Coconut processing

present status and future status of coconut

1. Present status, Future Prospect and Potential of Post harvest Processing of Coconut Presented by: Kumari Dipti Dhoba (10PFE/15)

2. Contents Introduction Production Types of Coconut Structure & Composition of Coconut Health benefits of Coconut Post harvest processing of Coconut Value Added Products From Coconut Conversion rates for coconut products By product utilization of Coconut wastes Present status & future prospect of Coconut processing in India References

3. Introduction Scientific name Cocos nucifera Family Arecaceae Shape Elongated to Spherical Weight( avg ) 850-3700g (Matured coconut) Varieties Over 20 Varieties Types Tall and Dwarf variety Known as: King of Palms Coconut is consist of Exocarp(Thin hard skin) Mesocarp (Husk) Endocarp(Shell) White endosperm(kernel) Large Cavity(Filled with water)

4. STATUS OF COCONUT PRODUCTION IN INDIA One of the leading producers of coconut in the world producing 13 billion nuts per annum. Grown in 19 States & 3 Union Territories’s Area – 1.9 Million ha Production – 24397.50 Million Nuts Average yield : 80 Nuts/Palm/Year GDP Contribution – Rs.20000 Crores *Source-Coconut Development Board(CDB) Orissa is one of the major coconut-producing states and ranks 5 th position in production in the country. Area-5Lakh hectares Overall production-427millilon nuts Productivity-8379Nuts/ hac Five districts of Odisha ; Puri , Ganjam . Cuttack, Nayagarh and Khurda produce more than 60 percent of the total coconut production in the state.  In Orissa, coconut forms an important constituent of food basket and meets the economic needs of people dependent on its business.

5. States /Union Territories    AREA ('000 Hectares)  Production (Million nuts) Productivity (Nuts/ha) 1 Kerala 770.62 7429.39 9641 2 Tamil Nadu 459.74 6171.06 13423 3 Karnataka 526.38 5128.84 9744 4 Andhra Pradesh 103.95 1427.46 13732 5 West Bengal 29.51 373.58 12658 6 Odisha 50.91 328.38 6451 7 Gujarat 22.81 312.68 13706 8 Maharashtra 22.75 271.24 9775 9 Bihar 14.90 141.38 9489 10 Assam 19.73 132.59 6720 11 Chhattisgarh 1.85 30.54 16508 12 Tripura 7.20 29.51 4097 13 Nagaland 0.33 2.67 8091 14 Others 52.80 388.13 7351   All India 2088.47 22167.45 10614 All India Area, Production & Productivity of Coconut ( 2015-16) * Source-Coconut Development Board(CBD)

6. Types of Coconut DWARF CULTIVARS TALL CULTIVARS Kalpa Sree Kalpa Dhenu Kalpa Pratibha Kalpa Mitra Chandra Kalpa Kera Chandra Kalpa Tharu

7. *Source-Post Harvest Technology Centre, TNAU, Coimbatore Structure and Composition of Coconut Mesocarp (Husk) 50% Endosperm(Kernel) 25% Endocarp(Shell) 15% Water 10% The whole coconut is composed of 4 major parts: Nutritional composition (Amount per 100gms) Product Kernel(wet)(%) Coconut Water(%) Copra(%) Coconut powder(%) Energy 354kcal(1480KJ) 19kcal(79KJ) 354kcal(1480KJ) 354kcal(1480KJ) Moisture 40-50 95 6-7 1.3-2.5 Carbohydrate 8-20 3.7 15 18 Protein 4 0.7 7.5 6.0-6.6 Fat 35 0.2 62-65 68 Fiber 2 1.1 3-4 4-6 Minerals 1 _ 2 - The pure coconut meat contain Moisture - 36.3%

8. Health benefits of Coconut Coconuts are excellent for one’s  immunity . They are antiviral, antifungal, antibacterial and anti-parasitic. They kill harmful bacteria, viruses, fungi, and parasites, because of that, we can consume coconut in any of its various forms (whether it be raw coconut, coconut oil, coconut milk, coconut butter, etc). Tender coconut Good for feeding infants suffering from intestinal disturbances. Oral rehydration medium. Contains organic compounds containing growth promoting properties. Keeps the body cool. Diuretic (a substance which tends to increase flow of urine). Coconut oil Coconut oil has Antimicrobial benefits. It has   antioxidant properties   and slow down the aging process by protecting the body from harmful free radicals , as well as makes the skin free from dryness.

9. COCONUT DEHUSKING MACHINE De-husking of coconut De-husking is done to remove the husk part of the Coconut. De-husking machine uses electric powered rotary blade mechanism to tear off the husk from the coconut 120 to 200 nuts per hour Post harvest Processing of Coconut *Source-Kerala Agricultural University. 2011.

10. Coconut Defibring Coconut fibre screener Coconut defibring machine Coconut fibre extracting plant Coconut fibre , is a natural fibre extracted from the husk of coconut and used in products such as floor mats, doormats, brushes and mattresses. Coir is the  fibrous material  found between the hard internal shell and the  outer  coat of a coconut. White coir harvested from unripe coconuts, is used for making finer brushes, string, rope and fishing net. Coconut Fibre Cocopeat Fibre Bales

11. Drying Coconuts should be dried for several days at ambient temperature before de-husking. The copra should be dried within 24 hours after the nuts are split to prevent mould contamination. Continuous sun drying of copra for four to five days (in good sunlight) will helps to achieve 6% moisture content. When the copra is dried using a dryer, a drying temperature of 35 o C to 50 o C should be maintained for the first 16 hours of drying followed by 50 o C during the next phase until a final moisture content of 6% is reached.

12. Packaging material used for Coconut Mature de-husked coconuts are packed in Plastic or burlap sacks (40 to 50 coconuts) . Plastic mesh bags (12 coconuts). Cartons (20 to 25 coconuts) . Controlled Atmosphere (CA) Consideration Tender coconuts are waxed or film-wrapped to reduce water loss(the major cause of loss in quality). Wrapping in high oxygen plastic film significantly improves postharvest life. Immature de-husked nuts can also be film-wrapped or waxed. Siriphanich et al. (2011). Shaped coconut being delivered to market Film-wrapped shaped coconut packed for shipping.

13. The coconut chips are hygroscopic in nature, therefore chips are packed in metallised poly film or aluminium foil laminated with LDPC film (good to maintain the color and flavor of coconut chips up to six months without affecting nutritional and biochemical changes). In order to avoid breakage of chips during transportation, nitrogen flushing is usually done in pouches. Virgin Coconut Oil can be stored in stainless steel containers and poly lined drums. For long-term storage glass is used for packaging. PET bottle can be used for day-to-day use. Grated fresh coconut  should be put in a tightly sealed container or plastic bag and  stored  in the refrigerator for up to four days or frozen for up to six months. Packaging material used for Coconut products

14. Storage Pre-Cooling Conditions Room-cooling is generally used for mature husked nuts. Forced-air and hydro-cooling are acceptable. A rapid temperature change of 8°C (46.4°F) can cause cracking. Optimum Storage Conditions Mature coconuts with their husks can be kept at ambient conditions for 3 to 5 months before the liquid endosperm has evaporated. Storage at 0 to 1.5°C (32 to 35°F) and 75 to 85% RH is possible for up to 60 days for mature de-husked coconuts and 13 to 16°C (55 to 60°F) and 80 to 85% RH for 2 weeks or less. Low RH and high temperature should be avoided . Chilling Sensitivity When stored at 0°C (32°F), the green skins of immature nuts turn brown after 7 days and changes occur in other quality characteristics. Chilling injury is not seen when coconuts are stored at 5ºC (41ºF) for 6 weeks.

15. Value Added Products From Coconut Coconut is used as staple part of the diets in many Asian countries for centuries. It is used as food, as flavoring agent and made into beverages. Coconut water Coconut honey Coconut lemonade Nata -de-coco Coconut kernel Desiccated coconut Coconut pickle Coconut chips Coconut crips Coconut milk Coconut cream Coconut Candy Coconut Milk powder Coconut syrup

16. Coconut kernel Desiccated coconut are the edible dried-out shredded coconut meat, prepared from fresh kernel of fully matured coconut and it is available in coarse, medium and fine grade. The meat is disintegrated and dried in hot air driers at 60-76ºC to 2% moisture content (fat 65-68 %) and used in the manufacture of cakes, pastries and chocolates. De husking of coconuts(Matured Coconut) ▼ De-shelling ▼ Removal of brown testa ▼ Desiccated Coconut ▼ Blanching ▼ Grinded in to powder form ▼ Drying(80-90ºC) ▼ Sieving/Grading (Vibratory Screen) ▼ Packing (moisture and oil-proof polythene-lined plywood boxes) Desiccated coconut *100 coconuts gives around 12-13 kg of coconut powder.  Desiccated Coconut powder

17. Coconut milk Coconut milk is the milky fluid, freshly extracted from the coconut kernel with or without adding of water. Coconut milk was prepared by blending skim milk powder with coconut milk, obtained from freshly grated coconut and pasteurized at 70-72ºC for 10min. It contains 6 percent skim milk powder and 9.65 percent total solids. ( Agrawal ,  et al . 2011) Coconut milk powder:  Coconut milk powder was prepared by dehydrating the milk under controlled conditions. The composition of the milk was adjusted with fat percentage in the range of 50-60 % of the total solids. For dehydration spray drier was employed at high temperature (around 180ºC).

18. Preparation of coconut milk : De-husked Coconut De-shelling Pairing of Testa Grating Addition of Water Blending Straining Coconut Milk Thermal treatment Addition of Stabilizer &Sugar Sweetened Coconut Milk Thermal treatment Addition of Sugar& Starter Culture Coconut Yoghurt Coconut Fibre

19. Virgin Coconut Oil Extraction Virgin Coconut Oil Virgin coconut oil obtained from fresh, mature endosperm (kernel meat) of the coconut by mechanical or natural means, with or without use of heat. There is no chemical refining, bleaching or de-odorizing and maintains the natural aroma From coconut milk, virgin coconut oil is extracted via high speed centrifuge and low temperature processes. Processing methods 1. Hot process 2. Natural fermentation method 3.Centrifugation 4. Extraction from dried grating

20. Fully mature coconut(11-12 month) Removal of husk husk Cut into halves coconut water Removal of shell shell Washing in clean water Grating/pulverising the kernel Coconut milk extraction Removal of testa testa Hot processing/fermentation/centrifuging coconut milk Virgin coconut oil Packaging Two steps of processing Extraction of milk Cooking the milk (Mc 0.2% or below)

21. Coconut oil processing methods are classified into two major types: the dry and the wet processes. The oil extraction technology which starts with copra as the raw material is termed as the dry process. The method that uses fresh coconuts as starting material is generally called the wet process. Continued…

22. Oil Extraction from Copra Copra Drying: After deshelling , the coconut fruits are cut in to small pieces and sun dried. Drying pieces of coconut meat under sunlight Copra Grinding : Grinds the dried copra into copra flakes Copra Oil Extracting : Expel copra oil from dried copra flakes Copra grinding machine ( hammer mill ) Copra Oil Extracting Machine * Source- www.coconutmachine.com

23. Coconut cream coconut cream is the high-fat cream-like material obtained from the coconut milk by either gravitational separation or centrifugation The concentrated milk cream extracted from fresh matured coconuts can either be used directly or diluted with water to make various curry preparation, sweets, desserts, puddings etc. Processed and packed coconut cream had a shelf life of six months and once opened it should be stored in refrigerator for subsequent use.

24. Coconut Syrup Coconut syrup is a translucent, free-flowing liquid, prepared by cooking coconut milk with an equal amount of refined sugar and di -sodium-phosphate equivalent to 0.25% of the volume of the milk, until the mixture attained a TSS content of 68-70 %. The hot mixture was poured in sterile containers and sealed hermetically. It was used as a topping for bakery products or as a mixer in alcoholic drinks or may be diluted in water and used in cooking rice cakes and other delicacies. Coconut Chips Coconut chips is a value added product of coconut kernel . Coconut chips, the thinly sliced crispy coconut meat which may be sweetened or salted and may be used as a ready to eat snacks food. 120-150g chips -from one coconut. Shell life of coconut chips -6 months.

25. Processing of Coconut Chips Coconut(10 month matured coconut kernal ) Removal of shell Removal of Testa Cutting in to pieces Slicing of Kernel 0smotic Dehydration (1 hr/40 min) Drying (70-80ºC for 4-6 hrs) Packaging

26. Coconut candy Coconut candy was prepared from grated coconut meat mixed with coconut milk. The grated coconut was moistened with a portion of the milk. The remaining milk and the molasses were poured in a cooking pan, and the mixture was heated to boiling. Refined sugar was added and the mixture was cooked until it gets hardened when dropped into cold water. It was then poured in butter-greased pans, allowed to cool slightly, cut into desired sizes and individually wrapped in cellophane sheets.

27. Coconut water Coconut honey Coconut honey is viscous, free-flowing syrup, similar to coconut syrup but less creamy and less nutty in flavour and used as topping for pancakes and waffles. One part of coconut water was mixed with ½ part of refined sugar and ½ part of glucose and then blended with sodium alginate at 0.5% as stabilizer. Coconut cream may be added to improve the flavour of the product. The mixture was heated for 15 minutes, homogenized and cooked with constant stirring in steam-jacketed kettle to a TSS of 75%. It was poured hot into sterile containers and then sealed hermetically.

28. Coconut water preservation and processing A. Prades et al 2012. Coconut water preservation and processing. Fruits, vol. 67 (3).( http://www.fruits-journal.org )

29. CONVERSION RATES FOR COCONUT PRODUCTS Product (Output ) Raw Mateiral (Inputs) 1 MT of Copra 7,000 coconuts 1 MT of Coconut Oil 1,560 kg copra / 11,000 nuts 1 MT of Desiccated Coconut 10,000 coconuts 1 MT of Coconut Chips 10,000 coconuts 1 MT of Coconut Milk Powder 10,000 coconuts 1 MT of Virigin Coconut oil 16,666 coconuts 1 MT of Coconut Shell Powder 12,000 coconut shells 1 MT of Coconut Shell Charcoal 30,000 coconuts shells 1 MT of Activated Carbon 90,000 coconuts shells / 3 MT of coconut shell charcoal

30. By product utilization of coconut wastes 1.Coconut shell charcoal:  Obtained by burning the shell of fully matured nuts with a limited supply of air. 2. Activated Carbon:  Shell charcoal on activation is transformed into activated carbon which is used in solvent recovery processes. 3.By-Products from husk:  About 30 percent of the husk is fiber a 70% is coir dust. Coir pith is used as manure (After composting) and mulch material . 4.Mushroom Cultivation Using Coconut By-Products:  Coconut bunch waste, leaf stalk, mixtures of leaf stalk and coir pith in 1:1 ratio were found to be better substrate for mushroom cultivation.  

31. Present status & Future prospect of coconut processing in India India contributes 22.34% of the world’s coconut production and one of the major players in the world’s coconut trade. According to the Asian and Pacific Coconut Community (APCC), India produces 15,730 mil-lion nuts annually, next to Indonesia and the highest domestic consumer with 1494.4 million nuts annually. Coconut is not only significant in socio cultural needs of our society, but also has gained considerable importance in the national economy as a potential source of rural employment and income generation among the plantation crops. The future prospects of the coconut industry lies completely on its overall competitive ability. Coconut producing countries need to exploit the fullest of their individual competitive advantages in cultivation, processing and marketing of coconuts. Coconut Industry has to tap the full potential of coconut as a renewable resource, which could be used to generate range of environment friendly natural products, with a wide array of end-uses and applications. .

32. References Paull and Ketsa (2015). Coconut Postharvest Quality-Maintenance, Food Science Technology and Nutrition, vol -8(45) . Obibuzor , J.U. (2015). Storage Stability of Grated and Milled Desiccated Coconut Meat, Global Journal of Biotechnology & Biochemistry 10 (4): 131-134. Swamy , G.M.S (2013). Coconut Neera production and processing in Karnataka, Coconut Development Board. www.agmarknet.nic.in www.apeda.com www.icar.org.in www.fao.org www.coirboard.nic.in www.nabard.com www.coconutboard.nic.in

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