ýALAyý, ý\ Iý i W EMCJA mml 1"1'", 11 PILOT SCALE PRODUCTION OF SUGARS FROM SAGO STARCH Hafizah Binti Booty Master of Science 2011 Akademik Maklumat Khidmat Pusat SARAWAK MALAYSIA SITI IJNIVER. P.KHIDMAT MAKLUMATAKADEMIK UNIMAS 1111111111111111111111 11111 1000246247 PILOT SCALE PRODUCTION OF SUGARS FROM SAGO STARCH HAFIZAH BINTI BOOTY A thesis submitted in fulfillment of the requirement for the Degree of Master of Science (Biotechnology) Faculty of Resource Science and Technology UNIVERSITI MALAYSIA SARAWAK 2011 DECLARATION I hereby declare that no portion of the work referred to in this thesis has been submitted in for degree or qualification another support of an application or institution HAFIZAH learning. higher of BINTI BOOTY 07021255 August 2011 i to this or any other university ACKNOWLEDEMENTS First of all, I would throughout heartfelt the project. gratitude encouragement like to convey my deepest gratitude I would Also, Prof. to my supervisor, and comment like during to Allah S. W. T for His blessings my appreciation to express Dr. Kopli this project Bujang sincere for his advice, and guidance, and thesis preparation. Special thanks to all my seniors who had given useful technical advice, patience and help in the laboratory Lenny, Merlina, friendship friends lab like I thank to mates and my would also work. Ugam, and Nur and advice while working Hafizah, for their continuous together in the laboratory. namely, encouragement, I am also thankful to Lab assistants Mr. Ajis and Mr. Amin for their assistance. Lastly, I thank my parents Mr. Booty Osman and Mdm. blessings, financial support, encouragement Halimah and patience throughout you so much. ii Bujang for the this project. Thank ABSTRACT (Production (1L) from hydrolysis lab scale of sugars was performed at of various types of flour). The (sago, tapioca starch slurries was enzymatically sweet potato and corn, starch hydrolysed for four hours at the starch concentration Filtration suspended in 1L water). of sugar syrup with powdered activated charcoal of glucose was based on the yield referred as (PAC) was made and the measurement dextrose equivalent (200g DS 20% of starch powder of (DE). Upon filtration, the highest sugar (mainly glucose) recovery (84% DE), by followed DE, tapioca 99% by corn starch at starch sago was produced (72% DE). (76% DE) starch and sweet potato starch concentrations The effectsl of different in hydrolysis of sago starch (HSS) were then studied) Evidently, starch 50% DS (TRS) 30% 40%, to highest total and compared sugars the reducing amount of generated 20% DS at 413 g/L, 377 g/L, 298 g/L, and 205 g/L, respectively. filtered from glucose produced much higher concentration HSS (20% DS) gave the highest recovery (99% DE), a (89% DE) DS 40% 30% to and compared of glucose produced DS (81% DE). Furthermore, Enzymatic DE. 63% at only larger However, the amount of lowest DS 50% the sugar yield produced of the concentration hydrolysis thereafter of sago starch was performed DS 20% of sago starch scale using at 5L and 50L working volumes. at a It was (suspended DE PAC in 66% 5L 1,000g water) yields after of sago starch observed that from hydrolysed 10,000g DE 62% of of sago starch. to produced compared Consequently, (99% by 33% 66%), from 200g 1,000g the to to reduced sugar yield the process scaling up but scaling up further 1,000g to 10,000g reduced the sugars yield by only 4% (66% to 62% DE). These results confirmed significant loss in sugar yield. that the process could be further In addition, 111 60°C was proved scaled up without to be the best temperature conditions for sugar syrup be the most promising to starch seems or hydrolysed as an alternative sago starch raw material (HSS). Sago for the sugar industry of Malaysia. Key words: Sago starch, enzymatic hydrolysis (PAC), dextrose equivalent (DE) iv of starch, powdered activated charcoal PENGHASILAN GULA DARIPADA KANJI SAGUDAI. AM SKALA INDUSTRI ABSTRAK Penghasilan gula melalui proses hidrolisis berenzim telah dijalankan kanji telah berjaya dihidrolisiskan oleh enzim dalam tempoh empat jam pada kepekatan (200g dilarutkan DS 20% tepung sago sago kemudiannya pada skala (sagu, kanji jenis jagung, ubi kayu dan keledek). Cairan tepung empat IL menggunakan kanji kanji dijerap paras gula diukur warnanya dalam IL air). Larutan (PAC) di mana serbuk arang teraktif menggunakan gula pula kepada nilai setara dektros (DE). Terbukti dengan merujuk hidrolisis kanji sagu menghasilkan hidrolisis kanji jagung (84% DE), kanji ubi kayu (76% DE) dan kanji keledek (72% DE). paras glukosa yang tertinggi Kesan terhadap perbezaan kepekatan kanji (HSS) turut sagu dikaji. substrat 99% DE, diikuti (kanji sagu) ke atas proses hidrolisis bahawa HSS dengan kepekatan Terbukti paras gula penurun yang tertinggi menghasilkan iaitu bahawa berbanding kepekatan 50% DS 40% 30% dan 20% DS, maisng-masing pada 413 g/L, 377g/L, 298 gIL dan 205 g/L. Tetapi larutan gula HSS (20% DS) yang telah dijerap paras glukosa tertinggi menghasilkan kanji ke atas enzim dalam (20% diteruskan DS) sagu dengan karbon 5L air) teraktif menghasilkan ditingkatkan kepekatan 50% DS kanji lagi dengan mengekalkan menunjukkan 30% pula hidrolisis kepekatan kanji sago yang 66% DE selepas proses penyahwarnaan menghasilkan berbanding substrat telah berjaya glukosa sebanyak 63% DE. Kajian 20% DS pada skala 5L dan 50L air. Keputusan diampaikan air yang sebanyak 99% DE, diikuti iaitu hanya mampu menghasilkan sebaliknya oleh serbuk arang teraktif 40% (81% DE). Kepekatan (89% DE) dan kepekatan substrat warnanya dengan 10, OOOgkanji sagu diampaikan 62% DE sahaja. Manakala, apabila kuantiti daripada 200g kepada 1,000g, telah berlaku pengurangan V dalam 50L kanji sagu paras glukosa (99% Apabila, kepada 66%). 33% sebanyak 1,000g kepada 10,000g pula, hanya kanji sagu ditingkatkan kuantiti 4% penurunan daripada Berdasarkan dicerap. yang nilai kanji hidrolisis ke lanjut kajian sago pada skala yang terhasil, atas proses glukosa yang lebih besar masih boleh diteruskan. larutan optimum untuk menyimpan dijadikan bahan alternatifdalam Kata kunci: Kanji Tambahan suhu 60°C merupakan kesimpulan, Sebagai sagu. gula industri sagu, hidrolisis pula, kanji kanji suhu boleh sagu gula di Malaysia. karbon berenzim, serbuk sagu dektros V1 teraktif, nilai Pusat Khidmat Makiumat Akademik UNIVERSITI MALAYSIA SARAWAK TABLE OF CONTENTS Pages Declaration 1 Acknowledgements 11 Abstract 111 Abstrak V Table of contents List of Tables Vii List of Figures List of Abbreviations X11 xi xiv INTRODUCTION 1 1.0 Introduction 1 1.1 Objectives 4 CHAPTER 1 CHAPTER 2 2.1 2.2 LITERATURE 5 REVIEW 5 Sugars 2.1.1 Sources of sugars 7 2.1.2 Sugar Productions 9 2.1.3 Types of sugars 12 2.1.4 Application 13 2.1.5 Sugar industries of sugars in Malaysia 14 16 Starch 2.2.1 Sago Palm (Metroxylon 2.2.2 Sago starch and its properties 21 2.2.3 Extraction 23 2.2.4 Applications 2.2.5 Sago starch industries in Malaysia 30 2.2.6 Other starch sources 32 vii sagu) of sago starch of sago starch 17 29 2.3 2.4 Conversion of starch hydrolysis 2.3.1 Enzymatic 2.3.2 Large scale enzymatic Purification CHAPTER 3 3.1 3.2 36 of starch hydrolysis of starch 38 39 of sugars 2.4.1 Sugar de-colorization 2.5 34 to sugars using activated carbon 41 Storage and handling sugar products 42 MATERIALS AND METHODS 44 Materials 44 3.1.1 Starch 44 3.1.2 Enzymes 44 3.1.3 Powdered Activated Charcoal (PAC) 3.1.3.1 Pretreatment of PAC 44 45 3.1.4 Pilot scale (50L) stainless steel hydrolyser 45 Methods 47 3.2.1 Enzymatic hydrolysis of starch 47 3.2.2 Lab scale production of sugar from enzymatic hydrolysis of starch 3.2.2.1 Effects on various types of starch 3.2.2.2 Effects on different sago starch concentrations 48 viii 48 48 3.2.3 3.3 CHAPTER Pilot scale enzymatic hydrolysis of 20% DS sago starch 3.2.3.1 Hydrolysis of 1Kg sago starch suspended in 5L water 3.2.3.2 Hydrolysis of 10Kg sago starch in 50L water suspended 49 49 51 3.2.4 Purification of sugars using Powdered Activated Charcoal (PAC) 54 3.2.5 Effects of storage at different temperatures 56 methods 57 3.3.1 Reducing sugars 57 3.3.2. Starch 58 3.3.3 Colour 59 3.3.4 Protein 60 Analytical 4 RESULTS 61 4.1 Lab scale enzymatic hydrolysis of starch 61 Effects on various types of starch 61 4.1.2. Effects on different starch concentrations 64 Purification of sugars using Powdered Activated Charcoal (PAC) 67 4.2.1 Effects on different types of starch 67 4.2.2 Effects on different sago starch concentrations 73 4.1.1 4.2 4.3 Pilot scale enzymatic hydrolysis of 20% DS sago starch 78 4.4 Effects of storage at different temperature PAC purified sago syrup on conditions 82 ix CHAPTER 5 DISCUSSION 85 CHAPTER 6 SUMMARY 87 REFERENCES 88 APPENDIX A 102 APPENDIX B 104 APPENDIX C 107 X List of Tables Table 1 Physicochemical properties (Ahmad of sago starch et al., 1999). Table 2 Sugar recovery obtained from enzymatic sago, corn, tapioca and sweet potato. Table 3 Sugar production from enzymatic hydrolysis of sago starch at different starch concentrations (20%, 30%, 40% and 50%). Table 4 Table 5 hydrolysis of various 22 starch, 62 65 Percentage of protein and colour removal before and after PAC treatment on filtered sugar syrups. Sugar recovery obtained from hydrolysed starch (sago, corn, tapioca (from PAC before 5 replicates). treatment and after and sweet potato) 69 71 Table 6 Sugar recovery obtained from HSS before and after PAC treatment different sago starch concentrations (from 5 replicates). Table 7 Sugars recovery obtained from pilot scale hydrolysis of sago starch (20% DS) at 5L and 50L, (from 5 replicates). Table 8 Effects of storage temperature sago syrup. Table 9 Dried matter, moisture and starch content based on (1%, w/v) of flour. tapioca and sweet potato corn, sago, 107 Table 10 Amount of protein loss after purified with PAC. 107 Table 11 Percentage of color removal in after PAC treatment sago, corn, tapioca and sweet potato starch. Table 12 Percentage of color removal after PAC treatment DS. 30%, 40% 50% 20%, and concentrations; Table 13 Table 14 Table 15 on TRS concentration at of PAC purified from hydrolysed; from HSS at various Percentage of color removal after PAC treatment from pilot scale (20% DS) hydrolysis of sago starch at 5L and 50L working enzymatic volume. Amount of total reducing sugar obtained from enzymatic hydrolysis of sago, corn, tapioca and sweet potato starch. Amount of TRS obtained from HSS at various concentrations; 20%, 30%, 40% and 50% DS before and after PAC treatment. 76 79 83 107 108 108 109 109 Table 16 Amount of TRS obtained from pilot scale of HSS at 5L and 50L before PAC treatment. and after volume working 109 Table 17 Amount of TRS obtained from HSS when stored at various temperatures; 60°C, 4°C and room temperature (RT). 110 XI List of Figures Flow diagram of operation in a raw sugar mill (Andreis et al., 1990). 9 Figure 2 Sago palm (Metroxylon 19 Figure 3 Typical sago estate in Sarawak. 20 Figure 4 Harvested sago logs awaiting collection. 24 Figure 5 Sago logs are transferred mills. Figure 6 Sago logs are debarked using either an auto debarking machine or manually with a machete. 26 Figure 7 Debarked sago logs are rasped and mixed with water for starch extraction. 26 Figure 8 Schematic plan of a typical sago mill in Sarawak, (Bujang pers. comm., 2009). 27 Figure 9 Separation of starch slurry from the waste water. 27 Figure 10 Bagged sago starch ready for export. 28 Figure 11 (a) Schematic design and (b) 50L vessel for Pilot-scale enzymatic hydrolysis of starch. 46 Figure 12 Lab scale enzymatic hydrolysis of sago starch using a stainless (5L). steel vessel 50 Figure 13 Process of saccharification Figure 1 sagu) in Sarawak. (a) (b) lorry using or as sago rafts to sago (50L) hydrolyser. the using pilot scale 25 51 process of the hydrolysed sago starch from the prototype 50L system. 52 Figure 15 Hydrolysed sago starch (HSS) with reddish brown colour. 53 Figure 16 Removal of colour and impurities columns. 55 Figure 17 Effects of starch concentrations on HSS after 6 hours. Figure 14 Harvesting (a) Figure 18 from purified HSS using PAC 64 Sugar syrups from enzymatically hydrolysed starch upon filtration on Whatman (0.45 µm); From left: sago starch (MA); tapioca starch (MB); corn starch (MC); sweet potato starch (MD) (b) Sugar syrups upon filtration and purification on PAC; From left: sago starch, tapioca starch, corn starch and sweet potato starch xii 68 Figure 19 Comparison of sugar recovery (DE) before and after treatment with PAC. 70 Figure 20 (a) Filtered sugar syrups using Whatman 0.45µm cellulose nitrate membrane filters. From left: HSS 20%, 30%, 40% and 50% DS (b) Purified sugars syrup on PAC. From left: HSS 20%, 30%, 40%, and 50% DS 74 Figure 21 Comparison of sugar recovery (DE) from HSS at different starch PAC before treatment. and after concentrations 75 Comparison Figure 22 Figure 23 Figure 24 Figure 25 (DE) obtained from pilot-scale of sugar recovery hydrolysis of sago starch before and after treatment enzymatic with PAC. Removal of colour and proteins from HSS (a) before and (b) after PAC filtration. Stability of PAC purified sago sugar syrup under storage at different temperature after 21 says (from 5 replicates). Formation (brown of melanoids days during 21 syrup after colouration) storage at 4°C. in PAC purified 78 80 82 sago 84 Figure 26 Starch standard calibration curve from Iodine method at 590nm. 104 Figure 27 Glucose standard calibration curve from DNS method at 575nm. 105 Figure 28 Protein standard calibration curve from DC Protein Assay Kit (BSA) Serum Albumin Bovine as standard at 750nm. using 106 X111 List of Abbreviations % Percentage %/kg Percent per kilogram cm Centimeter DE Dextrose equivalent DS Dry substrate g Gram g/L Gram per liter HCl Hydrochloric hr Hour hrs Hours H2SO4 Sulfuric acid HSS Hydrolysed sago starch HPLC High performance liquid chromatography kg Kilogram L Liter M Molarity mg/L Milligram min Minute mL Milliliter mug Milliliter nm nanometer NaCl Sodium chloride NaoH Sodium hydroxide OD Optical Density xiv acid per liter per gram PAC Powdered activated charcoal RM Ringgit Malaysia R2 Correlation coefficient RT Room temperature t Tones tons/ha Tones per hector TRS Total reducing sugar USD US dollar v/v Volume per volume w/v Weight per volume w/w Weight per weight pLJg Microliter µm Micrometer µL Microliter xv per gram CHAPTER 1 INTRODUCTION 1.0 Introduction Sugar industries in Malaysia can be categorized as well developed as reflected by the rapid increase in direct domestic consumption which is amplified by an equally fast (FOMCA, 2006). Commercial sugar that we consumed growing food processing industry these days is derived from sugar cane. Sugar cane is a very easy and profitable grow but rather ineffective in reproducing processing industries in Malaysia still naturally (Braun, depend on imports plant to 1997). Up till now, sugar for about 90% of its raw materials which has reached a record of 1.0 million tones, compared to export at 101,000 tones. Owing to lack of raw materials sugar naturally and increases in industrial application of cane lead to higher price of this commodity. Starch is one of the essential energy source of the living world. Nevertheless, (Chulavatnatol, plant species can actively accumulate and store starch only some 2001). Sago, corn, known the plants with high starch content which is potato, cassava and rice are among a natural raw material alongside other starch-producing is Sago extracted starch wheat. plants such as tapioca, rice and from the sago palm (Metroxylon ), spp. also known as "rumbia" by local people (Ahmad et al., 1999). This crop is found abundantly in the state of Sarawak mainly Mukah, Igan and Oya and well-known More 90% Malaysia. than in of all sago-planting producer Sarawak in East Malaysia. The largest (75%) sago planting 1 as one of the great starch areas are found in the state of area is in Mukah where over 50% of the sago starch is produced (Bujang and Ahmad, 1999). A fully cultivated estate has about 138 palm/ha/year, and at about 185 kg starch/palm, sago a total of 25.53 tons can be expected. starch/ha/year Sago starch is utilized in the form of sago flour or sago pearl. Other than foodstuffs, sago for be to adhesives paper or even as a stabilizer produce used starch can also in (Aziz, 2002). Sago starch is highly recommended in the production of pharmaceuticals sugar for fermentation products, pharmaceutical 100,000 tones of sago starch are used annually including the food industries, sago planting commercialized bioconversion and cosmetics. About application in Malaysia for various household, and glue manufacture. With about 90% of all has industry in the a remarkable country, sago sugar areas in Sarawak. A study done by Bujang potential to be (2004) has discovered of sago starch into glucose is a more sensible alternative (US$0.50/kg) fetches a higher price then sago starch (US$0.20/kg). 2 applications that since glucose Our previous study has shown that sago starch is highly recommended as the starchysubstrate for sugar production to be used in the production of ethanol Bujang, 1998) and lactic acid (Bujang et al., 2000). This study highlights and potentials of sago starch as an alternative the highest recovery of sugar from for the production sago starch, glucose) produced using sago starch, a locally available and cheaper substrates. 3 the importance source to sugarcane for the production of is determine The the to aim study of commercial sugars. (mainly (Adeni and of commercial sugars 1.1 Objectives The principle aim of this research is to maximize glucose production, recovery and consequently to enhance the value of sago starch in Malaysia. purification In order to achieve this aim, the objectives of the research project are to: i) compare the amount of sugars produced from enzymatic hydrolyzed of different starch sources ii) develop the separation and purification iii) different the of effects study procedures of sago sugars starch concentrations during hydrolysis in order to maximize glucose recovery iv) from hydrolysis the pilot scale enzymatic of sugars study recovery of sago starch (20% DS) at 5L and 50L v) develop the optimum conditions for storage of liquid sago sugars 4 Pusat Khidmat fNaklumat Akademik UNIVERSITI MALAYSIA SARAWAJi CHAPTER 2 LITERATURE REVIEW 2.1 Sugar Sugar is a class of edible substance, mainly sucrose. It is a broad term applied to a large number of carbohydrates present in many plants and characterized sweet taste. In non-scientific white crystalline by a more or less use, the term sugar refers to sucrose or "table sugar", a (Anonymous, Wikipedia, 2010; disaccharide solid 2009a). Scientifically, (simple sugar) or disaccharide. sugar refers to any monosaccharide carbon, hydrogen and oxygen belonging to a class of carbohydrates. into three main groups; monosaccharide, disaccharides It is composed of It can be categorized and polysaccharides. the simplest sugars in the monosaccharide family. The disaccharides Glucose is are formed by the union of two monosaccharides with loss of one molecule of water, which includes lactose, maltose and sucrose. Polysaccharides are polymers that contain many monosaccharide residues; one of the common example is starch. Sugar has a central position in human consumption animals. The sugar we normally sugarcane; therefore, the industrial sugar and sugar beet processing. flavor and properties and serves as a major foodstuff for used nowadays is made of sucrose obtained production from of sugars today is mostly based on cane Sucrose is a common table sugar that is used to alter such as preservation, 5 mouth feel and texture in foods and beverages. they Sugar may dissolve in water to form syrup. Generically also have specific preparing name such as "honey" or "molasses". known as "syrup", Manufacturing and foods may involve other sugars such as palm sugar and fructose, obtained from corn (maize). According to Toth and Rizzuto (1990), back in the 15th century, sugar was economically important to all European. European sugarcane was planted in large plantations Indonesia, Philippines in Venice. Later in other regions in the world including India, sugar was mainly and the Pacific. Toth and Rizzuto 110,000,000 tons of sugar per year was used in manufactures refined (1990) revealed that and consumed worldwide. One of the early applications of sugar, it was a crude pharmaceutical bitter the today to or unpleasant taste of medicine. still used masked 6 over ingredients, as it is 2.1.1 Sources of Sugars Sugar primarily (Andreis from beet from sugar cane and sugar et al., 1990). It also comes honey, sorghum, maple sugar and in many other sources. Sugar is appears in fruits, normally leaves for in and as a source of energy plant growth and at the synthesized same time will be sent to the stalks for storage. The sweet sap in the stalk source gives rise to sugar. (Andreis, tropical 1990; Toth and or subtropical climate requires a Sugarcane cultivation Rizzuto, 1990), with a minimum photosynthesizer of 600mm annual rainfall. It is one of the most efficient that can convert as much 20% of incident solar into biomass. One thing from it is that propagates cutting with at least one bud, rather usually about sugarcane than from seed. Once planted, a stand of cane can be harvested several times. Usually, each successive harvest gives a smaller yield, and most eventually justifies replanting. the declining yields Average yields is about 100 tons of sugarcane per hectare producing 10 tons of cane sugar. Sugar beet is a member Amerenthaceae, of the Chenopediaceae subfamily high root contains concentration a plant whose under the family of (Food-Info, of sucrose 2009). It is a temperate climate biennial root crop, producing sugar during the first year for flowers it the the in to over winter and see and seeds in the second of growth order harvested in first in It is the therefore spring and autumn sown year. or early winter. The sucrose is stored in the bulbous root, which bears a strong resemblance to a fat Typical for (Food-Info, beets is 17% by weight but 2009). content sugar mature parsnip the value depends on variety and location, and it does vary from year to year. Up untill 7
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