Progress Towards Reducing - PowerPoint Presentation

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Progress Towards Reducing Contaminants: Setting New Targets for the Industry

MOSTA Palm Oil Production: Best Practices Workshop 2017QUALITY IMPROVEMENT: From FFB (Fresh Fruit Bunch) to PPO (Processed Palm Oil)19 - 20 July 2017

Datuk Dr Choo Yuen May

Dr Tan Yew Ai

Dr Goh Swee Hock

Tan Sri Emeritus Prof Academician Datuk Dr Augustine SH Ong

MOSTA

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Presentation outlineIntroductionDefinition of contaminants

Occurrence and sources Toxic Oil Syndrome Contaminants, food safety and qualityPreventive Measures Along the Supply ChainStrategy for Policy InterventionIdentification, originRegulation and policies – Limits, TDIs, MRLs Analytical methodsAddressing Specific Contaminants- Current KnowledgeEvolution of the Contaminant IssueNew Industry TargetsConclusion

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What is a contaminant?Chemical, biological of physical; cross-contaminationToxic, poisonous, allergenic, carcinogenic,

etc Unintended consequence – production, manufacture, processing, preparation, treatment, packing, packaging, transport or environmental pollution

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Cost of contaminationHuman lives

Disruption in supply chainDisruption in trade Increased costs to eliminate/reduce contaminantsLoss in consumer confidence

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ContaminantsToxic Oil Syndrome

1981, contaminated cooking oil Death of 1000 people in SpainEpidemic – Toxic Oil Syndrome Aniline poisoning Aniline was added to rapeseed oil for industrial use

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Contaminants – 3 Broad CategoriesAccidental contamination with foreign objects due to carelessness

Accidental contamination throughout the supply chain, can be naturally occurringBacteria, mould, fungi, microbial toxinsContaminants

Chemical

Physical

Biological

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Types of Contamination

ContaminationCross-ContaminationI

Environment:

Cultivation

Transport

Storage

Operators:

Transport

Storage

Processing:

3-MCPDE

GE

trans

Packaging:

Phthalates,

Bisphenol

A

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Veg Oils ContaminationEnvironmentCultivation practicesTransport

Holding – Cross-contaminationProduction processes:Extraction RefiningModification processes

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Groups of ContaminantsHeavy metals Pesticides, weedicides PAHs

Phthalates, bisphenol ADioxins, PCBs, POPsAflatoxins, ZEN Microorganisms Other foreign matter

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Quality & Safety New Trace ContaminantsFood safety

Quality standardsContaminants from refining (trans FA, . dimers, furan, 3-MCPD, GE)New contaminants from food . processing (acrylamide)Validated methods, Analysis, Detection . and Quantitation

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Preventive MeasuresPalm Oil Supply Chain

Consumers

Refinery

Milling

Agriculture

Contract

Buyers

Transport

Storage & Transport

Storage & Transport

Storage, Packaging & Transport

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Preventive MethodsAgriculture

Judicious use of agro-chemicals Reduced contamination by pesticides and fertilisersIPMPest Control – Biological, mechanical, ecological methods Beneficial to environment LimitationsEffectiveness still lag behind agro-chemicalsOutcomeReduction in contamination

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Preventive MeasuresHarvesting

Timely harvest – optimal timeminimization of loose and damaged fruits (over-ripe FFB)Limitations Labour shortage, Large and Remote estatesImplicationsIncreased labour costsOutcomeQuality fruits, improved oil yield and quality

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Transport to MillsTimely transport of FFB to the millMinimize enzymatic activity which produces free fatty acids, DAG and MAG

LimitationsDifficult to implement in remote estates OutcomeGood quality oil with low FFA and DAG; less refining problems & less processing contaminants

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Preventive MeasuresMilling StageTimely processing of FFB

Wear and tear of screw pressHydraulic oil or lubricants Boiler chemicals for generation of steamSteam that come into contact with the FFB and extracted oil must be free from harmful chemicals

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…Preventive Measures Milling StageWater quality

(Chloride-free)Steam used for sterilization of FFBWater used for diluting oily mesh LimitationsBacklog of FFBs during peak period may delay processing of FFBOutcomeProduction of quality crude oil which is easy to refine

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Preventive Measures Refining StagePre-Washing of Crude Oil

Removal of Chloride, P and associated impuritiesModification of refining conditionsLower bleaching temperatureLower deodorisation temperature/pressureProcessing aids (silica, activated charcoal, etc.)Chemical refining in selected casesCheck on processing aidsDegumming agentWater quality (Steam for deodorization)Chloride-free Bleaching earth

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Preventive Measures ... Refining

Double bleachingMay be needed to achieve desired refined oil quality if lower temperature is used Two-stage deodorization (short stage at high T and a longer stage at lower T, at low pressure)Post treatment of refined oil with adsorbents ( e.g. magnesium silicate, cation-exchange resin, etc)Processing of high quality virgin oil

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Preventive Measures … Refining

LimitationsExtra effort and additional costs Increased oil loss because of additional stepsIncreased costs in disposal of processing aidsPossible problems if final product does not meet quality specifications OutcomeLow levels of process contaminants

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Preventive Measures – Storage & TransportationStorage and transport in clean tanks/dedicated tanks/pipelines

LimitationsCost implicationsOutcomePrevention of cross-contamination Current Status: no longer an issue

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Strategy & Policy InterventionIssue of ContaminantsIdentification

Analytical methodsSetting limitsRegulations – basic legislation based on minimization principle

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Identification of ContaminantChemical structureOccurrence/origin

Formation mechanism (for process-derived contaminants)Safety concerns

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Analytical MethodsRepeatable, Reproducible, RecoveriesValidation through collaborative study

Artefact-free?True accurate value! Calibration range & Precision Limits – LOD and LOQHarmonise various methods to obtain an acceptable standard method

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Setting LimitsSurveys: extent of contamination

Pesticides & Herbicides: MRL, LODToxicity: TDICarcinogen: T25, LOD

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Regulatory Standards forPalm Oil

Set criteria similar toMS, CODEX, BS, AQSIQ, OthersSet specifications & standards (all stakeholders)Legislation with Regulations: legally valid/bindingQuality Product as meeting Standards

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Guidelines established by International Organisations

WHO (World Health Organisation)FAO (Food and Agriculture Organisation)EC (European Commission) JECFA (Joint FA)/WHO Expert Committee on Food Additives) FAO/WHO Codex Alimentarius

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FAO/WHO Codex Alimentarius

Intergovernmental forum for negotiating food standardsCodes of practiceGuidelines – basic principles governing the regulation of contaminants are built into the relevant standards and code of practiceLargest number of specific standards in Codex Alimentarius is the group under commodity standards where limits of contaminants are identifiedCodex general standard for contaminants and toxins in food

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Codex Standard for named vegetable oils – CX-STAN 210Essential composition and quality factors

Food additivesContaminantsHygiene Labelling Methods of analysis Safety and health are ensured through all these checks and practices

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Codex Committee for Fats and Oils (CCFCO)In 2007, Malaysia designated as the host government for this committeeThe 25

th CCFO held in Feb 27 to 3rd March 2017 at the Royale Chulan KL, was attended by 39 member countries, one member organisation and seven observer organisations

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Codex Specifications for Quality

Parameters (max) CPO

RPO

Acid value (mg KOH/g)

10.0

0.6

Volatile matter (% m/m)

-

0.2

Impurities (% m/m)

-

0.05

PV (

meq

O

2

/kg)

15

10

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Specifications on RequestStipulate criteria demanded by the buyer of a particular product or consignmentMay be above or below those in a standard or may be concerned with criteria not covered in a standard

Variations from a standard are usually the subject of price negotiations for the product

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Food safety assurance/management system Protection against product adulteration, contamination, vegetable oil processing should be according to internationally recognized food safety standards e.g. Hazard Analysis Critical Control Points (HACCP), FAO)/WHO Codex

Alimentarius, and ISO 22000Enhanced monitoring schemes for dioxin and dioxin-like polychlorinated biphenyls (PCBs)Use of food grade processing aids

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The Malaysian Palm Oil Industry:Well regulated

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Malaysian Standard (MS) – Characteristics

Identity Quality

Apparent density (50ºC)

FFA

Refractive index (50ºC)

Moisture & Impurities

Saponification value

Peroxide value

Unsaponifiable

matter

Anisidine

value

Fatty acid composition

Colour

Iodine value

DOBI

Slip melting point

Total carotenoids

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MS 814: CPO Quality Specifications

ParameterSpecial Quality (SQ) Grade Standard Quality (STD)Grade

FFA, % max

2.5

5.0

M & I, % max

0.25

0.25

PV,

meq

/kg, max

1.0

2.0

DOBI, min

2.8

2.3

AnV

, max

4

5

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PORAM Specifications

Parameters

Refined palm oil (RPO)

Refined palm

olein

(

RPOo

)

FFA (as %

palmitic

acid, max)

0.1

0.1

Moisture & Impurities (% , max)

0.1

0.1

Melting point (

。

C)

33 - 39

24

Iodine value (min)

50 - 55

56

Colour (max)

3 Red

3 Red

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Achievable Quality Targets

ParameterCPO, maxRPO, max

FFA, %

3.5

0.05

M & I, %

0.25

0.02

Colour

-

2.5 R

PV, meq/kg

1.0

0

Carotene, mg/kg

500 - 800

-

DOBI

2.5*

-

AnV

5

2

3-MCPDE

*

1*

GE

*

0.5*

*

Minimum ( EU)

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Standard Specifications for QualityPresent MS specifications for CPO have not changed significantly over the years!Advanced knowledge and technology should mandate the tightening of the MS specifications for CPO especially parameters which are contaminant-related such as FFA

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Addressing contaminants: Heavy metals

Arsenic, lead, cadmium, mercuryLimits: Codex Alimentarius and the ECStandardised methods : ISO Oil refining is effective in removal of metalsMostly concentrated in the meal CPO extraction and refining – no issueRisk Level: Low because of existing regulations and standardized methods for analysis

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Addressing quality-related ContaminantsCopper and iron (use of stainless steel – non issue)Endogenous and exogenous sources

Standard methods for determinationSafe dietary intake levels: JECFAMaximum levels set for copper and iron Risk Level: Low in view of strict quality specifications which are related to level of Fe and Cu in vegetable oils

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Addressing contaminants: PAH – Non-Issue

Lipophilic aromatic hydrocarbons with two or more fused benzene ringsEC: limit of 2 mg/kg in vegetable oilsDeodorizing step eliminates light PAH Heavy PAH can be eliminated with activated carbon during the bleaching stageISO methods for quantification of PAHRisk Level: Medium (for some oils)if refining process is not efficient

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Source: OCL Vol 17N° 2 MARS-AVRIL 2010

Carcinogenic PAH Contaminant Benzo[a]pyrene

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Addressing contaminants: Mineral OilSaturated hydrocarbons (

e.g. lubricants)Determination based on isolation on a silica column followed by GC analysis with an internal standardNeed to improve harmonization of analytical method to get a robust ISO methodSolution found – use food-grade lubricantsRisk Level: Medium for solvent-extracted vegetable oils. Low for screw-pressed palm oil

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Addressing contaminants: Phthalates (Non Issue)

Plasticizers in ubiquitous plastic materialsSuspected to be endocrine disruptorsEC has set specific limitsSterilisation in CPO milling; low moisture contentRisk Level: Medium to high because of the ubiquitous use of plastic materialsMicrobiologicals (Non- Issue)Risk Level: Low

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Addressing contaminants: Pesticides (Non-Issue: being monitored

)Pesticides include insecticides, herbicides, fungicides, rodenticidesGAP; moving towards IPMIf pesticide levels were found to be above regulated levels, process validation for removal of pesticides from crude oil Risk Level: Very low in refined oil

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Addressing contamination: From previous cargoesC

odex Code of Practice for the Storage and Transport of Edible Fats and Oils in BulkCodex list of acceptable previous cargoesImmediate previous cargoes must be in the list of acceptable immediate cargoesUse of dedicated pipelines at loading and unloadingRisk Level: Low

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Addressing New Process Contaminants: MCPDE and Glycidyl esters (GE)

3-MCPD estersGlycidyl esters (GE)Others – Dichloropropanol esters; Isomers & StereoisomersR = Linear AlkylR

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Addressing Process-Derived Contamination: MCPDE & GENew processing techniques

Modified refining conditionsNew processing stepsNew processing aidsPost refining steps (?)Processing of quality oilTimely harvesting rounds and oil extractionCorrect storage and transport3-MCPD

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3-MCPD: Mitigation strategyReducing chloride from the raw material and milling steps

Minimizing DAG and MAG componentsModifying the refining process conditions especially bleachingNeutralisation of FFA with one mole eq of NaHCO3 or Na2CO3Washing of palm fruits before oil extraction, separate waste stream oilWashing of the CPO before refining reduces chloride and P & M impuritiesRemoval of MCPD mono-esters in stripping/deodorization at low pressuresChemical refiningBetter quality CPO

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Source: EFSA Journal (2016) Vol 14 (5), 3 MAY 2016 DOI: 10.2903/j.efsa.2016.4426

Risks for human health related to the presence of 3‐ and 2-MCPD, and their fatty acid esters, and glycidyl fatty acid esters in foodPresence of 3- And 2-MCPDE and GE in Edible Oils

1 ppm: Barely achievable

0.5 ppm: Achievable

PO

PO

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Recommendations of the EFSA& Other GroupsFuture data collection to include samples from all food groups

Further studies on rates and degree of release of the free compounds from 3- and 2-MCPD fatty acid mono- and diesters, and also from free glycidol from esters of different fatty acids. Long-term toxicity testing of 2-MCPDE and DCPE is required to provide a basis for quantitative risk assessment.More extensive testing carcinogenesis of glycidol esters and MCPD estersEfforts to further reduce levels of process contaminants

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Quality – 1980s and 1990sSustainability – 2000Strong parallel between the quality and sustainabilitySustainability is the New Total Quality management

Convergence of Quality and SustainabilityKey Sustainability Certification Schemes for Palm Oil

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Launched in August 2007 by Minister of

Plantation Industries and CommoditiesSeven Codes of Practice (CoP):Good Practice for NurseryGood Agricultural Practice for Oil Palm Estates & Smallholdings Good Milling Practice for Palm Oil MillsGood Crushing Practice for Palm Kernel Crushers Good Refining Practice for Palm Oil Refineries

Good Practice for the Handling, Transport and Storage of Products from the Oil Palm

Good Practice for Bulking Installations

Codes of Practice (

CoP

)

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Setting New Industry TargetsDigital Strategy: Data bases, Big Data, Integration of data sets along the supply chain, Analytics, Problem finding and SolutionsNew Quality Targets for Food Products

Guidelines and then New Standards for Oil QualityNew Technical, Animal Feed Products and Biofuels

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ConclusionRole of the Industry

Establish SOP for containment of contaminants In the absence of legislation, should set limits for contaminants Industry standards Tighten quality specifications as these are invariably linked to contamination i.e. FFA should be reduced from current 5% for CPO to at least 3.5%Target for more rapid and yet precise methods for analysis of contaminants to prevent movement of contaminated consignment further down the supply chain

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ConclusionRole of the Industry…

Develop a Toolbox for mitigation of contaminantsEstablish intervention steps to prevent and reduce contamination of palm oil along the supply chainIndustry must be willing to incur additional costs to produce contaminant-free oilSolutions may be costly but there are benefits in terms of gaining consumer confidenceGuidelines for purchase of refining aids Use of Big Data for establishing industry targets

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Role of the GovernmentThere is no easy solution due to the play of different factorsContinuing R&D needed for novel solutions

Legislation of standards, set limits for contaminantsParticipation in activities of international organisations/bodies

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Way ForwardSet up a tripartite Committee: Ministry (MPIC), MPOB and Malaysian Oil Palm Industry

Government to legislate sludge oil, fibre oil, EFB oil, high FFA oil and sterilizer condensate oil To address labour shortage problem, MPIC to set up a one-stop centre to receive foreign workers To introduce and enforce HACCP in palm oil mills

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Way Forward…Nation-wide survey on CPO and RPO and RPOo

Survey to cover as many mills and refineries as possible Time-line: depends on data typeSet mandatory timeline to implement 4 % FFA by end 2018, and3.5 % FFA by 2020

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