Combined industrial olive oil extraction plant using ultrasounds, microwave, and heat exchange: Impact on olive oil quality and yield

Innovative technologies to enhance oil recovery

The processes for extracting and refining edible oils are well-established in industry at different scales. However, these processing lines encounter inefficiencies and oil losses when recovering crude or refined oil. Palm oil and olive oil extraction methods are used mainly as a combination of physical, thermal, and centrifugal methods to recover crude oil, which results in oil losses in the olive pomace or in palm oil effluents. Seed oils generally require a seed steam conditioning, and cooking stage, followed by physical oil recovery through an inefficient expeller. Most of the crude oil remaining in the expeller cake is then recovered by hexane. Crude seed oil is further refined in stages that also undergo oil losses. This chapter provides an overview of innovative technologies using microwave, ultrasound, megasonic and pulsed electric field energies, which can be used in the above-mentioned crude and refined oil processes to improve oil recovery. This chapter describes traditional palm oil, olive oil, and seed oil processes, as well as the specific process interventions that have been tested with these technologies. The impact of such technology interventions on oil quality is also summarized.

A review on application of ultrasound and ultrasound assisted technology for seed oil extraction

Oil has extensively been extracted from oil-bearing crops and traded globally as a major food commodity. There is always a huge demand from the fats and oils industries to increase oil yield because of profitability benefits. If extraction is conducted under mild operating conditions to preserve and improve the oil quality, then it would be an added value. Ultrasound that works on the cavitational action helps to fulfil the gap. Ultrasound is gaining tremendous interest as an alternative to replace the current conventional extractions approach because of its multiple benefits. Cavitation generated by ultrasound eases the release of oil from cell matrices, thereby allowing the extraction to be carried out under mild processing conditions. The effect enhances the oil yield whilst preserving the quality of the oil. In ultrasound, green solvents can be used to replace toxic organic solvents. Recent up-to-date approaches utilised a combination of ultrasound with enzyme, microwave and supercritical technology to further enhance the oil extraction. This review highlights a comprehensive work of the impact of ultrasound and ultrasound in combination with other technologies on oil extraction, which emphasises the extraction yield and physicochemical properties of the oil, such as fatty acid composition, oxidative stability with the retention of the lipophilic phytochemicals and iodine, saponification values and colour parameters. Understanding of ultrasonication techniques for oil extraction served to be essential and useful information for the fats and oils scientists from academia and industries to explore the possibility of employing a sustainable and mild approaches for extracting oil from various crops.

Effect of Controlled Oxygen Supply during Crushing on Volatile and Phenol Compounds and Sensory Characteristics in Coratina and Ogliarola Virgin Olive Oils

In virgin olive oil industries, the technological choices of the production plant affect the biochemical activities that take place in the olives being processed throughout the entire process, thereby affecting the quality of the final product. The lipoxygenase pool enzymes that operated their activity during the first phases of the process need the best conditions to work, especially concerning temperature and oxygen availability. In this study, a system was equipped to supply oxygen in the crusher at a controllable concentration in an industrial olive oil mill at pilot plant scale, and four oxygen concentrations and two cultivars, Coratina and Ogliarola, were tested. The best concentration for oxygen supply was 0.2 L/min at the working capacity of 0.64 Ton/h. Further, using this addition of oxygen, it was possible to increase the compound's concentration, which is responsible for the green, fruity aroma. The effect on volatile compounds was also confirmed by the sensory analyses. However, at the same time, it was possible to maintain the concentration of phenols in a good quality olive oil while also preserving all the antioxidant properties of the product due to the presence of phenols. This study corroborates the importance of controlling oxygen supply in the first step of the process for process management and quality improvement in virgin olive oil production.

Comparison of four classification statistical methods for characterising virgin olive oil quality during storage up to 18 months

This study examines the ability of fluorescence spectroscopy for monitoring the quality of 70 Moroccan virgin olive oils belonging to three varieties and originating from three regions of Morocco. By applying principal component analysis and factorial discriminant analysis to the emission spectra acquired after excitation wavelengths set at 270, 290, and 430 nm, a clear differentiation between samples according to their storage time was observed. The obtained results were confirmed following the application of four multivariate classification methods: partial least squares regression, principal component regression, support vector machine, and multiple linear regression on the emission spectra. The best prediction model of storage time was obtained by applying partial least squares regression since a coefficient of determination (R²) and a root mean square error of prediction (RMSEP) of 0.98 and 24.85 days were observed, respectively. The prediction of the chemical parameters allowed to obtain excellent validation models with R² ranging between 0.98 and 0.99 for free acidity, peroxide value, chlorophyll level, k₂₃₂, and k₂₇₀.

A Review on High-Power Ultrasound-Assisted Extraction of Olive Oils: Effect on Oil Yield, Quality, Chemical Composition and Consumer Perception

The objective of this review is to illustrate the state of the art in high-power ultrasound (HPU) application for olive oil extraction with the most recent studies about the effects of HPU treatment on oil yield, quality, chemical composition, as well as on the consumer's perception. All the examined works reported an increase in oil yield and extractability index through the use of HPU, which was ascribed to reduced paste viscosity and cavitation-driven cell disruption. Olive oil legal quality was generally not affected; on the other hand, results regarding oil chemical composition were conflicting with some studies reporting an increase of phenols, tocopherols, and volatile compounds, while others underlined no significant effects to even slight reductions after HPU treatment. Regarding the acceptability of oils extracted through HPU processing, consumer perception is not negatively affected, as long as the marketer effectively delivers information about the positive effects of ultrasound on oil quality and sensory aspect. However, only a few consumers were willing to pay more, and hence the cost of the innovative extraction must be carefully evaluated. Since most of the studies confirm the substantial potential of HPU to reduce processing times, improve process sustainability and produce oils with desired nutritional and sensory quality, this review points out the need for industrial scale-up of such innovative technology.

Cold Storage and Temperature Management of Olive Fruit: The Impact on Fruit Physiology and Olive Oil Quality—A Review

Cold storage of olive fruit has been the subject of study for over more than 50 years. From the 1990s on, an increasing amount of knowledge is build-up about the impact of the conservation on the physiological response of the fruit as well as on the quality of the extracted oil therefrom. This review offers a comprehensive synopsis of this research, discusses the most important influential factors and summarizes the results on the influence of the studied parameters on both the fruit and the oil. Currently, changing climatic conditions, new harvesting techniques and a more demanding consumer market are triggering the need to broaden this strict focus on conservation. A more dynamic view on the effects of temperature from the moment the fruit is harvested up to the oil extraction process, reveals the necessity to manage this crucial influential factor more diversely. An overview of how this management can take form is structured through a focus on the different phases of the postharvest processing and the widely different harvesting scales. Future prospects of research are presented based on the actual state of the art of cold storage research as well as on the necessities that come forward from a broader fruit temperature management perspective.

Development of a Pressure Control System According to Paste Rheology for Ultrasound Processing in Industrial Olive Oil Extraction

Recent research has demonstrated how ultrasound can benefit the industrial processing of olive paste before oil extraction. However, the absence of a device for controlling pressure inside the sonication cell is a major hindrance to its application. To address this problem, a pneumatic device with a programmable logic controller was implemented to automatically adjust pressure in the sonication cell according to a preset value: its functionality was tested in industrial oil extraction. An experiment was conducted to compare device performance when applied to olive batches with different solid/liquid ratios and differing rheology. The control system adjusted the flow section of the valve at the outlet of the sonication cell and the mass flow rate of the feed pump in order to maintain the pressure preset by the operator. Results indicate that the pressure was 3.0 ± 0.2 bar, 3.5 ± 0.2 bar, and 4.0 ± 0.2 bar when the set point was 3.0 bar, 3.5 bar, and 4.0 bar, respectively: there was thus no significant difference between controlled and set values. This indicates that the device is able to control pressure inside the sonication cell with a maximum deviation of 0.2 bar. In this case, the sonication intensity was stabilized at 135 W/cm2, 150 W/cm2, and 165 W/cm2 at 3.0 bar, 3.5 bar, and 4.0 bar, respectively. This study presents an advancement in ultrasound applications for industrial olive oil extraction: optimal pressure control in the sonication cell.

Assessment of the olive oil extraction plant layout implementing a high-power ultrasound machine

The objective of this study is to assess the effects of installation and operation of a high-power ultrasound machine (HPU) for the treatment of olive paste by using ultrasound technology in order to evaluate the best way installation and the best definition of the operating conditions of the machine. The study was conducted installing in an industrial olive oil mill a continuous processing ultrasound machine, which used a frequency of 20 kHz able to work at 3200 kg h^-1 as feed capacity. Checking of performance has been carried out by the assessment of the different operating and process conditions, assessing in particular the impact of the ultrasound treatment before and after the malaxation phase on performance indicators of the continuous olive oil plant (plant extractability, olive paste rheological characteristic) and on selected chemical properties of the olive oil extracted (quality parameters, antioxidant content, and volatile profiles). In the tested conditions, high-power ultrasound treatment did not produce significant effect on the legal parameters (free acidity, peroxide index and spectrophotometric indexes), while a significant increase in the content of phenolic compounds was generally observed; higher enhancements were more evident when the high-power ultrasound treatment was carried out before the malaxation phase.

Preliminary study on the potential application of Fourier-transform mid-infrared for the evaluation of overall quality and authenticity of Moroccan virgin olive oil

BACKGROUND

Olive oil provides a wide range of health-promoting compounds. The quality of olive oil is an even more complex concept as it is affected by several factors, such as variety, season, stage of maturation, extraction processing, and so on. The main objective of this study was to determine the potential of chemical and mid-infrared spectroscopy techniques to determine the quality and authenticity of virgin olive oil (VOO). For this, we studied 41 VOOs originating from five regions of Morocco (Fez/Meknes, Eastern, Northern, Beni-Mellal/Khenifra, and Marrakech/Safi) and produced using different agricultural and technological conditions during two successive crop seasons (2015-2016 and 2016-2017).

RESULTS

By applying principal component analysis and factorial discriminant analysis with leave-one-out validation to the mid-infrared spectroscopy, clear discrimination between VOO samples according to their geographic origin and variety was observed, with correct classification rates of 91.87% and 91.87% being observed respectively. The application of partial least-squares regression to mid-infrared and chemical data sets allowed excellent prediction of free acidity, peroxide value, k₂₇₀ , and chlorophyll level with R² of 0.99, 0.97, 0.98, and 0.93 respectively, and good prediction of k₂₃₂ (R² = 0.84).

CONCLUSION

The results demonstrate that mid-infrared spectroscopy coupled with chemometric tools could be used as a rapid screening tool for evaluating the overall quality and authenticity of VOO. © 2020 Society of Chemical Industry.

Adjustment of Olive Fruit Temperature before Grinding for Olive Oil Extraction. Experimental Study and Pilot Plant Trials

Harvesting at high temperatures and bulk transport can negatively influence the quality of olives and lead to undesirable alterations in the extracted oil. Cooling the fruit in the field would be the most logical solution, but it means that the olives arrive too cold at the mill for immediate processing. In this work, the use of warm water in the washing tub to warm up the fruit before grinding instead of flash heat treatment on the paste was assessed in two experiments. In the first one, at the laboratory level, the temperature after milling was determined in three olive cultivars, previously stored at 5 or 10 °C, and then submerged at different water temperatures (25, 30, and 35 °C) for 15, 30, 45, and 60 s. In the second one, two batches of olives were cooled in the field at 5 °C and then conditioned with washing water to obtain a paste at the entrance of the pilot plant malaxer at 27 °C. The temperature of the olives was measured at five points from the discharging up to their entering, as paste, into the malaxer. The results demonstrated the feasibility of the method as the temperature of the ground olives was kept at the desired temperature (28 ± 1 °C). The trials highlight the potential for automating an even more precise adjustment of the temperature of the olives before milling once the washing tub is equipped with a safe heating system.

Impact of Emerging Technologies on Virgin Olive Oil Processing, Consumer Acceptance, and the Valorization of Olive Mill Wastes

There is a growing consumer preference for high quality extra virgin olive oil (EVOO) with health-promoting and sensory properties that are associated with a higher content of phenolic and volatile compounds. To meet this demand, several novel and emerging technologies are being under study to be applied in EVOO production. This review provides an update of the effect of emerging technologies (pulsed electric fields, high pressure, ultrasound, and microwave treatment), compared to traditional EVOO extraction, on yield, quality, and/or content of some minor compounds and bioactive components, including phenolic compounds, tocopherols, chlorophyll, and carotenoids. In addition, the consumer acceptability of EVOO is discussed. Finally, the application of these emerging technologies in the valorization of olive mill wastes, whose generation is of concern due to its environmental impact, is also addressed.

A preliminary study on the potential of front face fluorescence spectroscopy for the discrimination of Moroccan virgin olive oils and the prediction of their quality

This study examines the feasibility of using front face fluorescence spectroscopy (FFFS) to authenticate 41 virgin olive oil (VOO) specimens collected from 5 regions in Morocco (Fez/Meknes, Eastern, Northern, Beni-Mellal/Khenifra, and Marrakech/Safi) during 2 consecutive crop seasons (2015-2016 and 2016-2017). By jointly applying factorial discriminant analysis (FDA) to the emission spectra acquired after excitation at 270, 290, and 430 nm, clear discrimination between VOOs according to their geographic origin (96.72% correct classification) and variety (95.12% correct classification) was observed. This trend was confirmed following the application of partial least squares regression (PLSR) to the fluorescence spectra, where excellent prediction of free acidity (R2 = 0.98) and peroxide (R2 = 0.96) values and good prediction of k232 (R2 = 0.88), k270 (R2 = 0.88), and chlorophyll content (R2 = 0.89) values were observed.

The ultrasound application does not affect to the thermal properties and chemical composition of virgin olive oils

In this work, the effects of high power ultrasound treatment (40 kHz) on virgin olive oil (VOO) for different times (0, 15, 30 min) were studied, in order to verify if extent modifications in their chemical composition and thermal properties. The effects of the different ultrasound treatments on VOOs were determined considering the following parameters: quality index (free acidity, K₂₃₂ and K₂₇₀), lipid profile (fatty acids and triglycerides composition) minor components (phenols, tocopherols, pigments and volatiles) and thermal properties (crystallization and melting) by Differential Scanning Calorimetry (DSC). During the ultrasound treatments, bubbles growth was present in the VOO due to the phenomenon of cavitation and a slight increase of the temperature was observed. In general, the ultrasound treatments did not cause alterations on VOO parameters evaluated (oxidation state, lipid profile, minor components and thermal profiles). However, a slight decrease was observed in some volatile compounds.

A Glimpse into the Extraction Methods of Active Compounds from Plants

Naturally active compounds are usually contained inside plants and materials thereof. Thus, the extraction of the active compounds from plants needs appropriate extraction methods. The commonly employed extraction methods are mostly based on solid-liquid extraction. Frequently used conventional extraction methods such as maceration, heat-assisted extraction, Soxhlet extraction, and hydrodistillation are often criticized for large solvent consumption and long extraction times. Therefore, many advanced extraction methods incorporating various technologies such as ultrasound, microwaves, high pressure, high voltage, enzyme hydrolysis, innovative solvent systems, adsorption, and mechanical forces have been studied. These advanced extraction methods are often better than conventional methods in terms of higher yields, higher selectivity, lower solvent consumption, shorter processing time, better energy efficiency, and potential to avoid organic solvents. They are usually designed to be greener, more sustainable, and environment friendly. In this review, we have critically described recently developed extraction methods pertaining to obtaining active compounds from plants and materials thereof. Main factors that affect the extraction performances are tuned, and extraction methods are chosen in line with the properties of targeted active compounds or the objectives of extraction. The review also highlights the advancements in extraction procedures by using combinations of extraction methods to obtain high overall yields or high purity extracts.

Modified Rotating Reel for Malaxer Machines: Assessment of Rheological Characteristics, Energy Consumption, Temperature Profile, and Virgin Olive Oil Quality

The properties of food products are the result of changes produced in raw materials as a result of process treatments. In the olive oil extraction process, these changes can be observed as differences in quality, nutritional characteristics, taste, and flavor, and are especially due to the time and temperature of the malaxation phase. These parameters are closely related to the mechanical design of malaxer machines. In this study, a new reel model for malaxer machines was designed. The new model was incorporated into an industrial malaxer machine and experimental tests were carried out to study the effects of two different reel designs (modified and unmodified profile) on the rheological characteristics of olive paste, the energy consumption of the plant, and the temperature profile inside the machine. The main commercial parameters of the produced olive oil were studied, as well as the extraction yield and the extraction efficiency of the plant. The malaxer machine equipped with the modified reel showed better homogenization of the paste, which led to improved heat exchange and rheological properties. The results of this study showed that a specific modification of the rotating reel can improve the performance of the malaxer in terms of improving the viscosity of the paste, 127,157.67 (mPa sⁿ) for the malaxer with the modified reel at the beginning of malaxation, reaching a final value of 64,626.00 (mPa sⁿ) at the end. The unmodified malaxer showed an initial viscosity coefficient of 133,754.00 (mPa sⁿ) and a final value of 111,990.67 (mPa sⁿ). This led to a reduction in malaxing times, an increase in the work capacity of the plant, and a reduction in total energy consumption and slowed down the oxidative phenomena responsible for the decrease in the quality of olive oil.

Re.Ger.O.P.: An Integrated Project for the Recovery of Ancient and Rare Olive Germplasm

The olive tree is one of the most important economic, cultural, and environmental resources for Italy, in particular for the Apulian region, where it shows a wide diversity. The increasing attention to the continuous loss of plant genetic diversity due to social, economic and climatic changes, has favored a renewed interest in strategies aimed at the recovery and conservation of these genetic resources. In the frame of a project for the valorization of the olive Apulian biodiversity (Re.Ger.O.P. project), 177 minor genotypes were recovered in different territories of the region. They were submitted to morphological, molecular, technological and phytosanitary status analysis in comparison with reference cultivars, then they were propagated and transferred in an ex situ field. All the available information was stored in an internal regional database including photographic documentation and geographic position. The work allowed obtaining information about the genetic diversity of Apulian germplasm, to clarify cases of homonymy and synonymy, to check the sanitary status, and to identify candidate genotypes useful both to set up breeding programs and to enrich the panel of olive cultivars available to farmers for commercial exploitation.

Pulsed Electric Fields for the Treatment of Olive Pastes in the Oil Extraction Process

The aim of this study was to evaluate the ability of pulsed electric field (PEF) technology to improve the extractability and enhance the oil quality in an industrial olive oil extraction process. Using a PEF device on olive pastes significantly increased the extractability from 79.5% for the control, up to 85.5%. The PEF system did not modify the primary legal quality parameters or total concentrations of phenols, aldehydes, and esters. On the contrary, the non-thermal treatment slightly enhanced the dialdehydic forms of decarboxymethyl elenolic acid linked to hydroxytyrosol (3,4-DHPEA-EDA) and tyrosol (p-HPEA-EDA), and decreased the total saturated and unsaturated C5 and C6 alcohols of the PEF EVOO (Extra Virgin Olive Oil) compared to the control test. This study confirmed that PEF technology can improve olive oil extraction and quality.

Innovative technologies in virgin olive oil extraction process: influence on volatile compounds and organoleptic characteristics

BACKGROUND

Innovative technologies are experimentally applied to the virgin olive oil extraction process in order to make it continuous and more efficient. Most of the efforts aim at overcoming the limitations of the traditional malaxation step, which, however, is essential for the development of virgin olive oil sensory notes.

RESULTS

Compared to the traditional process, innovative technologies based on the heat exchanger led generally to a decrement in volatile lipoxygenase (LOX) alcohols linked to alcohol dehydrogenase activity and, conversely, to a slightly increase in volatile LOX esters. Aldehydes from the same pathway were not significantly affected. However, an industrial combined plant constructed from a heat exchanger, low-frequency ultrasound device and microwave apparatus determined the highest 'fruity' intensity perceived by panellists, in accordance with the highest value of total volatiles, with values significantly higher than heat exchanger alone, which, instead, had the lowest levels of hexanal and LOX alcohols. The pungent taste showed the same trend observed for 'fruity' intensity, whereas bitter taste did not show significant differences among trials.

CONCLUSION

The introduction of ultrasound, coupled with heat exchanger and microwave, seemed not to modify the behaviour of enzymes of the LOX pathway, and the obtained virgin olive oils showed volatiles and organoleptic characteristics not significantly different from those obtained by the traditional olive oil extraction process. These findings provided the first insights into the effect of the combination of innovative technologies in the olive oil extraction process on virgin olive oil volatiles and sensory characteristics. © 2019 Society of Chemical Industry.