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Sunflower seed pretreatment and pressing process
1.sunfower seed pretreatment:
Flowchart
light impurity Big impurity small stone,clay cake→solvent extraction
↑ ↑ ↑ ↑
sunflower seed→Wind screen→Screening→Destoner→Flaker→Roasting→pressing→crude sunflower oil ↓
Refinery
Process specification (optional parts of process)
1. The oil-seed cleaning step
1.1. In process of oil-seed harvesting, drying,transportation and storage,which will mix some impurities such as sand, mud, stems and leaves,iron,etc. If not clear before production, which effect the production process and product's quality. These impurity content contain three categories, inorganic impurities, organic impurities and oily impurity.
1.1.1.Inorganic impurities: mud, sand, dust and metal, etc.
1.1.2.Organic impurities: stem leaf, rope, skin & shell and other seeds.
1.1.3.Oily impurity: immature oil-seed, other's oilseed, non-regulation seed from the sieve bottom , the breakage oil-seed and oil-seed with plant diseases and insect pests, etc.
1.2. Oil-seed cleaning is to remove the above impurities, not only to limit the content of the impurities, as well as control oil-seed content in impurity after cleaning.
1.2.1. Screening: Depend on the different particle size (width, thickness and length) between oil-seed and impurities , with the help of sieve's mesh method for separation of impurities.
1.2.2. Magnetic separation: To use a magnetic removal method to rid off metal impurities from oil-seed.
1.2.3. Water washing: Use water to wash away the surface of oil-seed,including to attaching marl, sand, metal, the water can also effectively prevent the dust floating in the sky. This process is specially important for the fruit kinds oil-plant.
1.2.4. Stone & Mud separation: these tow kinds' shape, size ,weight ,which is nearly equal with oil-seed, normally adopt the Destoner for removing.
1.2.5.Dehulling process: the shell does not contain oil,or less oil,which also effect the oil color,and more shell contain wax,so it is necessary for dehulling process.
2. Oil-seed dehulling , separation of kernel & shell
2.1. the kernel in shell : less than 5%.
2.2. shell contains kernel rate (hand pick) : less than 4%.
3. The oil-seed drying process
To process high moisture of oil-seed dehydration to appropriate moisture (safe moisture10-12%) .
Using drying equipment to produce the hot wind for heating oil-seed, make the moisture evaporation, to control the appropriate moisture of oil-seed for safe storage.
4. Oil-seed flaking process
To use pressure from granular oil-seed into thin slices.
The aim of flaking process, destroy the organization of oil-seed's cells to create favorable conditions for steaming and frying, easily and quickly separating the oil, improve the oil yield.
Basic requirements of oil-seed flaking: thin embryo flake, uniform surface, less powder, not showing oil content on surface, powder are controlled less than 10% - 15%( under the screen hole 1 mm sieve), the thickness of the material embryo to keep to a certain extent,0.25mm orso.
5. Oil-seed conditioning treatment process : two kinds
5.1. Fried seeds at low temperature
Oil-seed Heating is one of the most important in whole extracting oil process.
With the aid of moisture and temperature effect, make the internal structure of oil-seed for big changes,destroying the internal structure of the cells, protein frozen denaturation, segregation and combining the phospholipid and protein.
The changes is not only beneficial to easily separate out more oil from oil-seed, also the improvement of oil quality .
5.2. Oil expanding process
Adopt expanding and extruding method for replacing high temp steaming and frying method,which is new methods, with high temperature in short time, low material protein denaturation, good oil color characteristics.
6. Screw pressing oil process
Low oil-seed pressing temperature, good oil quality and invariance cake protein.
Twin screw press is one kind low temp screw press .
This process get the crude oil for refinery and cake for feed or continusely going into solvent extraction for more oil.
7. The crude oil purification process
Crude Oil Cool water
↓ ↓
settling tank→ plate filter →cooling tank → settling tank →Micr-filter→final oil
Process description
Adopt low temperature filtering method, cooling to 15- 20 ºC,minimize volatilization loss of fragrance.
This method, Filtering out non-hydrophilic phospholipids adequately, make phospholipid content minimum, to improve the stability of the storage time.Also while filtering,because the micr-phospholipids could absorb the color,this filtering process could improve the final oil color.
(1) 1st filtering: Crude oil from settling tank is pump into the filter,to filter out the sludge,then go into for cooling and settling.
(2) 2nd filtering. After cooling and settling, moisture combined with aqueous phospholipids, goes into the Micr-filter for separation out polymerization of phospholipids.
After Micr-filtering , The oil has excellent transparency and improve the sensory index, at the same time, further improve the stability of storage life.
Note: oil yield of kinds of oil seed
|
Oil-seed |
Rape seed |
Peanut kernel |
soya |
sesame |
Cotton seed |
Sunflower seed |
Tung seed |
Jatropha seed |
Palm kernel |
Flax seed |
Rice bran |
copra |
olive |
Corn germ |
|
Oil yield (%) |
35-44 |
35-48 |
12- 19 |
45-50 |
12-18 |
38-41 |
30-38 |
40-45 |
45-48 |
32-42 |
10- 12 |
50-55 |
27-33 |
35-40 |
Sunflower oil refinery Process
1.Sunflower seed oil hydrated
In crude oil most of impurity are phosphorus.
The existence of phospholipid and other colloidal substances can not only reduce the quality of oil, but also promote the transitional emulsification between oil and lye, increase the difficulty of separation of soap and aggravate the loss of neutral oil, so it should be removed first.
2.The deacification of sunflower oil
Mainly to remove free fatty acids from crude oil, as well as a small amount of colloid, pigment and trace metal substances in oil.
De-acid operation is one of the important factors that directly affects the oil yield and quality of oil refined.
The most widely technology method is alkali refinery and deacification.
3.Sunflower oil decolorizering process
The pigment and other impurities in sunflower oil, must be removed out,to meet the product quality standard.
While providing more favorable conditions for deodorization .
The decolorizering method comprises the following steps of: decoloring to obtain the final color index of the product; removing the related pigment and the amount of metal; and further removing the trace amount of soap, the phospholipid and other colloidal impurities and certain off-flavor substances remaining in the oil, removing the polycyclic aromatic hydrocarbon and the residual pesticide, and reducing the oil quality peroxide value.
4.Deodorizer process
The purpose of deodorizing of sunflower oil is to remove the odorous substances and other volatile substances from the oil, to improve the smell and color of the oil, and to improve the stability of the oil.
The peculiar smell of oil, the peculiar smell produced in decolorization, the odor of produced by oil oxidation, etc.
In the deodorization stage, these unpopular odors are required to be removed by steam distillation at vacuum high temperature.
5.Dewax process
Dewaxed deodorized oil is heat exchanged with refrigeration liquid through plate heat exchanger. After the oil temperature drops to 22-25ºC, it is pumped into the stainless steel crystallization tank. Under the action of stirring, the refrigerant is slowly cooled to 18ºC to form crystals.
The crystallization time is about 3 hours.
The oil deodorized is fed into a crystal tank, and the crystal is maintained at a constant temperature of 18 degrees for 3 hours ,then be filtered to obtain the dewax oil.
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