Pared Ground coconut meat coconut meat Coconut milk Virgin coconut oil Processing of VCO, coconut flour and skimmed milk 2.4 Billion liters / year ( potential volume of coconut water from matured coconut left unutilized during copra processing…) Total production in = 15 Billion nuts per year 2012 (FAO, 2013) Estimated Damaged = 3 Billion nuts per year due to calamaties (30M trees x 100 nuts/yr) Estimated prod (2014 ‐ = 12 Billion nuts per year 2020) Assuming 80% for = 9.6 Billion nuts per year copra processing Available water from = 2.4 Billion Liters / year matured coconut, 0.25 kg water /kg nut or 0.25 L water /kg nut (Aragao, 2000) Production, MT 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 COCONUT PRODUCTION BY REGION (PNS, 2016) 500,000 0 CAR ILOCOS REGION CAGAYAN VALLEY CENTRAL LUZON CALABARZON MIMAROPA BICOL REGION WESTERN VISAYAS CENTRAL VISAYAS EASTERN VISAYAS ZAMBOANGA PENINSULA NORTHERN MINDANAO DAVAO REGION SOCCSKSARGEN CARAGA ARMM MEMBERS OF ASSOCIATION OF PHILIPPINE COCONUT DESICCATORS (APCD) (UCAP, 2016) 3,000,000 1 Franklin Baker 1. Pater Paul (Sorsogon) 1 Franklin Baker 2. Peter Paul 2,500,000 3. Pacific Royal 4. Atson COCO 1. Roxas Sigma 2,000,000 5. Fresh Fruits Ingredient 1 Franklin Baker or Peter Agriventures (North cot) 6. Primex COCO Products Paul? (Palawan) 2. Century Canning 7. Superstar Coconut Products (GenSan) 1,500,000 Production, MT 1,000,000 500,000 0 CAR ARMM CARAGA MIMAROPA CALABARZON BICOL REGION ILOCOS REGION DAVAO REGION SOCCSKSARGEN CENTRAL LUZON CAGAYAN VALLEY EASTERN VISAYAS CENTRAL VISAYAS WESTERN VISAYAS NORTHERN MINDANAO ZAMBOANGA PENINSULA Dehusked Nut inspection and Nut boring Empty nut coconut counting Filtered coconut Filtered coconut Deshelling Coconut shell water water (Single strength) (Single strength) Pared/white Pairings Feeds coconut meat Sterilization (done by toll Concentration Grinding/ processors) Milk extraction Grits Shreding Sterilized coconut Concentrated Coconut Milk Drying water coconut water Dehydration Dessicated VCO extraction Size Aseptic packaging Keep at Coconut and purification reduction in food- grade -16oC (Wet Process) barrel Packaging Skimmed Coco VCO Cocomilk Flour Export / domestic consumption General Process Flow of an Integrated Coconut Processing Facility Research Challenge ? 100% Pure ? NO Preservatives ? NO Additives ? Un‐utilized Technology Interventions coconut water Presentation Copyright by PHilMech Coconut Positive water displacement Pump Chilled Coconut Water Heating Pre-Cooling Chilling Conceptual design of a continuous flow pasteurizer‐chiller Stored for 4 weeks under chilled condition (4⁰C±2⁰C) Fresh coconut water Heating Cooling Storage Laboratory pasteurization of coconut water Establishment of PHilMech Village Level Coconut Water Processing System The technology was granted patent (Utility Model) to PHilMech by Intellectual Property Office of the Philippines (IPOPHL) on November 11, 2015, with Registration No. 2‐2015‐000266. Components of the PHilMech Village Level Coconut Water Processing System The village level processing system can be installed in an area of about 200 m2. The system contains basic processing equipment as illustrated, including, washing bins (a), coconut cage (b), extractor (c), pasteurizer‐ chiller, and (d) filling & capping machines (e). The plant includes small laboratory for quality analyses and a dry room for supplies and materials. The assumed useful life of the machines is 10 years. Pasteurizer‐chiller Extractor Cage Distilled water Chlorinated water Tap water Pre‐cleaned coconut Experimental set up for the production of bottled coconut water Performance testing in the production of bottled coconut water using the developed continuous‐flow pasteurizer‐chiler. The village level coconut water processing plant located in Pili, Cam Sur Harvesting De-husking Pre-cleaning Washing Extracting 100%Pure cocowater, no additives or preservatives Storage under chilled Pasteurizing-chilling Filling Capping condition Actual processing of bottled coconut water following the PHilmech established processing procedures and protocols. Actual processing... Presentation Copyright by PHilMech Presentation Copyright by PHilMech Total count of coconut water pasteurized at 70 ⁰C , 80 ⁰C & 90 ⁰C and stored for 4 weeks at chilled condition (4±2 ⁰C ) and ambient Condition (28±2⁰C) Mold Counts of coconut water pasteurized at 70 ⁰C , 80 ⁰C & 90 ⁰C and stored for 4 weeks at chilled condition (4±2 ⁰C ) and ambient Condition (28±2⁰C) Sensory evaluation of pasteurized coconut water vs. commercial cocowater Presentation Copyright by PHilMech Sensory evaluation of pasteurized coconut water vs. commercial cocowater (n‐100) Commercial Coconut Water PHilMech CCW Brand A Brand B Brand C Product Characteristics PHilMech CCW Brand C Parameters Brand A [240ml] Brand B [330ml] [350ml] [250ml] Product Characteristics Preservation technique Pasteurization Sterilization Sterilization Flash Pasteurization No sugar added Cane Sugar Cane Sugar No sugar added Sugars Sodium Sodium No preservative Preservative No preservative Metabisulfite Metabisulfite Concentrated CCW Concentrated