OLEORESIN EXTRACTION PLANT FROM CHILLIS

[EIRI/EDPR/3665] J.C.: 1750

INTRODUCTION

Oleoresins are the concentrated liquid form of the spice. They are obtained from
spices by extraction with a non-aqueous solvent followed by removal of the solvent
by evaporation. This spice derivative has the same character and property of the
spice it is obtained from. They reproduce the character of the respective spice and
spice oil fully. Spice oleoresins represent the complete flavour profile of the spice. It
contains the volatile as well as nonvolatile constituents of spices. Oleoresins can
replace whole/ground spices without impairing any flavour and aroma
characteristic. Spice oleoresins guarantee superior quality of flavour and aroma.
They are complete and balanced, consistent, and standardised. The quality of an
oleoresin is typically evaluated on the basis of presence of the active ingredients in
desired levels. As these are concentrated extracts, they are typically used as a
diluted dispersion plated on a neutral dry carrier or as a diluted blend in a
solubilizing medium such as vegetable oil to match the desired strength of the
ground spice/herb. All the spices contain essential oils in varying proportions which
can be extracted by steam distillation.

The main products in a spice oleoresin plant are oleoresins of chilli, pepper, ginger
and turmeric. The co-products are corresponding spice oils, which are widely used
in food and pharmaceutical industries. Spent meals of spice powders after oleoresin
extraction are by-products and are devoid of essential oils, pungent principles, fixed
oils and resinous matter for which the spices are valued. This may be considered for
incorporation in animal feed formulations, as spent meal is rich in carbohydrate and
cellulose.

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Spice oleoresins are the most concentrated viscous liquid form of the spice and
reproduce the character of the respective spice and spice oil fully. They are obtained
by the solvent extraction of the powdered dried spices with subsequent removal of
solvent. The oleoresins are used mainly as a flavoring agent in the food processing
industry. They are more economical to use, are easier to control for quality and are
cleaner than the equivalent ground spices. Their distinct advantage over the
equivalent essential oils is that they are more stable when heated.

The main products in a spice oleoresin plant are oleoresins of chilli, pepper, ginger
and turmeric. The co-products are corresponding spice oils, which are widely used
in food and pharmaceutical industries. Spent meals of spice powders after oleoresin
extraction are by-products and are devoid of essential oils, pungent principles, fixed
oils and resinous matter for which the spices are valued. This may be considered for
incorporation in animal feed formulations, as spent meal is rich in carbohydrate and
cellulose.

In contrast to essential oils, oleoresins contain many more non-volatiles. This fact
makes them more interesting for the flavour and food industry. Non-volatiles are
substances that do not vaporize easily. They are not lost when exposed to open air.
In fact, oleoresins combine the volatiles and non-volatiles of plants to yield a more
complete flavour profile. For example, pepper oleoresin contains the non-volatile
piperine, whereas the essential oil of pepper does not. Piperine is the spicy hot part
of pepper.

Another difference between oleoresins and essential oils is that oleoresins dissolve in
fats, oils and lipids, whereas essential oils do not. This property of oleoresins is
called lipophilicity and provides manufacturers with different options for food
formulation compared to essential oils.

With the exception of paprika and turmeric oleoresins, the extraction of oleoresins
starts with the extraction of the volatile part of the plant (the essential oil) by a
distillation process. The remaining raw material is then exposed to a solvent suitable
to extract the non-volatiles. After this process, the solvent is removed from the
extract. This procedure is repeated various times until all nonvolatile are removed
from the plant material.

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Finally, the non-volatile part (resin) and the volatile part (oil) are blended and
homogenized (mixed to get the same composition in all parts of the blend) to make a
smooth oleoresin and to get the whole flavour (including spiciness) plus colour. The
solvents used in the extraction process are mainly ethyl acetate, alcohols, acetone or
hexane, depending on the oleoresin to be extracted. The appropriate solvent,
pressure, temperature and duration of the extraction mainly depend on the raw
material that contains the oleoresin. In recent years, the “supercritical fluid
extraction” (CO2 extraction) has become another frequently used extraction method.
This method is expensive, but it may increase the extraction rate and results in an
oleoresin with different properties.

From the time the first batch of Oleoresins rolled out of our factories in 1972 to date,
Synthite has been at the forefront of the evolving food industry. Oleoresins are pure
extracts of a spice or herb. They are concentrated natural liquid flavourings that
contain both volatile and non-volatile flavour components. Oleoresins provide flavour
profiles characteristic of the ground spice or herb with a more rapid flavour release.
Our Oleoresins are produced with the finest spices from around the world; they
preserve the robust flavour and aroma of the spice. Today, we account for 30% of the
global Oleoresin market.

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Why Oleoresins?

Achieving efficient and consistent results using ground spices is a challenging task.
Oleoresins can replace the original ground spice with a standardized taste and
aroma that can be tailored as per the requirement of the product.

They are economical, with easier quality control, and require lesser storage space.
They have a longer shelf life, are cleaner (no bacterial contamination) and are a
convenient substitute for ground spices.

Oleoresins are the concentrated form of spices where you get the wholesome flavour
and aroma of the spice. Spice oleoresins are characterised by high potency of active
components which enables their usage in small dosages. Spice Oils and Oleoresins
can be used to advantage wherever spices are used, except in those applications
where the appearance/ filler aspect of spice is important. Usage of spice oleoresins
leads to standardisation in taste and consistency in flavour. Oleoresins find
application in Beverages, Meat Canning, Confectionery, Sauces and
Pharmaceuticals. They are also used as a base for a number of seasonings.

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Technology

Generally, extraction of spice oils and oleoresins using a non-aqueous solvent is a

small scale operation. For easy standardization of oleoresins, the spice oils need to
be distilled first. Then the oleoresins are extracted using solvent. The spent residual
meal after extraction can be used in animal feed formulation. The oleoresin extract is
mixed with the dry spice oil to the required level to produce spice oleoresins before
they are finally packed.

Process control is vital to get a uniform product in every batch. Delicate processing
under controlled conditions of temperature is a must to maintain the freshness and
flavour of spices. Solvents that are used for extraction of spice oleoresins are
Ethylene dichloride, Acetone, Hexane or alcohol. Stripping off residual solvent at the
final stage of preparation of oleoresins is crucial. The choice of solvent governs the
ratio of spice constituents that are extracted. Example – highly coloured turmeric
oleoresin without characteristic odour of turmeric can be obtained or a low-coloured
product having highly aromatic smell of ground turmeric in a liquid state can also be
produced.

Super critical fluid extraction (SCFE) is a sophisticated method for extracting spice
oleoresins. It is a two-step process where Carbon di oxide is used as a solvent above
its critical pressure and temperature for extraction of various natural materials. In
this process, there is no residual solvent.

Correct extraction technology is a must to make the product with the right flavour
profile. Identification of components in spices that give optimum flavour potency is a
must.

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A combination of technology and innovative manufacturing practices is essential to
get the desired properties of final product. Due to food safety laws, use of solvents
and residual solvent limits in the final product is becoming more and more a
concern for food industry. To overcome this, technologies like SCFE are becoming
popular.

 Spice Oleoresins offer the following advantages

 Consistency in flavour
 Not affected by bacterial contamination
 Much longer shelf life
 Easier storage and handling
 Full release of flavour during cooking
 Easy blendability to achieve the desired features

The usage of spice oleoresins is not without its limitations. There is low awareness
about the product in the Indian market. Oleoresins are highly concentrated and so
they need to be used in diluted form. While oleoresins can be used for Italian,
Mexican and other continental dishes, surprisingly not much has been done to take
spice oleoresins to the Indian kitchen. Research needs to be done to explore use of
oleoresins in dishes like sambar, rasam, lassi and dal. The level of research in these
areas has been sub-optimal.

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 CONTENTS
INTRODUCTION
WHY OLEORESINS?
TECHNOLOGY
ADVANTAGES & DISADVANTAGE OF OLEORESINS
THE ADVANTAGES OF OLEORESINS
ADVANTAGES & DISADVANTAGE
ADVANTAGES OF SCFE
ADVANTAGE OF CO2 AS A SOLVENT
RAW MATERIALS
BOTANICAL DESCRIPTION
NUTRITIONAL VALUE OF CHILLI
USES
INDIAN NAME OF SPICES
FOREIGN NAME OF SPICES
INDIAN CHILLI VARIETIES
DIFFERENT VARIETIES
BIRDS EYE CHILLI (DHANI)
BYADAGI (KADDI)
ELLACHIPUR SANNAM-S4 TYPE
GUNTUR SANNAM-S4 TYPE
HINDPUR-S7
JWALA
KANTHARI-WHITE
KASHMIR CHILLI
MADHYA PRADESH G.T.SANNAM
METHODS OF OLEORESIN EXTRACTION
SOLVENT EXTRACTION PROCESS
SUPERCRITICAL FLUID EXTRACTION PROCESS
STEAM DISTILLATION PROCESS
SCF MANUFACTURING PROCESS
SAMPLE PREPARATION
SUPERCRITICAL FLUID EXTRACTION (SFE)
SCF TECHNOLOGY DEVEN SUPERCRITICALS PVT. LTD., INDIA
SPECIAL FEATURES ON OUR SCFE SYSTEM
PLC BASED CONTROL SYSTEM
INSTRUMENTATION
PROPERTIES OF SCF
PHASE DIAGRAM
COMPARISON OF SUPERCRITICAL CO2 FLUID EXTRACTION (SCFE)
AND CHEMICAL EXTRACTION
SFE ADVANTGE OVER OTHER PROCESS
SUPERCRITICAL FLUID EXTRACTION TECHNOLOGY AND ITS APPLICATION
IN FOOD INDUSTRY

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PRINCIPLE AND INFLUENCING FACTORS
THE BASIC PRINCIPLE OF SUPERCRITICAL FLUID EXTRACTION
FACTORS INFLUENCING SUPERCRITICAL FLUID EXTRACTION
RAW MATERIALS
SOLUBILITY (TEMPERATURE AND PRESSURE)
APPLICATION STATUS AND PROGRESS
PROPERTIES OF OLEORESIN
PHYSICAL PROPERTIES TO BE CHECKED
EFFECT OF PH STABILITY OF NATURAL OLEORESIN EXTRACTED
BY SUPERCRITICAL CO2
HEAT STABILITY OF OLEORESIN EXTRACTED BY SUPERCRITICAL CO2
TEM OF OLEORESIN NANOPARTICLES EXTRACTED BY SUPERCRITICAL CO2
TEM OF OLEORESIN NANOPARTICLES EXTRACTED BY SUPERCRITICAL CO2
STANDARD CURVE OF OLEORESIN
FT-IR ANALYSIS OF OLEORESIN
PH STABILITY OF NATURAL OLEORESIN EXTRACTED BY SUPERCRITICAL CO2
HEAT STABILITY OF OLEORESIN EXTRACTED BY SUPERCRITICAL CO2
DSC OF NANO OLEORESIN
VARIOUS OLEORESINS & THEIR APPLICATIONS
SOLVENTS
MARKET POTENTIAL
SPICE OILS AND OLEORESINS MARKET SEGMENTATION
INDIA DOMINATES GLOBAL MARKET FOR SPICE OLEORESIN AS DEMAND
FOR NATURAL AGENTS’ SWELLS
SEGMENTATION
KEY PLAYERS
REGIONAL MARKET SUMMARY
GLOBAL OLEORESINS MARKET SHARE (%), BY REGION, 2017
GLOBAL OLEORESINS MARKET, BY PRODUCT
GLOBAL OLEORESINS MARKET, BY RAW MATERIAL
GLOBAL OLEORESINS MARKET, BY APPLICATION
GLOBAL OLEORESINS MARKET, BY REGION
"RISING DEMAND FOR PACKAGED SPICES AND SEASONING IN RESTAURANTS"
"PAPRIKA OLEORESIN HELD OVER ONE THIRD OF THE REVENUE SHARE IN 2015"
"FLAVOR WAS THE LARGEST APPLICATION SEGMENT IN 2015"
"EUROPE HELD OVER ONE-THIRD OF REVENUE SHARE IN 2015"
"FEW COMPANIES HOLD A LARGE MARKET SHARE OF THE OVERALL OUTPUT"
THE GLOBAL OLEORESIN MARKET IS CONCENTRATED IN NATURE WITH FEWER
COMPANIES HOLDING A MAJOR SHARE IN THE INDUSTRY. THE GLOBAL INDUSTRY IS
EXPECTED TO WITNESS AN INCREASE IN MERGERS, ACQUISITIONS AND STRATEGIC
ALLIANCES OVER THE NEXT SEVEN YEARS.
MAJOR COMPANIES INCLUDE UNIVERSAL OLEORESINS, UNGERER & COMPANY,
PLANT LIPIDS, AKAY, SYNTHITE, AVT NATURAL PRODUCTS LTD, INDO WORLD,
PAPRIKA OLEO’S, PARAS PERFUMERS, AMBE GROUP, ASIAN OLEORESIN
COMPANY, CYMBIO PHARMA PVT LTD AND BIOPREX LABS.
OLEORESIN MARKET KEY DEVELOPMENTS
OLEORESIN MARKET MAJOR PLAYERS
EUROPE AN INTERESTING MARKET FOR OLEORESINS

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EUROPEAN INDUSTRY INCREASINGLY USES FORMULAS WITH NATURAL
INGREDIENTS
ETHNIC FOODS ARE GAINING POPULARITY
SALT REDUCTION PROVES TO BE A CHALLENGE
REQUIREMENTS MUST OLEORESINS COMPLY WITH TO BE ALLOWED
ON THE EUROPEAN MARKET
QUALITY REQUIREMENTS
COLOUR AND FLAVOR
PURITY
INDIA DOMINATES THE OLEORESIN MARKET
BUYERS SHOW INTEREST IN NATURAL SUBSTITUTES
NEED FOR PRODUCT DISTINCTION
TWO MARKET SEGMENTS FOR OLEORESINS
TARGET IMPORTERS
EXPORTS TO FLAVOURING MANUFACTURERS
END-MARKET PRICES FOR OLEORESINS
VALUE ADDITION BY IMPORTERS
PRICE DEVELOPMENTS FOR SELECTED OLEORESINS, FOURTH QUARTER 2017
LABELLING & PACKAGING REQUIREMENTS
LABELLING
YOUR LABELS MUST INCLUDE
PACKAGING
PLANT & MACHINERY MANUFACTURER
CHILLI SUPPLIERS
RAW MATERIAL PHOTOGRAPHS
PRODUCT PHOTOGRAPHS
MACHINERY PHOTOGRAPHS
PRESSURE REGULATING EQUIPMENT
TRIPLEX PLUNGER PUMPS MAX. FLOW RATE OF 600 LTR/HR
CO2 PRESSURE INCREASE FROM 50 BAR TO 300 BAR
CO2 PASSED THROGH SUPER HEATER TO REACH A SUPER CRITICAL STATE
FOOD GRADE STAINLESS STEEL 316/304
SEPARATION OF UTILITY AREA AND CLEQN AREA EQUIPMENT
SCADA SYSTEM WITH ABILITY ADD NEW RECIPES
ACTIVE SYSTEM MONITORING FOR SAFETY AND RELIABILITY USING PRESSSURE
GAUGES, PRESSURE TRANDUCERS
ADVANCED INTEGRATED CONTROLS AND COMMUNICATION
SPECIALLY DESIGNED HEAT EXCENGER TO OPTIMIZE DESIGN TEMPERATURE
THE CO2 IN SUPER CRITICAL STATE PASSES THROUGH THE EXTYRACTOR
AND CARRIES WIT IT THE ESSENTIAL OILS AND NATURAL EXTRACTS.
THE CO2 IN THE SEPARATPOR AT LOWER PRESSURE TURNS IN TO A GAS AND THE
EXTRACT IS SEPARATED DUE TO THE GAS LIQUID SEPARATION.

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

COST ESTIMATION

Plant Capacity 28480 Ltr/Year

Land & Building Rs. 1.57 Cr
Plant & Machinery Rs. 3.02 Cr
Working Capital for 1 Month Rs. 1.27 Cr
Total Capital Investment Rs. 6.44 Cr
Rate of Return 39%
Break Even Point 46%

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