SAIFUL IRWAN ZUBAIRI PMIFT, Grad B.E.M.

B. Eng. (Chemical-Bioprocess) (Hons.), UTM

M. Eng. (Bioprocess), UTM

ROOM NO.: 2166, CHEMISTRY BUILDING,

TEL. (OFF.): 03-89215828,
FOOD SCIENCE PROGRAMME,
CENTRE OF CHEMICAL SCIENCES AND FOOD
TECHNOLOGY,
UKM BANGI, SELANGOR
 PROCES S ING OBJECTIVES

 Preserve active phytochemical ingredients

 Concentrate the active phytochemical ingredients

 Covert the raw material into the most convenient form

 Remove the unwanted materials

 Adding economic value to herb material to satisfy

 To obtain pure phytochemical

 Chart of Classification and Separation of Plant Material Essential Oil (e.g. mono &
Based on Solvent Polarity and Process Esquiterpenes: geraniol, limonese
(Phytochemicals Approach)
Diterpenoids (Phytol, abietic acid)

SFE
(Phytonics: Triterpenoids (Cucurbitacin)
Phytosol)
Terpenoids Carotenoids (β-Carotene, lutien,
Non-Polar
Zeaxanthin, etc)
compound
extraction Terpenoids (e.g. Menthol, carrone, squalene,
Multi Solvent α-Carotene, lycopene)
Extraction
Process
Lipids

Polar Compound Extraction Flavanoid (e.g. anthocyanin-cyanidin, flavanols-

Kaemferol, isoflavanoid-rotenone)

Plant H2O-Glycerol Polar alkaloid (e.g. Ephedrine)

Material Extraction
Sugar & Derivatives (e.g. monosacharide,
filtrate Oligosacharide, sugar alcol)
Fiber Cellulose
Acid
Hydrolysis filtrate Hemicellulose

filtrate Lignin
 Chart of Classification and Separation of Plant Material
Based on Solvent Polarity and Process
(Herbal Approach)

Freeze dried Whole concrete extract

filtrate Solvent
Extract Membrane
Filtration or
Low T vacuum Whole concentrate extract
evaporation

Plant Material
Spray dried
Whole powder extract

Water Freeze dried

Whole freeze dried extract
Extract

Spray dried
Concentrate extract
 EXAMPLES OF
RAW MATERIALS

TEA TREE TONGKAT ALI

PANDAN CITRONELLA

KESUM CINNAMON

EUCALYPTUS CURRY
OVERALL PROCES S ING TECHNIQUES
PRETREATMENT OF HERBS
 PREPARATION OF RAW MATERIAL AND THE
PROCES S ING OF ES S ENTIAL OILS

RAW MATERIAL

EXTRACTION

PRETREATMENT
PROCESS

PURIFICATION
Percolation
Process
Reflux Extraction
Soxhlet Extraction
Steam Distillation
Phytosol Extractor (industrial scale)
PURIFICATION PROCES S ES
 FREEZE DRYING
• Freeze drying is the process of removing water or
other solvent from a frozen product by sublimation.

• Conventional drying cause the

material to shrink, damaging the
cells while in freeze drying
process, the solid components
are held in place by rigid ice.

• Freeze drying is also used to

prepare tissue samples for
electron microscopy.
 S PRAY DRYER
• SPRAY DRYING is the most widely used industrial process
involving particle formation and drying.

• Highly suited for the continuous production of dry solids in either

powder, granulate or agglomerate form liquid feed stocks as
solutions, emulsions and pump able suspensions.

• Spray dryer involves the atomization

of a liquid feedstock into a spray of
droplets and contacting the droplets
with hot air in a drying chamber.
PHYTOCHEMICAL
PROCESSING :
CASE STUDIES
 CASE STUDY I:
Production of Cinnamon Oil from Cinnamon Leaves
Process Flow Chart for Crude Cinnamon Oil Production
Cinnamon Leaves

Drying

Size Reduction

Deionized Water Extraction

(Apply heat & agitation)

Steam is formed carrying

along essential oil

Condensation

Product (Crude Essential Oil)

 CASE STUDY I:
Production of Cinnamon Oil from Cinnamon Leaves
Process Flow Chart for Crude Cinnamon Oil Purification

Crude Essential Oil

Neutralization (pH Control)

Solvent Solubility
Distillation (add solvent)

(using laboratory set) Separation (centrifuge)

Other method: clarifying,
purifying and decanting Evaporation

Product (Essential Oil)

 CASE STUDY I:
Production of Cinnamon Oil from Cinnamon Leaves
Deionized water Condensation Rate :
(5000 kg) 700 kg/hr
1000 kg

Cinnamon Leaf
(1000 kg)

Water + Oil

COARSE GRINDER Leaf + 30% water Water C

1 L 0.5 M NaOH

Oil (15%) Oil (85%)

26 L Cinnamon Oil
Purified
Cinnamon Oil C
(25 L)

Soap
 CASE STUDY II:
Production of Phyto-Extract from Tongkat Ali
Process Flow Chart for Herb Processing – Tongkat Ali
Tongkat Ali

Sizing (Grinding)/Drying
Solvent
Extraction
(Deionized Water)
Filtration EXTRACTION

Concentrate

Product (Concentrate Extract)

Spray Dryer (other product intensification
method can also be used - freeze drying)

Product (Powdered Form)

Packaging
 CASE STUDY II:
Tongkat Ali Production of Phyto-Extract from Tongkat Ali
(40kg) Water Extract
T feed = 70OC
Deionized Water 1.5 brix
(120kg)

EXTRACTOR

T = 120OC HOLDING Hot Air T1 = 170OC

t = 2 Hr TANK 306 kg/hr
T = 170OC t = 7 hrs
T2 = 103OC

SPRAY DRYER
efficiency = 80%
Extract
+ fibre
(40kg)
Evaporation Rate = 12.6 kg/hr
Recovery = 3%
Moisture content = 2%
FILTER Temperature = 700C
efficiency = 56%

Slurry
 CASE STUDY III:
Production of Soybean Powder
Soy bean

Soak (24 hrs)

Solvent
(Deionized Water) Dehulling

Wet Grinding (Soy:

Water 1:4)

Filtration

Soy Extract T = 900C, t = 1 hr

5% Maltodextrin, 1%
Sodium Casienate Spray Dry

Product
 CASE STUDY III:
Production of Soybean Powder
1000 kg Soy
200 kg Maltodextrin

40 kg Sodium 2420 kg Soy Solution

Dehulling Casienate 2 brix

4000 kg 4000 kg extract

Deionized
water
Wet Grinding Hot Air Feed
(2300 kg/ hr)
T1 = 1850C
t = 24 hrs
T2 = 1050C
Filter Press

T = 900C
t = 1 hr
Soy Fiber Evaporation Rate = 100 kg/ hr
Product Flow Rate = 20.16 kg / hr
Recovery = 20 %
Moisture content = 2 %
 CASE STUDY IV:
Extraction of Oleoresin (Curcuminoid) from Turmeric
Process Flow Chart for Production of Cucurminoid
Turmeric

Sizing & Drying

Solvent Steam Distillation Volatile Oil

(Deionized Water)
Wet Turmeric
Packaging

Drying

Fine Grinding

Ethanol Vacuum Distillation

Crystallization

Product (Curcuminoid)
 CASE STUDY IV:Extraction of Oleoresin (Curcuminoid) from Turmeric
Evaporation Rate:
5000 kg Dioinized water
833 kg/hr
OIL
4200 kg water SEPARATOR
+ volatile Oil

1000 Kg Turmeric

Coarse Grinder Water

STEAM 20 kg
DISTILLATION volatile oil
UNIT 800 kg water
+ 1000 kg turmeric

OIL
STORAGE
600 kg
fine turmeric Fine Grinder
DRYER

70% Water
VACUUM
EXTRACTION DISTILLATION Volatile Oil
VESSEL UNIT Packaging

FILTER
UNIT CRYSTALLIZER 24 Kg Curcuminoid
 CASE STUDY V:
Production of Plant-Based Sugar from Stevia
Raw Material

Sizing (Grinding)/Drying
Solvent
Extraction T = 1000C, t = 2 hrs
(Deionized Water)
Filtration

Microfiltration
PURIFICATION
Ultrafiltration

Reverse Osmosis

Maltodextrin Spray Dryer

Product (Stevioside: 66%)

 CASE STUDY V:
Sweet Tea Production of Plant-Based Sugar from Stevia
(100kg)
Water Extract
(400 kg solution + 2 kg maltodextrin)
Deionized Water
T feed = 70OC
(2500kg)
1.5 brix

T = 100OC Hot Air T1 = 170OC

t = 2 hrs 550kg/hr
EXTRACTOR T = 170OC t = 4 hrs
T2 = 103OC

SPRAY DRYER
efficiency = 80%

PURIFICATION
Water Extract (microfiltration,
Ultrafiltration Evaporation Rate = 100 kg/hr
Reverse osmosis) Product Flow Rate = 1.75 kg/hr
Recovery = 5%
Moisture content = 2%
Purity = 66%

Impurities
 CASE STUDY VI:
Production of Pegaga Powder

Pegaga (cleaned and ground)

Water Extract SPRAY DRYER
T feed = 70OC
Deionized Water
5 brix

EXTRACTOR
M EVAPORATOR BLENDING
TANK
Hot Air
M M 306 kg/hr
T = 1200C T = 170OC T1 = 170OC
t = 2 hrs

T2 = 103OC

Water
T = 700C

Recovery = 2% from raw material

Moisture content = 2% max

PLATE &
FRAME FILTER

Process Plant Layout for the Production of Pegaga Powder

 Pegaga

Cleaning

Sizing

Extraction

Evaporation

Blending

Spray Drying

Packaging

Dehydrated
Product

Figure 1: Process Flow for the Production of Pegaga Powder