October 2014

OVERVIEW OF COCONUT
 Bingkai Lemari Coconut Air Kelapa Dingin
Tempat Buah water Buko Segar / Minuman Segar
Janur Daging Buah Cuka Kelapa
Cuka
Tatakan Daun Kecap Kelapa Pengganti
Kelapa Kelapa Kelapa
Keranjang Sapu Lidi Kue Kelapa Pengganti Dekstrosa Dekstrosa
Sampah Muda Manisan
Sarang Ketupat Manisan Serutan Kelapa Sari Kelapa Nata de Coco
Keranjang Sampah Serutan Kelapa Es Krim
Salad Kelapa Minyak yang
Asinan
dapat dimakan
Bonggol/Kelapa Daging Kopra Minyak Goreng Minyak Goreng
Makanan Ternak
Muda/Ubod Pucuk Daun Buah Bungkil Kelapa Bahan Kimia
In Brine Segar Cat Gliserin
Pelet Kopra Cat
Lumpia Buah Gliserin
Minyak yang
Kelapa Krim Rambut
Jenewer/Gin/ tidak dapat dimakan
VCO Minyak Mentah
Lambanog Minyak
VCO Minyak Rambut
Ragi Sabun Cuci Rambut
Tuba Tuba Manggar Minyak Goreng
Sabun Mandi Krim
Gula Kelapa Coconut cream Shampo Rambut Shampoo
Kipas
Kelapa Lemak
Tua Daging
Kipas Sandal Kelapa Permen Susu Bubuk
Pelepah Ampas Kelapa Sari Susu
Tas Parut Kelapa Minyak Murni Cosmetics
Topi Kering Rendah Lemak
Tangan Susu Iris
Topi Margarin
Margarin
Asbak Biscuits
Asesoris Meja Tepung Santan Susu Kelapa Tepung Santan Biscuits
Batang
Bangku Duduk Santai Kelapa Parut Kering Makaron Kering
Binkai Lukisant Kelapa
Kulit Ari Santan Kelapa Bubuk Susu Susu Kocok
Cawan Kue Kelapa Kering
Daging Kue Kelapa
Meja Komputer Arang
Kelapa Asbak
Pemberat Kertas Minyak Semi Murni
Perabot Celengan
Tempat Buah Hiasan Dinding
Tempat Klip Ikat Pinggang
Tempurung Penggaruk
Tropi Arang
Dan Kreasi Lainnya Kelapa Kancing dan Asesoris Bahan Pembersih
Kotak Perhiasan
Papan Bahan Pemurni
Obat Nyamuk
Genteng Activated carbon Activated carbon Bahan Penyerap
Kayu Balok Penyaring/Filter Katalisator
Kayu Sendok
Gelondongan Bahan Tas Tangan
Bangunan Tali Vas Bunga Ikat Pinggang
Papan Kayu Tepung Batok Kelapa
Bahan Sikat
Keset Obat Nyamuk
Obat-obatan
Bahan Pewarna/ Akar Sabut Carpets
Bahan Celup Insulator
Bahan
Kelapa Isi Jok Kursi Pewarna
Root Beer Batik
Obat-obatan Gantungan Bunga
Patung Kecil

Coconut is very VERSATILE

Coconut Applications
Coconut

Peel out the outer shell (at fibre and inner shell )

Fibre Inner Shell Black Meat

Mattress Activated Carbon Peel out the black part

Black Part Dried Meat White Meat

Coconut Oil Factories Coconut water Coconut Milk Desiccated Coconut

Coconut Virgin Oil

ooilOilOiloilVirgin
Oil
 Variety of coconuts
What differs between variety of coconut?
• Volume of water
• Age of maturity
• Taste of profile
• Physiochemical
properties
• Enzyme activities
Parts of a coconut
 Maturity of coconut
Tender (7-8 months) vs Mature
(10-12 months)
 Weight of Various Parts of Coconut
(Laguna Tall) at Different Stages of
Maturity
► Coconut 7th month 9th month 12th month 15th month
g g g g
• Husk 1,190.0 740.4 518.5 269.0
• Shell 140.0 189.1 156.6 134.3
• Meat 20.3 180.5 244.5 160.4
• Water 425.01 255.0 165.0 35.0
• Total Weight 1,775.3 1,365.0 1,084.6 598.7

• Ref: Banzon, J.A. and J.R. Velasco, 1982. Coconut Production and Utilisation,
Philippine Coconut Research and Development Foundation, inc (PCRDF), Pasig.
M.M., Philippines, p37.

• 1Cavity is completely filled with water.

Traditional Way of preparing coconut
fibre for wet market
Grating and Selling of coconut fibre in
wet market
Small Scale Screw Press for Production
of Coconut Milk in wet market
Sale of Coconut Milk and Fibre
in the wet market
 Traditional Method of Cream
Production in wet market
• Unhygienic
• Non-processed
• Short storage time
• Need refrigeration
• Only for local consumption
 Production and Handling of
Coconut Cream
• Complex product to handle
• Rapid microbial spoilage
• Rapid fat separation in coconut extract
• Rapid fat oxidation (free fatty acid and rancid
taste)
• Heat sensitive with special regards to colour,
flavour, protein instability
Coconut water collecting processes
De-husk coconut

Cracking/Cutting

Filtering

Cooling

Cold Storage

Heating

De-Oil

Pasteurising

Cooling

Cold Storage
 Dehusk coconut –
still protecting the eyes
Cracking coconut for the water
 Cracking/Cutting and
primary filtering processes
Deshelling
Paring
Pared coconut white meat
Cracking/Cutting and primary filtering
processes
Coconut water in to food grade plastic
bag and closed with elastic
Coconut water Keeping/Pre-storage condition
Keeping coconut water in Huge/Bulk storage
tank
De-Oil and Pasteurisation processes
 Group discussion
• 4 groups
• General comments on the process & practices
• Potential quality risks
• Suggestion for improvement
Pasteurised coconut cream processing
Filtration

Standardisation

Deshell Pasteurization

Paring Cooling

Storage
Disintegration Cutting

Cold
Filling
storage
Pressing Coconut milk
collection
 Raw Material Specification
Coconut Milk Coconut Water
Protein % 2.7 - 3.1* 0.1 - 0.2
Fat % 27 - 32 0.1 - 0.2
pH Min 5.8 Not less than 5.6
Dry Matter % 34-40* 5.6 - 6.0
Free Fatty acid % Max 0.8 -
(as Lactic Acid)
Sludge % Max. 0.2 -
Viscosity <100 cps at RT -
Colour Creamy white Clear to turbide
Odour Coconut odour Refreshing
free from rancid or free from rancid or
foreign odour foreign odour

* Subject to confirmation
Raw Material Storage and Handling

Refrigerated storage

Handling of raw material

Inspection and Sorting of Raw Material
Coconut cream and fibre from screw press
Separation of residue fibre from coconut cream

Coconut cream from screw press

Filling of pasteurised cream in pouches
 Pasteurised Coconut Cream
Total Plate Count FFA PV Stability Taste
Samples stored @ 35°C for 48 As (meg. Peroxide
@ 4°C hrs (org/gm) Oleic 02/kg fat)
Before Acid
> 39,000,000 0.18 ND OK
pasteurisation
Immediately
12,000 - - No sep. OK
after
pasteurisation
After 3 days 16,000 0.28 ND S1 sep. OK

After 5 days 13,000 1.91 ND Some sep. OK

After 7 days 12,000 0.68 5.33 Some sep. Slight

rancidity
Note: ND = Not Detected
 Coconut cream/milk
processing

QAM Training LMH-

05/05/2014
 Coconut Cream Process parameters
Coconut creamcollection
Pumping
Heating 63°C
Filtration 100 µm
Pasteurisation 68°C/120 s
Cooling to 8-10°C, Check pH  5.8, dry matter
sludge content, organoleptic quality
Temporary Storage (positive pump pumping)

Stabilizer + Sugar Hot water 70°C (min.

13% of batch size)
Mixing
Cooling 4°C
Pumping Blending: Adjust pH 6.0 - 6.2, DM - 30%
Viscosity < 100 cps, taste temperature < 10°C
10% Sodium Carb. solution
Sterilization: 142°C/10s (4s)
Homo pressure: 150 + 50 bar
Aseptic packaging: Sampling 15 min interval for
sterility tests, viscosity, coding, sealing, pH, taste.
Storage as finished product.
Coconut meat nutrients

What is the fat &

protein% ?
 Design basis for coconut cream
Quantity
Description Unit Case 1 Case 2 Case 3
Avg weight of de-skinned white meat kg 0.304 0.304 0.304
Avg cream recovery yield % 60% 70% 80%
Avg cream recovery per nut kg 0.182 0.213 0.243
Fat content by weight after extraction % 27% 27% 27%
Final fat content required % 24% 24% 24%
Regulated to final fat content per nut kg 0.205 0.239 0.274
Packaging volume1 ml 330 330 330
Filling machine capacity pack / hr 9000 9000 9000
Filling machine capacity L / hr 2970 2970 2970
Number of dehusked nut equivalent nut / hr 14473 12406 10855
Production duration per day hr 20 20 20
Dehusked nut required per day nut / day 289460 248120 217100
1 Example: A3 Compact Flex 330ml – 9,000 packs per hour
 Formula for fat recovery yield

Amount of fat extracted

Fat recovery yield (%) 
Amount of fat in the feed
xy
Yield % 
Avg weight of white meat  fat content %
Yield %  Avg weight of white meat  fat content %
x
y
Where
x : Amount of coconut cream produced
y : Fat content (%) in coconut cream
 Critical parameters for
coconut cream processing
Filtration

Pasteurization

Deshell Cooling

Paring Storage

Aseptic
Disintegration Cutting Blending
Processing

Pressing Coconut milk

collection
 Coconut cream Process Steps
• Raw material quality is vital for cream
quality
• Foaming during fibre separation can be an
Cream issue
collection
• Pasteurization and cooling to reduce
bacteria activities
Pasteurisation
• Minimize air intake in storage and blending
• Choice of direct and indirect system
Formulation
depending on taste profile and product
formulation
UHT Treatment • Direct system is recommended for quality
cream
Packing
 Commercial Products of
Unsweetened Coconut Cream

Total FFA % (as Total

Product Protein
pH Solids Fat % lauric acid) Sugar on Comments
Identification %
% in fat Invert
White; smooth texture, very little
A 5.8 30.54 23.14 0.7 2.39 2.20
temperature
Grey/white: lumpy texture; much
B 6.2 14.43 11.40 2.2 1.21 1.23
separation
Grey/white: lumpy texture; much
C 6.4 13.69 9.31 1.6 1.13 1.53
separation
Greyish; opaque; lumpy texture,
D 6.2 13.89 9.48 0.8 1.11 1.04
much separation
Off-white; opaque; lumpy texture;
E 5.7 13.74 10.20 1.1 1.75 1.61
separation with fat globules visible
White: opaque; smooth texture;
F 6.2 31.10 25.61 0.5 2.50 1.71
very little separation
Greyish; uneven texture; much
G 6.0 25.88 20.28 0.6 1.28 1.6
separation
 TS vs Fat content of coconut cream
TS vs Fat
35
y = 1.1635x + 2.2794
R² = 0.9884
30

25
TS in %

20

TS vs Fat
15
Linear (TS vs Fat)
10

0
0 5 10 15 20 25 30
Fat content in %
Protein vs Fat content of coconut cream
Protein vs fat content in coconut cream
3

y = 0.0797x + 0.498
2.5
R² = 0.868
Protein content in %

Protein vs fat content in

1.5
coconut cream
Linear (Protein vs fat content
1 in coconut cream)

0.5

0
0 5 10 15 20 25 30
Fat content in coconut cream in %
 Factors Influence - Aseptic Process
Engineering System
• Product Composition & formulation
• Viscosity
• Residual fibres
• Protein Coagulation
• Heat Sensitivity & impact on taste
• Final product textures
• Foaming and creaming
• CIP issues
Choice of UHT Plant for coconut cream
processing

Tetra Therm Aseptic VTIS Tetra Therm Aseptic Flex

Direct heat treatment Indirect heat treatment

Comparison of UHT plant for coconut
cream/water
Direct UHT Indirect UHT
Fresher product quality More cooked taste

Recommended for high Generally good for 18% fat content.

fat/viscosity content 22-24% Need more THE for heat transfer
High steam consumption Better heat recovery
Downstream homogenizer Downstream or split homogenizer

Higher maintenance cost Lower maintenance cost with split

homogenizer
Lighter colour for coconut Darker colour
Coconut processing
block chart
Coconut cream
Reception and cooling
Coconut cream
Pasteurization
Coconut cream
Stabilizer preparation and blending
Coconut cream
UHT treatment
Coconut cream
Aseptic storage and filling
Coconut cream
CIP station
Coconut cream
 Direct vs. indirect heating
Coconut cream

Direct UHT Indirect UHT

Not suitable for

high fat content
Limitation High fat content
product due to
high viscosity

Color Lighter Darker

 Coconut cream Processing: Critical Factors
Process Criteria: Reasons: Recommended Methods: Impact on:
Supply should be as fresh
Raw Material as possible, minimum To obtain the best possible Good raw material storage condition
Quality contamination with soil quality of coconut cream Processed in shortest possible time
possible
Quality of
Good hygiene coconut cream
Deshelling and Good hygienic environment
environment and GMP to Avoid contamination - sensory,
paring process Sorting of damaged nuts
minimize microorganism - visual and
- MiBi aspects.
Cleaned coconut meat, Reduce microbiological
Proper washing of coconut meat with
Coconut milk proper shredding loading of milk and
chlorine water and rinsing
extraction machine, minimum heat contamination
Low speed and gentle extrusion
generation from presses Avoid protein denaturation
Causing unsterility and Removed fibres and sludge immediately
Filtration to Avoid big fibres and
increasing microbiological after extraction
remove fibres sludge in product Microbiological
loads Use continuous scrap surface filter
counts and
Low pasteurisation @ 68 -72deg C 2 min minimised in
Reduced microbiological
Low temperature and cooling product to 8-10 deg C for FFA that cause
Pasteurisation loading and avoid protein
pasteurization storage rancidity
contamination
Processed in shortest possible time
Keep microbiological
Low temperature storage Shortest possible time
Formulation & loading low
and short storage time Right mixing equipment and variable
blending Avoid air incorporation
Optimun agitation speed speed control
into product
Obtained commercial
Direct UHT and Indirect with split
UHT Treatment sterility and avoid Sterilized product Shelf life
homogenisation150/50 bar
product browning,
Final product
As low ambient Minimise browning and
storage Ideally 25°C and below
condition taste quality changes
temperature
 General Guide to Coconut Water Processing

Extraction and Filtration Chilling and addition of Pasteurisation and Blending

Anti-oxidants Separation

Aseptic Filling Aseptic Storage UHT Treatment

Existing Coconut Processing in the region
and desiccated coconut Dehusked
Coconuts

Deshelling Shells Fuel/Activated Carbon

Animal Feed
Paring Reject Nuts + Parings
Coconut Oil

BY customer Cutting Coconut Water

Disintegration

Pressing Drying Desiccated Coconut

Coconut Milk

Coconut Milk Collection Collection

Heating Filtration Filtration

Concentration Skim milk Pasteurisation Pasteurisation

Phase Inversion Cooling Cooling Cooling

Purification Storage Storage Storage

Heating Skim milk Coconut Milk Coconut Water

Drying Blending

Polishing Sterilisation

Cooling Aseptic Packaging

Storage

Virgin Oil Coconut Water

Coconut Skimmilk
Coconut Cream
 Potential Sources of Raw Matured Coconut
Water Supply
• Coconut cream producers
– Major producers in Thailand, India, Malaysia, Philippines
and Indonesia
– Coconut water is recovered
– Recovery yield ???
• Desiccated coconut producers
– Major producers in India, Indonesia and Philippines
– Coconut water is recovered
– Recovery yield ???
• Coconut oil producers
– Major producers in India, Indonesia and Philippines
– Coconut water mostly untapped
– How are they going to collect the water & maintain quality???
• Small farmers
– Coconut producing countries
– How to collect the coconut water & maintain quality???
 Issues with traditional set up on
coconut water processing
• Most existing plants
– were designed with focus for coconut
cream and desiccated coconut
production
• Lacking focus on coconut water
– coconut water recovery
– quality of coconut water
– not designed for young coconut water
• Coconut water for copra oil production is
not tapped
 Ways to improve Coconut Water Supply
• Existing coconut cream and desiccated coconut
producers
– recover water from coconut by drilling prior to
deshelling
– improve recovery of coconut water
– better focus on pre-treatment and processing

• Collection centre
– Collect coconut water from collection centre
– chilled and transport by truck to processing
plant
– delivery time and product temp can be issues.
– Small capacities
– Long buffer and waiting time
 New Avenue for coconut water supply – raw
material from copra processing
Dehusked Coconuts

quality check

water extraction

Coconut water recovery

Fitration Deshelling waste for waste heat boiler

Buffer tank Size reduction

Pasteurisation/separation Drying

Cooling Copro oil production

Potential
Storage opportunity
for coconut
Blending
water supply
UHT

Filling
 Benefits of new avenue and
plant design

• Plant designed for coconut water

• Focus on quality of coconut water
• High recovery of coconut water
• Good control of quality of raw material
• Short processing time
• No issue with water clarity or turbidity
• Low losses in separation
• High overall plant efficiency and low losses
 From plantation to consumer

Local Tetra Pak Processing Solutions Tetra Pak

systems Packaging Solutions

Harvest/ Filtration
collection

Dehusk Pasteurization

Deshell Cooling

Paring Storage

Coconut water Aseptic

Disintegration Cutting Blending
collection Processing

Pressing Coconut milk

collection
 Coconut
processing
block chart:
Coconut water
Reception and cooling
Coconut water
Pasteurization and separation
Coconut water
Blending: Coconut water
UHT treatment: Coconut water
Aseptic storage and filling: Coconut water
CIP station: Coconut water
 Direct vs. indirect heating
Coconut water

Direct UHT Indirect UHT

Colour Lighter Darker

Taste Lighter coconut taste Light caramelic taste

Longer shelf life

Shelf life (using colour as
limiting factor)
 Direct vs. indirect heating: Trial
Direct vs. Indirect heat treatment
-Significantly different taste profiles
-Indirect slightly more yellow than direct samples but difference is not
significant initially.
-Difference is significant after three months at ambient storage

Direct Indirect Direct Indirect Direct Indirect

Day 1 Day 35/ ~ one month Three months

 Generic Formulation for Coconut Water

INGREDIENTS %
Coconut water 98.777
Antioxidant (added immediately after extraction) 0.003
Vitamin C 0.02
Fructose 1.2
TOTAL 100
 Enzymes Causes of Browning & Pinking

1. Enzymatic browning & Non-enzymatic

oxidation
• Greatest concentration in plants 2. Maillard Reaction - Melanoidins
– Found in coconut husk, meat and 3. Intermediate Pink compounds
water 4. Leucoanthocyanin  anthocyanin
– Introduced into water during
extraction
• Catalyze 2 different reactions with
Enzymes
a large number of phenols with the
presence of oxygen
• Benzoquinone is unstable and Polyphenol Peroxidase
undergoes further oxidation to give oxidase (PPO) (POD)
brown discoloration
• Enzymes optimum at pH 6.0 (25°C)
and pH5.5 (35°C)
• Heat above 90°C with addition of
antioxidants helps to deactivate
enzymes
Effect of pH on the Relative Activity of PPO & POD in Green
Coconut Water
pH Enzyme Activity (%)
PPO POD
3.5 74.5±1.7 74.1±0.2
4.0 80.0±0.5 78.3±0.8
4.5 82.5±0.7 82.5±0.6
5.0 91.2±1.2 91.3±1.2
5.5 94.1±1.0 100.0±1.0
6.0 100.0±0.3 77.0±0.2
6.5 72.2±1.1 55.0±1.6
7.0 57.6±0.2 44.1±0.8
7.5 40.7±0.3 31.2±0.9
8.0 22.5±1.5 17.0±0.5
8.5 15.0±0.8 3.2±0.4

Activity is relatively to maximum activity at the optimum pH: 6.0 for PPO & 5.5 for POD
 pH of the Coconut Water of Tall, Dwarf
and Hybrid Varieties

Coconut Variety pH

Young Mature

Malayan Tall 4.7 5.2

West African Tall (Côte d’Ivoire) 5.1 5.5

Malayan Yellow Dwarf 5.2 5.8

Equatorial Green Dwarf 5.0 5.4

Malayan Yellow Dwarf × West African Tall 5.2 5.2

Effect of Temperature on the Relative Activity of PPO
& POD in Green Coconut Water
Temperature (°C) Enzyme Activity (%)
PPO POD
5 46.0±0.5 39.0±0.9
15 95.0±0.4 64.0±0.7
25 100.0±1.0 84.0±1.1
30 95.7±0.7 92.0±2.0
35 91.3±1.2 100.0±1.2
40 87.0±0.9 91.7±1.5
50 69.0±0.7 75.0±1.8
60 39.0±1.3 24.0±1.9

Activity is relatively to maximum activity at the optimum temperature: 25°C for PPO & 35°C for POD
 Initial Enzymatic Activity Tender & Enzymes
Mature Coconut
Peroxidase
Polyphenol (POD)
oxidase (PPO)

Tender Coconut Mature Coconut

Enzymatic Activity
Water Water
POD Enzymatic
Activity 0.052 ± 0.011 0.078 ± 0.018
(U mL-1 °Brix-1 min-1)
PPO Enzymatic
Activity 0.543 ± 0.163 0.126 ± 0.040
(U mL-1 °Brix-1 min-1)

PPO has higher enzyme activity than POD

 Deactivation of enzymes
• Complete deactivation of enzymatic activities require
95deg C and 5-10 min
• Do we need to have complete deactivation???
• Is deactivation really necessary?
• If not, how to overcome the browning and pinking?

Relative enzymatic activity at different

temperature vs time graph

(□) 80 °C

(△) 90 °C (◇) 85 °C

(○) 95 °C
 Critical parameters of coconut water processing

Filtration

Harvest/ Collection and

collection cooling

Enzyme
Dehusk deactivation

Separation
Deshell

• Freshest supply
Paring Cooling
possible
• Discard bad nuts
• Proper handling to
Cutting Coconut water
Storage
prevent cracks in nuts
Gentle
Blending
 Critical parameters of coconut water processing

Filtration
•Proper handling to prevent premature exposure of water to environment
•Minimise contamination during cutting stage
Collection and
Harvest/
collection cooling

Enzyme
Dehusk deactivation

Separation
Deshell

Paring Cooling

Storage
Cutting Coconut water

Gentle
Blending
 Cooling, N2 sparging and addition of
antioxidants
• To minimise microbiological growth and enzymatic and non-enzymatic
oxidation

Causes of Browning & Pinking

1. Enzymatic browning & Non-

enzymatic oxidation

2. Intermediate Pink
compounds
Micro-organisms can be found
everywhere...
Browning versus antioxidant concentration

Different antioxidants have different

antioxidant effect on coconut water
Critical parameters of coconut water processing

Filtration

• Cool and deactivate

Harvest/ Collection and enzymes to minimise
collection cooling deterioration reactions
• Remove fats with
Enzyme separation stage to
Dehusk deactivation prevent rancidity

Separation
Deshell

Paring Cooling

Storage
Cutting Coconut water

Gentle
Blending
 Hermetic Separation

• Closed system
• Remove residual fat from coconut water to prevent
rancidity
- Mature coconut water has higher fat content than
tender coconut water
• Remove contaminants from coconut water
• Hermetic system to prevent incorporation of air
 Turbidity meter – Hach 2100N IS in NTU

• Max value 500 pt/co (platinum-cobalt

scale). The requirement was to be below
300 pt/c

Expected clarified coconut water below100 NTU

 Colorimeter – Hach DR/890 for colour
measurement

Max value 500 pt/co (platinum-cobalt scale).

The requirement was to be below 300 pt/co.
 Other quality meter

• Fat content measured by Gerber method

• Sludge content by TP Spin test at 1500 G for
10 min
Critical parameters of coconut water processing
Filtration

Harvest/ Collection and

collection cooling

Enzyme
Dehusk deactivation

Separation
Deshell

• Cool to minimise
Paring Cooling deterioration reactions
• Minimise storage time –
minimise time from
Storage extraction to aseptic
Cutting Coconut water packing
• Prevent air
Gentle incorporation with
Blending gentle agitation
 Gentle blending
• Addition of ingredients for flavoured variants of
coconut water
- sugar, concentrates, juices ...etc
• Gentle agitation - Prevent incorporation of air
 Step by step
Ultra-high temperature(UHT) treatment
• Two systems – direct and indirect
 Mature coconut water: Trials

• 1) Effect of N2 used for aseptic tank

N2 vs compressed air
 Effect on coconut water with
Direct vs Indirect heat treatment
Mature coconut water
• Significantly different taste profiles
• Indirect slightly more yellow than direct samples but difference is not
significant initially.
• Difference is significant after three months at ambient storage

Direct Indirect Direct Indirect Direct Indirect

Day 1 Day 35/ ~ one month Three months

Critical parameters of coconut water processing
Filtration

Harvest/ Collection and

collection cooling •Storage temperature

Enzyme
Dehusk deactivation

Separation
Deshell

Paring Cooling

Storage
Cutting Coconut water

Gentle
Blending
 Coconut Water Processing: Critical Factors
Critical Factor: Criteria: Reasons: Recommended Methods: Impact on:
Supply should be as
To obtain the best possible Liaise with suppliers, inspect nuts and discard the
Quality fresh as possible, as
quality of coconut water bad nuts
clean as possible
Vacuum extraction system (tender), Filter, collect
Prevent flesh, husk water in smaller batches and discard conta-minated
Minimise introduction of Quality of
and spoiled water water. Recommended to have continuous scrap
Extraction browning enzymes and coconut water
from entering bulk surfaced filter.
microorganisms - sensory,
tank Antioxidants added from the start of water
- visual and
collection 30-50ppm
- MiBi aspects
Hermetic separation: clarifier for young coconut and
Minimise introduction of
Removal of fat and separator for matured coconut
browning enzymes and
Separation other particles and Recommended to separate the coconut water
microorganisms
fines immediately after cooling to 4 deg C to remove also
and prevent rancidity
all contaminants
N2 injection in process line and aseptic tanks
Oxygen
As low as possible Minimize enzyme activity Antioxidants adding to maintain concentration
exposure
when necessary
Colour of
Minimize enzyme activity*
Temperature As low as possible Immediate cooling to ≤4°C coconut water
and Maillard Reaction rate

Total theoretical deactivation temp/time for

*Enzyme Prevent enzymatic POD – 2.5 minutes
reactions - browning reactions as Minimize enzyme activity* PPO – 5.0 minutes
browning much as possible Exact time and temp depending on quality of raw
material. Std TP practise is 75°C /1min
UHT Treatment Obtained commercial
Direct /Indirect UHT140 °C 4sec
And Aseptic sterility and avoid Sterilized product Shelf life
Use N2 instead of compressed air for AT
tank product browning
Final product
Minimise browning and
storage As low as possible Ideally 25°C and below
taste quality changes
temperature
Process Steps for Young Coconut Water in
Brazil 1(2)

Green Coconut

Water extraction
manual or machine

Ascorbic acid or
sodium
Small tank metabisulphite
(BTD)
Nitrogen injection

Cooler / PHE
5°C

Small storage tank

(weight)
 Process Steps for Young Coconut Water in Brazil
2(2)
Storage & mix tank
(5-7°C)

Black
Clarifier
specs
Nitrogen
injection

Formulation tank
Sodium
(5-10 m3)
metabisulphite
(5-7°C)

Nitrogen
injection
UHT / TA Flex
(140°C-4 sec)

TP Filling machine
Process Steps for Coconut Water
Formulation from Concentrate
Coconut Dilution
water Fructose water
concentrate

Dilution tank

Formulation tank
(5-10 m3)
(5-7°C)
 Concentrated coconut water

• Some companies in Brazil mix concentrated coconut water

(produced in far states and transported frozen or in aseptic
bags) with fresh/raw coconut water just
extracted in production plant.
• The concentration is made using
reverse osmosis plus evaporation
(under vacuum).
• Because low availability of coconut
fruit and water (high demand) all
concentrated coconut water are
used by own producers.
Coconut Water – Storage & Washing
Coconut Water Extraction Machine
(160 Fruits/Minutes maximun)
Coconut Water Extractor
Original coconut extractor design
Improve version of coconut extractor design

Side View Front View

Capacity : 16 rpm x 10 fruits per cycle

8,640 fruits per hour with
90% efficiency
Liquefied Nitrogen Storage & Gasifier

Gasifier
 Nitrogen Injection and Flow Control

N2 in-line injector

N2 gas rotameter &

pressure control
 Summary for Coconut
Water Processing

• Use of anti-oxidants from start of extraction and

blending
• Use of N2 injection and blanketing to minimize
oxidation is added advantage
Extraction
• Pasteurization to deactivate enzyme activities is
recommended,
Pre-treatment • Young coconut water with good GMP and quality,
can do without the pasteurization as in Brazil
process
Formulation • Use of hermetic separator for skimming of fat in
matured coconut water
• Choice of direct and indirect UHT system is
UHT Treatment depending on customer preference

Packing
 What is Virgin Coconut Oil (VCO)?
• Virgin coconut oil is obtained from fresh, mature coconut kernel by
mechanical or natural means with or without the application of
heat, which does not lead to alteration of the nature of the oil

– The purest form of VCO is near colourless, free of sediment

with natural fresh coconut scent
– It is also free from rancid odour or taste
– It contains natural Vitamin E
– It has very low free fatty acid (FFA) content (even without
refining) and low peroxide value
Coconut Virgin oil and coconut juice Processing
 Business opportunity

• Increase demand in CVO, may not be in bulk

• Big market of coconut juice in China
• Enhance coconut juice quality with blend of
coconut water and skimmed coconut milk
• Potential market in China, Korea and Japan
What issues have you encountered for
coconut cream and water?
 Coconut water issues

• Turbidly and clarity.

• High wastage while operating the separator.
• Colour change.
 VTIS coconut cream issues
• Cleaning issue where tubular heat exchanger has
product residue after CIP.
• Temperature issue where temperature is unstable
that cause temperature fault.
• Vacuum Flash Vessel vibration.
• Homogenizer piston and piston seals quick wear-
out.
• Homogenizer inlet pipe difficult to clean due to
bigger pipe diameter.
• High viscous coconut cream > 275cp affecting pump
performance after S-Vacuum Flash Vessel.
• Sterility issue.
 Alsafe issues for coconut cream
• Due to viscous coconut cream then the filling
pressure to AFM will be higher than the non-
viscous product. Higher filling pressure still
not able to solve under-filled package then
filling pipe has to increase.
• End valve cluster pipe will not be clean when
Alsafe operates more than 24hrs with steam
barrier. To overcome longer operation time for
Alsafe then steam condensation should be
used instead of steam barrier.
• Alsafe side-inlet is not able to clean.
 Key components for coconut
processing
• Coconut water reception unit
• Tetra Centri – AirTight separators
• Tetra Almix – Inline mixer
• Tetra Plex – Plate heat exchanger
• Tetra Spiraflo – Tubular heat exchanger
• Tetra Alex – Homogenizer
• Tetra Alrox – Deaerator
• Tetra Therm Aseptic VTIS – Steam injection
• Tetra Alsafe – Aseptic storage tank
Thank you