Innovation in olive oil extraction

Abstract

The invention relates to an innovation in the malaxer machine and malaxation process used in continuous olive oil extraction machines, which ensures further rupture of olive cells and prepares oil particles for the subsequent liquid-solid phase separation by combining them, resulting in the production of olive.

Description

[0001] INNOVATION IN OLIVE OIL EXTRACTION

[0002] Technical Field

[0003] The invention relates to an innovation in the malaxer (kneading) machine and the malaxation (kneading) process used in continuous olive oil production.

[0004] More specifically, the invention relates to an innovation in the malaxer machine and malaxation process used in continuous olive oil extraction machines, which ensures further rupture of olive cells and prepares oil particles for the subsequent liquid-solid phase separation by combining them, resulting in the production of olive oil with enhanced aroma, volatile oils, high polyphenol content, and improved yield ratio.

[0005] Background Of The Invention

[0006] The health benefits of olives and olive oil are well-known. Today, olive oil production is largely carried out through a continuous system known as washing, crushing, paste kneading (malaxation), phase separation (decanter), and filtering (separator).

[0007] After olives are crushed in various types of crushers, they are transferred to malaxer machines. Malaxation times and temperatures vary significantly.

[0008] During malaxation, olive cells are ruptured with the help of olive pits and the effect of the malaxer machine mixers. The ruptured olive cell produces more enzymes, resulting in more aroma and polyphenols.

[0009] Released oil particles come together to form larger groups. This allows for higher yield in the subsequent decanter step, thus increasing the overall yield ratio. Malaxation is one of the most researched topics in the olive oil extraction process.

[0010] The malaxation (kneading) process typically takes between ten to fifty minutes. It can be roughly defined as slowly mixing the paste in a special container called a kneader (malaxer).

[0011] Heat, oxygen, and light affect olive paste and olive oil quality. In the two-phase continuous olive oil process, malaxation is where the olive paste is most exposed to the external environment. Therefore, to prevent undesired levels of oxygen contact, inert gas has been introduced, and positive results have led researchers and producers to perform malaxation under negative pressure (vacuum). In one advanced vacuum system application, vertical malaxers are used for easy cleaning and operated between negative 0.1-0.2 bar, aiming to reduce oxygen in the kneading tank and minimize the paste's exposure. At these pressure values, the temperature is maintained below 27 oC.

[0012] In another configuration, negative pressure is applied at around 700 mmHg. Under high vacuum, the olive paste in the malaxation cools very quickly. To maintain the malaxation temperature at around 18 oC, superheated steam circulates in the outer wall of the vacuum tank, and the water in the olive paste boils at 18 oC due to the high vacuum effect. The evaporated water is cooled back to liquid in a heat exchanger and returned to the olive paste. This aims to prevent the loss of polyphenols and volatile aromas. It is claimed that this application yields 50% more polyphenols and 15% higher ratio.

[0013] However, the above-mentioned configurations are complex applications that can be used in large facilities. They require high investment costs and training to work efficiently and provide the desired level of yield.

[0014] These systems are not easily accessible to certain levels of businesses, small producers, and farmers.

[0015] Fundamentally, it is known that during the malaxation stage, polyphenols reach maximum values in the 40 to 50 oC range and approximately one hour of malaxation time, while enzymes work around 15-25 oC for aroma and volatile oils. High ratio and efficiency require olive paste to be exposed to heat and long malaxation times.

[0016] The innovation aims to achieve maximum polyphenols and aroma for cold-pressed EVOO (extra virgin olive oil). It allows for working at appropriate temperature degrees in horizontal vacuum tanks under specified mmHg negative pressure, with either short or long malaxation times as desired.

[0017] Moreover, the majority of Turkiye’s olive oil production is in 3-phase form. There are efforts to transition to 2-phase olive oil production, which has higher added value. The 3rd phase of three-phase production, known as vegetable water, is a hazardous waste. The efficiency ratio in two-phase production is lower compared to three-phase. Therefore, two- phase production is not very popular.

[0018] The development subject to this invention has increased the efficiency ratio, which is a disadvantage of two-phase production. With this invention, efficiency increases by 10- 15%. This eliminates the disadvantage of the two-phase system, encouraging producers to switch to the two-phase system and produce higher added-value oil, largely eliminating the problem of environmentally harmful vegetable water.

[0019] Purpose and Brief Description of the Invention

[0020] The invention relates to an innovation in the malaxer (kneader) machine and malaxation (kneading) process used in continuous olive oil extraction machines, which ensures further rupture of olive cells and prepares oil particles for the subsequent liquid-solid phase separation by combining them.

[0021] The purpose of the invention is to mix the olive paste by colliding it with itself, rupturing cell membranes more extensively, allowing enzymes to function, and obtaining olive oil with enhanced aroma, volatile oils, high polyphenol content, and improved yield ratio.

[0022] Another purpose of the invention is to extract a higher percentage of existing oil from the olive paste compared to previous technical machines, despite being two-phase and cold- pressed.

[0023] The invention aims to increase the efficiency ratio, which is a disadvantage of two-phase production, thus facilitating the transition to 2-phase olive oil production with higher added value.

[0024] Another purpose of the invention is to minimize the loss of polyphenols, which are crucial components of olive oil, by preventing their mixing with waste.

[0025] Another purpose of the invention is to prevent the formation of vegetable water waste, which is environmentally harmful.

[0026] Another purpose of the invention is to minimize labor and installation costs.

[0027] Brief Description of the Figures

[0028] Figure 1 : A representative view showing the part details of the malaxer machine containing the innovations subject to the invention.

[0029] Figure 2: A view showing the position of the olive paste in the tank of the malaxer machine containing the innovations subject to the invention and the mixers carrying the paste layer to the created gap in thin layers.

[0030] Figure 3; shows a view from a different angle. Reference Numbers

[0031] 1. Paste Inlet

[0032] 2. Leak-proof V alve

[0033] 3. Observation, Control Unit

[0034] 4. Cover

[0035] 5. Tank

[0036] 6. Reducer and Electric Motor

[0037] 7. Paste Outlet

[0038] 8. Jacket

[0039] 9. Inner Wall

[0040] 10. Temperature Level, Pressure Sensor

[0041] 11. Conveyor Pipe

[0042] 12. Bearing

[0043] 13. Helix

[0044] 14. Mixing Blade

[0045] 15. Reverse Direction Mixing Blade

[0046] 16. Vanes

[0047] 17. Olive Paste

[0048] A.Malaxer (kneader) b: pressure area

[0049] Detailed Description Of The Invention

[0050] The invention relates to an innovation in the malaxer (A) machine used in continuous olive oil extraction machines and the malaxation (kneading) process that ensures thorough breakdown of olive paste and prepares oil particles for the subsequent liquid-solid phase separation by combining them.

[0051] Malaxation systems, a part of the continuous olive oil extraction process, have been one of the most researched topics. It is known that aroma, taste, smell, and polyphenols are formed with the secretion of enzymes during the olive crushing stage.

[0052] The invention is a high-vacuum horizontal malaxer (A) type. Its front cover can be easily opened when desired, allowing for detailed cleaning. This feature provides great convenience to users. The top cover can be opened for quick cleaning. The olive paste (17) coming from the crusher can be filled into the tank (5) from the bottom or top as desired for malaxation. Bottom filling ensures minimal oxygen contact with the olive paste until the malaxation is filled. The bottom filling process is provided through the paste inlet (1). The paste inlet (1) contains a leak-proof valve (2) resistant to vacuum pressure.

[0053] In the system subject to the invention, the malaxation (vacuum) tank is filled with olive paste to approximately 2 / 3 ratio, allowing as many olive cells as possible to contact the negative pressure. For this purpose, a horizontal malaxation type is preferred. The tank (5) has an inner wall resistant to vacuum pressure.

[0054] It has been observed that bottom pumping filling is more suitable to reduce oxygen contact, but in one configuration, top filling can also be done.

[0055] When 2 / 3 of the vacuum malaxation tank (5) is full, the inlet (1) and outlet (7) valves (2) are closed in a leak-proof manner to withstand vacuum.

[0056] The vacuum machine is set to 400-500 mmHg (medium) negative pressure. It has been observed that this negative pressure range of 400-500 mmHg is ideal, but operation is also possible in the 300-600 mmHg range.

[0057] During these processes, the temperature of the olive paste (17) needs to be constantly controlled for correct yield and quality oil extraction. The olive paste temperature needs to be maintained at the desired degree (22-27 oC). It should be cooled or heated if necessary. For this purpose, it contains a temperature level / pressure sensor (10). It also contains a jacket (8) where hot or cold water circulates for heating or cooling when needed.

[0058] The malaxation mixing blades (14) ensure the rupture of cell membranes and the continuation of enzyme functions by agitating the olive paste (17) towards each other.

[0059] In the application subj ect to the invention, vanes have been created in addition to the mixing blades (14). It contains vanes (16) that knead and agitate the olive paste, carrying it to the vacuum area created in the tank. The mentioned vanes (16), with their slightly curved form, carry the olive paste to the area created in the upper part of the tank with negative pressure and ensure it falls downwards in thin layers. As shown in the representative view in Figures 2 and 3, the olive paste (17) is ensured to fall downwards in thin layers over the vanes (16) to the pressure area (b).

[0060] This allows for easier rupture of olive cell membranes in this area created with negative pressure (300-600 mmHg). With the created negative pressure area, the internal pressure-external pressure balance of the olive cell is disrupted, the internal pressure will be higher, forcing outwards and allowing for easier rupture of the cell.

[0061] Before the vacuum environment is created, while the pressure inside and outside the cell is equal, by bringing the pressure inside our vacuum malaxation tank (5) to negative 400-500 mmHg, the pressure inside the olive paste cells will be higher. In this case, easier rupture of the cell membrane has been demonstrated.

[0062] Not completely filling the vacuum malaxation tank (5), leaving an empty space (b) at the top, the vanes (16) carrying the olive paste in thin layers to this space and ensuring it falls in thin layers, are applied to allow the cells to enter the pressure difference environment.

[0063] If the vacuum malaxation tank (5) is completely filled and the paste is not carried to this space in thin layers, the desired effect cannot be achieved as the cells cannot perceive the internal pressure-external pressure difference due to density and contact.

[0064] With the invention, a difference in internal and external pressure in the cells has been created, demonstrating easier rupture of olive cells.

[0065] Thus, olive cell membranes are more easily ruptured, causing more enzymes to work.

[0066] At the same time, this medium negative pressure will cause the olive paste to feel about 30 oC higher than its actual temperature, which will accelerate the rupture of cells and lead to the merger of oil cells. This has demonstrated increased yield, antioxidants, and aroma extraction.

[0067] This demonstrates an increase in cold-pressed oil production. Thanks to the desired level of malaxation, more efficient production is achieved in the decanter.

[0068] More rupture of olive cells demonstrates more release and more work of enzymes. This results in obtaining more polyphenols.

[0069] The actual temperature of the olive paste (17) in the vacuum malaxation is kept under control and remains at 22-27 oC. Therefore, aroma enzymes work and increase volatile oils, aroma, smell, and flavor. The oxygen that allows these enzymes to work is present in the olive paste and in area (b) as full vacuum is not applied continuously.

[0070] In the system subject to the invention, vacuum is not applied continuously but engages according to the values of the Temperature Level, Pressure Sensor (10). At its core, the system subject to the invention provides olive paste from the crusher to the malax er (A) tank (5) through the paste inlet (1) created at the bottom of the machine.

[0071] At this time, the vacuum pump is started and low pressure is set to negative 100 mmHg. The paste outlet (7) valve (2) is closed in a leak-proof manner. Thus, the olive paste begins to fill the malaxation tank (5) with less oxygen contact. The olive paste is filled to about % of the diameter (TD) of the malaxation tank. When the filling is complete, the sensor alerts and the inlet valve (2) is closed in a leak-proof manner. The malaxation tank (5) is closed in a vacuum-tight manner.

[0072] The tank contains a conveyor pipe (11) on the middle body, mixing blades (14) on the conveyor pipe, and a helix (13) on the blades. It also contains shorter and reverse direction mixing blades (15). It contains curved vanes (16) parallel to the mixing blade (14) axis that knead, agitate, and carry the olive paste to the vacuum-free area (b) as desired.

[0073] The mixing blades (14) start to rotate by means of a reducer and electric motor (6). It contains an observation, control unit (3) and an easily openable and closable, vacuumresistant glass observation cover (4) to monitor the olive paste. The observation, control unit (3) also allows for daily washing, cleaning, etc. operations.

[0074] To control the temperature, cold or hot water is circulated in the tank inner wall (8). The olive paste temperature is tried to be kept constant. At the same time, the vacuum pressure is adjusted to the desired negative pressure. This vacuum is adjusted to negative 300-600 mmHg, ideally 400-500 mmHg, and is considered medium pressure. When the vacuum machine reaches the desired pressure, it is turned off. Pressure, level, and temperature sensors (10) constantly keep the system under control. At this negative pressure, the boiling point of water is around 85 oC. This prevents evaporation. Also, the vacuum machine is not operated continuously. Thus, evaporation is kept to a minimum. It has been demonstrated that volatile aromas and phenols are prevented from evaporating and going to the vacuum machine, staying in the olive oil.

[0075] The reducer side bearing of the Conveyor Pipe (11) is on the cover. The other side is attached to a bearing (12) independent of the cover. This allows the cover to be opened independently of the mixer. Deep cleaning and maintenance are facilitated. It is designed to be leak-proof and vacuum-resistant. Mixing blades (14) are placed perpendicular to the top of the conveyor pipe (11). Short blades (15) at reverse angles are placed between the long carrier blades. Vanes (16) are added to the spring-like helix (13) as short pieces parallel to the tank axis, both as mixers and carriers. The rectangular pieces are slightly curved in the middle. The purpose of this is to take a thin layer on it as the mixer turns, bring it to the negative average 450 mmHg pressure space (b) at the top of the tank, and allow it to pour in thin layers. The internal pressure of the cells is positive 1 atm. Cell membranes cannot withstand this pressure difference and rupture more easily. Cells weakened by the pressure difference are further ruptured by colliding with each other thanks to the vanes (16), also with the effect of broken olive pits. Thus, more phenols and more oil particles emerge.

[0076] An important feature of the invention is that these vanes (16) and their curves allow for more cell rupture by carrying the paste in thin layers and under negative pressure. If the olive paste is not distributed in thin layers, only the cell membranes of the outer layers of the paste are affected. For the majority to be affected, it needs to be distributed in thin layers. At the same time, easy rupture of olive cells is ensured by colliding them with each other thanks to the vanes (16).

[0077] Additionally, the vacuum machine is started and stopped. There is no need for continuous vacuum as the aim is not to evaporate the olive paste water. As there is no high vacuum, there is no need for aggressive heat and heat exchanger (converting steam to liquid by cooling) systems. It is simple, easy to use, and economical to operate and own.

Claims

CLAIMSWhat claimed is:

1. A malaxer (A) machine and malaxation (kneading) process used in continuous olive oil extraction machines that ensures further rupture of olive cells and prepares the resulting paste for the subsequent liquid-solid phase separation by combining oil molecules, characterized by:- filling the mentioned malaxer tank (5) with olive paste up to 2 / 3 of its volume, allowing the creation of a pressure zone (b) where the olive paste is exposed to a pressure differential; creating a negative pressure of 300-600 mmHg inside the tank; containing curved vanes (16) parallel to the mixer axis that carry the olive paste to the negative pressure area (b) and pour it in thin layers, facilitating the rupture of cell membranes due to the internal cell pressure being higher than the negative ambient pressure of the system.

2. The malaxer (A) machine according to claim 1, characterized by containing vanes (16) that ensure aggressive mixing of cell membranes weakened in the vacuum environment, causing cells to collide and rupture more extensively.

3. The malaxer (A) machine according to claim 1, characterized by containing an observation / control unit with openable and closable vacuum-resistant covers that allow for monitoring, control, and cleaning of the olive paste inside the vacuumresistant tank when necessary.

4. The malaxer (A) machine according to claim 1, characterized by containing a paste inlet (1) with a leak-proof valve located at the bottom of the tank, ensuring minimal oxygen contact with the olive paste until the tank is filled.

5. The malaxer (A) machine according to claim 1, characterized by containing mixing blades (14) that agitate the olive paste (17) towards each other to rupture cell membranes and maintain enzyme activity, a helix (13) formed on the blades, and short reverse-direction mixing blades (15).

6. The malaxer (A) machine according to claim 1, characterized by containing a temperature / level / pressure sensor (10) for continuous temperature control,5 maintaining the desired temperature (22-27°C), and a jacket (8) through which hot or cold water circulates for cooling or heating as needed.

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