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PEMURNIAN MINYAK SAWIT
Tek. Peng. Nabati 2 - Teti Estiasih - THP FTP UB
TUJUAN
Pemurnian (purification) bertujuan untuk menghilangkan senyawa ikutan yang sering disebut sebagai impurities (kotoran) dalam minyak
Perubahan minyak kasar (crude oil) menjadi minyak makan (edible oil)
Meliputi satu atau lebih proses berikut: degumming, netralisasi atau physical refining, bleaching, dan deodorisasi
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JENIS-JENIS IMPURITIES
Proses ekstraksi minyak menyebabkan sejumlah senyawa non trigliserida terbawa
Meliputi: asam lemak, gliserida, fosfatida, sterol, tokoferol, hidrokarbon, pigmen (klorofil, karoten), fragmen protein.
Jenis minyak yang berbeda: kotoran berbeda Contoh: minyak hewani, CPO dan PKO :
asam lemak bebas; minyak canola: klorofil Kotoran tertentu dikehendaki seperti sterol
dan tokoferol Tek. Peng. Nabati 2 - Teti Estiasih - THP
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PROSES PEMURNIAN
Menghilangkan senyawa yang tidak dikehendaki tertentu dengan meminimalkan kerusakan trigliserida
kotoran yang dihilangkan: asam lemak bebas, fosfatida, gum, dll
Proses pemurnian meliputi: bleaching (penghilangan warna), deodorisasi (penghilangan bau), refining (penghilangan asam lemak bebas), degumming (penghilangan gum)
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Proses pemurnian PROSES PROSEDUR KOTORAN YANG DIHILANGKAN
Degumming H3PO4, H20, 70-80C
fosfolipid, trace metal, pigmen, karbohidrat, protein
Netralisasi NaOH (alkali lain)
Asam lemak, fosfolipid, pigmen, trace metal, senyawa bersulfur, oil-insoluble, water soluble
Pencucian H2O Sabun
Drying Na2SO4 anhidrat Air
Bleaching
Bentonit, adsorben lain
Pigmen, produk hasil oksidasi, trace metal, senyawa bersulfur, trace of soap
Filtrasi Spent of bleaching earth
Deodorisasi atau
Physical refining
Steam under reduced pressure
Asam lemak, MG dan DG, produk oksidasi, produk dekomposisi pigmen, pestisida, trace of oil-insoluble Tek. Peng. Nabati 2 - Teti Estiasih - THP
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Proses pemurnian secara kimiawi (kiri) dan fisik (kanan)
Storage of crude oil
Degumming Netralisasi Washing Drying Bleaching Filtration
Storage of partly refined oil
Bleaching Filtration
Storage of refined oil
Deodorization Polishing Cooling
Steam refining Polishing Cooling
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By Product
PROSES BY-PRODUCT
Degumming Lesitin
Netralisasi
Pencucian
Asam lemak
Steam refining Asam lemak, mono dan digliserida
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DEGUMMING
Pada proses ini minyak dipanaskan dengan penambahan asam fosfat
Perlakuan ini dilakukan jika sebagian besar senyawa berfosfor dapat terhidrasi dan menggumpal/tidak larut
By product dari proses ini adalah lesitin
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NETRALISASI
Netralisasi merupakan perlakuan dengan alkali yang dilakukan pada kondisi tertentu sehingga kehilangan minyak netral (trigliserida) serendah mungkin
Pemurnian fisik (physical refining atau steam refining) merupakan alternatif lain untuk menghilangkan asam lemak bebas
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BLEACHING
Terutama ditujukan untuk menjernihkan Dilakukan dengan pemanasan minyak (80-
180C) tetapi biasanya dilakukan antara 90-120 C.
Pada kondisi tanpa oksigen dengan menggunakan adsorben
Adsorben dapat berupa bentonit, fullers earth, karbon aktif, silika amorf
Tingkat penggunaan adsorben adalah 0.2-2.0% dari berat minyak
Minyak sawit dapat dibleaching dengan pemanasan suhu tinggi tanpa menggunakan adsorben Tek. Peng. Nabati 2 - Teti Estiasih - THP
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DEODORISASI ATAU PEMURNIAN FISIK
Merupakan langkah terakhir proses pemurnian yang bertujuan mendapatkan minyak yang tidak berbau dan daya simpan tinggi
Proses ini terutama bertujuan menghilangkan produk hasil oksidasi yang berperan terhadap bau minyak
Dilakukan dengan pemanasan suhu tinggi (170-250C) pada tekanan rendah dengan menggunakan uap air
Penggunaan suhu yang tinggi (lebih dari 220C beresiko terhadap streomutasi yang biasa terjadi pada asam linolenat
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PEMURNIAN MINYAK SAWIT
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EKSTRAKSI MINYAK SAWIT KASAR (CPO, CRUDE PALM OIL)
Beberapa tahapan ekstraksi minyak dari tandan sawit adalah:
1. Sterilisasi
2. Pelepasan buah (bunch stripping) 3. Digesti
4. Ekstraksi minyak
5. Klarifikasi dan Purifikasi
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Klarifikasi dan Purifikasi
CPO yang diekstrak mengandung air, padatan, dan partikel-pertikel terlarut yang harus dihilangkan
Partikel serat dipisahkan dari CPO dengan melewatkan minyak pada penyaring bervibrasi.
Pasir dan kotoran dipisahkan dengan cara pengendapan
Air dipisahkan dengan cara pengendapan atau sentrifugasi dilanjutkan dengan pengeringan vakum Tek. Peng. Nabati 2 - Teti Estiasih - THP
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Crude Palm Oil
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PEMURNIAN dan FRAKSINASI
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Komponen Minor
Komponen minor dalam CPO adalah fosfolipid, karbohidrat, trace metal, ALB, mono- dan digliserida, sterol, pigmen karotenoid, tokoferol, tokotrienol, produk hasil oksidasi, dan komponen-komponen berbau
Pemurnian mengurangi komponen pengotor yang dapat mempengaruhi mutu minyak akhir dengan tetap mempertahankan tokoferol dan tokotrienol
Proses pengolahan setelah ekstraksi adalah pemurnian dan fraksinasi
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Refining Crude Palm Oil: Unit Processes
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Refining Bleaching Deodorizing of Palm Oil
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Neutralizing, Bleaching, Deodorizing of Palm Oil
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A. PHYSICAL REFINING
Dilakukan dengan steam distillation pada suhu tinggi dan kondisi vakum
Terdiri dari dua tahap utama, yaitu pretreatment dan distilasi
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1. Pretreatment
Dilakukan dengan proses degumming menggunakan asam fosfat dilanjutkan dengan bleaching
Bleaching dilakukan dengan proses adsorpsi pada kondisi vakum, suhu 90-130C, dilanjutkan dengan filtrasi
Pretreatment mengurangi kadar fosfolipid, trace metal, peroksida, dan karotenoid.
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2. Degumming Pretreatment refers to the initial degumming of
crude palm oil with concentrated phosphoric acid and the subsequent adsorptive cleansing with bleaching clay.
Crude palm oil is dosed with phosphoric acid (8085% concentration) at a rate of 0.050.2% (of the feed oil), heated to 90110C, and given a residence time of 1530 min before passing to the bleacher where bleaching earth is added as a slurry.
The earth required ranges from 0.8 to 2.0%, depending on the quality of the crude oil.
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The purpose of the phosphoric acid is to precipitate the nonhydratable phosphatides while the function of the earth is fourfold:
to adsorb the undesirable impurities such as trace metals, moisture, insolubles, and part of the carotenoids and other pigments
to reduce the oxidation products
to adsorb the phospholipids precipitated by the phosphoric acid
to remove any excess phosphoric acid present in the oil after degumming.
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Removal of Phosphoric Acid
Complete removal of residual phosphoric acid in the bleaching stage is also critical as any slip through can result in the rapid rise of free fatty acid content and color of the final RBD oil
As a further assurance, a suitable quantity of calcium carbonate is often added after dosing of the bleaching earth to the degummed oil, to help neutralize the residual phosphoric acid Tek. Peng. Nabati 2 - Teti Estiasih - THP
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3. Bleaching
Bleaching is carried out under a vacuum of 2025 mmHg and at a temperature of 95110C with retention time of 3045 min
The slurry containing the oil and earth is then filtered to recover a clear, light orange color pretreated oil
Usually a small amount of diatomaceous earth is used to precoat the filter leaves to improve the filtration process.
As a quality precaution, the filtered oil is polished through another security filter bag in series, to trap any earth particles that escape through the first filter Tek. Peng. Nabati 2 - Teti Estiasih - THP
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Loss of Oil
This is essential as the presence of spent earth particles in the pretreated oil reduces the oxidative stability of the final RBD oil
The spent bleaching earth from the filter normally contains about 2040% oil, and this is the major source of oil loss in the refining process
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4. Deodorization
The pretreated oil is then ready for deacidification and deodorization.
The pretreated oil is first deaerated followed by heating to 240270C in an external heat exchanger before pumping into the deodorizer, which is kept under a vacuum of 25 mm Hg
Superheated high-pressure steam is now commonly being used,
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Temperatures above 270C are to be avoided to minimize loss of neutral oil, tocopherols/tocotrienols, and also the possibilities of isomerization and undesirable thermochemical reactions
Under such conditions and with the help of stripping steam, the free fatty acids, which were still present in the pretreated oil, are distilled together with the more volatile odoriferous and oxidation products such as aldehydes and ketones, which otherwise would impart undesirable odor and taste to the oil
At the same time, the residual carotenoids present are also thermally decomposed, and the end result is the production of a light-colored, bland RBD palm oil Tek. Peng. Nabati 2 - Teti Estiasih - THP
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Cooling after Deodorization
To maximize the recovery of thermal energy, the hot deodorized oil is heat exchanged against incoming pretreated oil to be cooled down to a temperature of 120150C
Further cooling is effected by water down to 5565C prior to storage
Antioxidant and citric acid, if required, are dosed into the RBD palm oil at this stage
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DALMS/PFAD
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Desirable Quality of Pretreated and RBD Palm Oil from the Factory
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B. CHEMICAL REFINING
Also called caustic refining, chemical refining involves three stages:
(1) gum conditioning and neutralization
(2) bleaching and filtration
(3) deodorization.
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Alkali refining sesuai untuk minyak dengan
kadar ALB tinggi Kelemahan alkali refining: terjadi
penyabunan minyak netral menyebabkan refining loss
Steam refining: hanya menghilangkan ALB sehingga refining loss rendah
Syarat minyak untuk steam refining: kadar fosfatida rendah dan tidak sensitif panas
Sebelum refining: fosfatida harus dihilangkan Tek. Peng. Nabati 2 - Teti Estiasih - THP
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1. Gum Conditioning and Neutralization
The crude oil is heated to a temperature of 8090C. Phosphoric acid of 8085% concentration is then dosed in at a rate of 0.050.2% (of the feed oil)
This serves to precipitate the phospholipids
After this, the degummed oil is further treated with a caustic soda solution
Tek. Peng. Nabati 2 - Teti Estiasih - THP FTP UB
Neutralization A caustic soda solution of about 4 N (or 20 Be)
concentration with a calculated excess (based on free fatty acid content of the crude oil) of about 20%
The reaction between caustic soda and the free fatty acids in the degummed oil results in the formation of sodium soap, which is readily removed by a centrifugal separator
The lighter phase discharged consists mainly of neutralized oil containing 5001000 mg/kg of soap and moisture while the heavy phase is mainly soap, insoluble impurities, gums, phosphatides, excess alkali, and a small quantity of oil loss through emulsification
As an excess of alkali is used, it is unavoidable that a slight loss of neutral oil through saponification also occurs
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Washing
The neutralized palm oil (NPO) is then washed with 1020% hot water to remove traces of soap still present
After another stage of centrifugal separation, the washed oil is then dried under vacuum to a moisture level below 0.05%.
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2. Bleaching and Filtration
The neutralized palm oil is treated with bleaching earth in a similar manner as that described in physical refining
In this case, the earth also removes traces of soap that are present
Tek. Peng. Nabati 2 - Teti Estiasih - THP FTP UB
3. Deodorization The neutralized and bleached oil is then channeled to the
deodorizer in a similar manner to that in the physical refinery
The oil is subjected to distillation at a temperature of 240260C and a vacuum of 25 mm Hg with direct steam injection
Under such conditions, residual free fatty acids, volatile oxidation products, and odoriferous materials are removed together with thermal decomposition of carotenoids
The final product, called neutralized, bleached, and deodorized (NBD) palm oil is then cooled down to 60C and passed through polishing filter bags before pumping to the storage tanks Tek. Peng. Nabati 2 - Teti Estiasih - THP
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Refining Factor
The efficiency of the refining process is estimated by the use of a refining factor (RF)
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Desirable Quality of Freshly Produced Intermediate and Final Products in Alkaline Refining of Palm Oil
Tek. Peng. Nabati 2 - Teti Estiasih - THP FTP UB
FRAKSINASI
Trigliserida utama dalam minyak sawit adalah oleodipalmitin dengan titik leleh 37C dan palmitodiolein dengan titik leleh 19C
Tujuan fraksinasi adalah menghasilkan fraksi olein yang cair (slip melting point 21.6C dan cloud point 8.8C) dan fraksi padat stearin
Fraksi olein digunakan terutama untuk minyak goreng dan minyak masak, sedangkan fraksi stearin digunakan untuk, margarin, shortening, dan minyak goreng
Fraksinasi dilakukan dengan dua proses yaitu dry fractionation dan detergent fractionation
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Fractionation and PMF
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Fatty Acid Compositions (%)
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Melting and Solidification Characteristics
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Dry Fractionation
Minyak dipanaskan pada suhu 70-75C untuk melelehkan inti-inti kristal
Minyak panas tersebut dimasukkan ke dalam crystallizer dan didinginkan pada suhu 18-20C selama 4-8 jam
Proses ini menghasilkan minyak dalam bentuk sluri
Fraksi padat dan cair dipisahkan dengan filtrasi membran
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Detergent Fractionation
Pada proses ini pemisahkan fraksi padat dan cair dalam sluri dari crystallizer dilakukan dengan mencampur sluri dengan deterjen
Deterjen yang digunakan natrium lauril sulfat atau magnesium sulfat
Pada proses sentrifugasi fraksi olein yang lebih ringan terpisah dari fraksi akueous yang mengandung stearin
Fraksi olein kemudian dicuci dan dikeringkan, sedangkan fraksi stearin direkoveri dari fraksi akueous dan deterjen didaur ulang
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Solvent Fractionation This process is the most expensive because of solvent loss, solvent
recovery equipment, much lower temperature requirement, and stringent safety features
The process involves the use of solvents such as hexane or acetone
The oil is first dissolved in the solvent followed by cooling to the desired temperatures to obtain the desired crystals
The miscella containing the partially crystallized oil and solvent is then filtered under vacuum suction in an enclosed drum filter
The olein miscella and stearin miscella are then separately distilled to remove the solvent and recover the fractions
Yield of olein is about 80%
The solvent process nowadays is only viable in the production of high value products such as cocoa butter equivalent or other specialty fats Tek. Peng. Nabati 2 - Teti Estiasih - THP
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Second Fractionation/ Double Fractionation
Dilakukan untuk mendapatkan superolein dengan titik leleh dan titik kabut rendah dan bilangan iodin tinggi
Palm Mid Fraction (PMF) diperoleh sebagai fraksi stearin dari fraksinasi kedua ini
PMF lebih lunak
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Jenis Asam Minyak Sawit dan Fraksinya
Jenis Asam Lemak
Refined
Palm Oil
RBD Palm Olein
RBD Olein (Double Fractionation)
RBD Stearin
PMF
Laurat 0.2 0.2 0.1 0.3 0.1
Miristat 1.1 1.0 1.0 1.5 1.2
Palmitat 44.0 39.8 36.6 52.0 51.0
Palmitooleat 0.1 0.2 0
Stearat 4.5 4.4 4.0 4.9 5.6
Oleat 39.2 42.5 44.8 33.3 34.0
Linoleat 10.1 11.2 12.6 7.6 7.4
Lunolenat 0.4 0.4 0.2 0.1 0.1
Arakhidat 0.4 0.4 0.7 0.3 0.6
Jenuh 50.2 45.8 42.4 59.0 58.5
MUFA 39.2 42.5 44.8 33.3 34.0
PUFA 10.5 11.6 12.8 7.7 7.5 Tek. Peng. Nabati 2 - Teti Estiasih - THP FTP UB
Krakteristik Minyak Sawit dan Fraksinya
Karakteristik Refined
Palm Oil
RBD Palm Olein
RBD Olein (Double Fractionation)
RBD Stearin
PMF
Bil. iodin 53.3 58.0 61.4 44 42.5
Slip melting point (C)
36.0 21.6 19.0 44-56
Solid Fat Content (%)
5C 62.2 51.1 67.2
10C 50.3 37.0 16.7 61.2 76.1
15C 35.2 19.2 5.0 53.1 66.2
20C 23.2 5.9 3.1 43.4 52.1
25C 13.7 33.9 21.9
30C 8.5 27.0 18.3
35C 5.8 22.2 13.4
40C 3.5 17.3 7.9 Tek. Peng. Nabati 2 - Teti Estiasih - THP
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QUALITY ASSURANCE
The two main quality problems associated with palm oil are hydrolysis, leading to formation of fatty acids, and oxidation, leading to rancidity
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Hydrolysis
The hydrolysis of palm oil is promoted by the presence of free moisture and heat and also by lipolytic enzymes endogenous to the plant tissue
This mode of deterioration occurs during the bruising of fruits in the harvesting and transportation of the FFB to the mill and also their extended storage under unfavorable conditions
In the case of oil during storage, the hydrolysis is attributed to a chemical reaction that is autocatalytic ith poor cold stability
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Hydrolysis The presence of high FFA in crude palm oil is undesirable:
(1) reduces the yield of RBD palm oil through higher loss of PFAD by-product
(2) reduces the capacity of refining
(3) results in poor bleachability of crude oil and poor stability in the final product
Crude palm oil with high FFA content invariably also contains a high amount of partial glycerides, especially diglycerides
Interactions between the diglycerides and the triglycerides often lead to formation of eutectics resulting in poor crystal formation during fractionation, difficulty in separation of olein and stearin by filtration, and also in production of olein with poor cold stability
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Oxidation
Oxidation of oils and fats is due to prolonged exposure to air
Palm oil is relatively more stable to oxidative deterioration than the polyunsaturated vegetable oils
In the presence of trace metals such as iron and copper, excessive oxidation at the olefin bonds of the oleic and linoleic acids can occur, resulting in rancidity
Highly oxidized crude palm oil is known to have poor bleachability and thus requires more bleaching earth and more severe refining conditions, and the final product will likely be of poor stability
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Quality Assurance Measures in Plantation and Milling
Availability of goodquality crude palm oil is a prerequisite for the production of good-quality refined palm oil products
The criteria for good-quality crude palm oil are:
Low free fatty acid content
Low in oxidation characteristics
Good bleachability
Low in trace metals and insoluble impurities
Moisture content of about 0.150.20%
High in deterioration of bleachability index (DOBI) Tek. Peng. Nabati 2 - Teti Estiasih - THP
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DOBI = Deterioration of Bleachability Index
DOBI, which is defined as the ratio of the uncorrected absorbance values at 446 nm to that at 269 nm, was introduced as a quality parameter to differentiate the refinability of good- and poor-quality crude palm oil
The relation to quality is DOBI >3, good; 2.42.9, fair, and
Quality Control
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Type Action
Raw material Each and every delivery must be carefully inspected to ensure that specifications are met and that the shipment is free from contamination. Good raw material is a prerequisite to good-quality product
FFB handling Minimize bruising and sterilize as soon as possible (24 hr)
Sterilization optimize conditions, avoid overheating, do not mix boiler condensate with crude palm oil
Clarification eliminate water and impurities; use hermetic system
Drying reduce moisture to 0.170.2% before storage
Quality Control
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Type Action In-process materials
Regular analyses of important quality parameters will serve as a check that proper processing has been achieved
Process control Proper processing conditions (dosage of processing aids, temperature, pressure/vacuum, flow rate, etc.) must be closely adhered to and monitored to ensure the oil is processed correctly and to minimize undesirable side reactions. In order to assess process efficiency, the oil losses through spent clay or soapstock (as in the case of alkaline refining only) must also be monitored
Finished products Regular checks on the finished products must be carried out to ensure compliance to quality specifications before the products are permitted for discharge to storage or shipment
Crude Palm Oil Quality
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PENGGUNAAN MINYAK SAWIT dan FRAKSINYA
Palm oil, palm olein, dan palm stearin masing-masing bersifat semisolid, cair, dan solid pada suhu 25C
Karena sifat plastisnya yang luas, minyak sawit digunakan secara luas dalam produk pangan dari yang bersifat cair sampai semisolid seperti margarin dan shortening
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Penggunaan dalam Produk Pangan
Minyak goreng/masak Shortening dan lemak masak Vanaspati (vegetable ghee) Margarin Cocoa butter substitutes Es krim Coffee whitener Lemak untuk bakery dan biskuit Mie instan Filled milk Soup mixes Tek. Peng. Nabati 2 - Teti Estiasih - THP FTP UB
Penggunaan untuk Non Pangan
Oleokimia (asam lemak, fatty alcohols, fatty amines, gliserol, dan metil ester)
Deterjen dan surfaktan Sabun Lilin Pelumas Kosmetik Pelapis kaleng Bahan bakar diesel Plasticizer untuk plastik
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Problem Solving-Small Group Discussion
Suatu perusahaan refinery minyak sawit mempunyai masalah:
1. Stabilitas oksidasi minyak goreng yang rendah
2. Minyak goreng bersifat keruh
3. Warna minyak kecokelatan
4. Aroma minyak yang tidak enak
Apa penyebab masalah tersebut (a), adakah kaitan masalah tersebut dengan kualitas CPO (b), tahap refining mana yang menyebabkan masalah tersebut (c), tindakan koreksi apa yang harus dilakukan (d)
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