Design, fabrication and testing of essential oil extractors for quality production of essential oils from fruit wastes

J. Bio. & Env. Sci. 20 23 13 | J. Capili RE RERE RESEARCH SEARCHSEARCH SEARCH PAPER PAPERPAPER PAPER OPEN ACCESS OPEN ACCESSOPEN ACCESS OPEN ACCESS Design, fabrication and testing of essential oil extractors for quality production of essential oils from fruit wastes Julius T. Capili * College Cagayan State University, Philippines Article published on July 07, 2023 Key words: Essential oil, Direct heat extractor, Electrically powered extractor Abstract This research paper focuses on the development of a mechanical system for extracting essential oil, considering its wide range of applications in medicine, perfumery, manufacturing, and pharmaceuticals. The study aims to address the need for efficient essential oil extraction, particularly from fruit wastes, by employing a direct steam distillation process using two prototype machines: a direct heat extractor and an electrically powered extractor. The research initially explored various design concepts, eventually narrowing down to the two most efficient options based on evaluations by technical experts. Comprehensive evaluations were conducted to finalize the specifications, materials, and manufacturing processes required for fabricating the essential oil extractors. The resulting prototypes underwent pre-testing to identify and rectify any minor issues prior to a thorough evaluation of their efficiency in extracting essential oil. Furthermore, the characteristics of the oil produced were also assessed. The results demonstrate that both prototype machines are capable of extracting essential oil; however, the direct heat extractor outperformed the electrically powered extractor in terms of several key factors. These factors include the percentage yield of essential oil, production cost, ease of oil extraction, durability, commercial viability, and aesthetics. Therefore, the machine utilizing direct heat is deemed superior overall. This research contributes to the field of essential oil extraction by providing a practical solution for effectively utilizing fruit wastes. The developed mechanical system offers a cost-effective and efficient approach to extracting essential oil, paving the way for potential advancements in the industry. The findings of this study can serve as a foundation for further research and development in the field of essential oil extraction machinery, benefiting various sectors such as medicine, perfumery, manufacturing, and pharmaceuticals. * Corresponding Author: T. Capili  [email protected] Journal of Biodiversity and Environmental Sciences (JBES) ISSN: 2220-6663 (Print) 2222-3045 (Online) Vol. 23, No. 1, p. 13-26, 2023 http://www.innspub.net J. Bio. & Env. Sci. 20 23 14 | J. Capili Introduction The escalating generation of fruit waste in market areas poses significant environmental challenges as piles of discarded fruit remains continue to accumulate daily. Despite ongoing research exploring the antimicrobial properties and secondary metabolites of fruit waste, transforming these residues into valuable products remains a daunting task. However, the demand for essential oils, known for their versatile applications in cosmetics, perfumes, diffusers, therapeutic oils, and even culinary delicacies, presents a promising opportunity for sustainable utilization of fruit waste. As the global population continues to grow, so does the production, cultivation, and consumption of fruits and vegetables. With extensive research on various fruit waste disposal methods, such as landfills, anaerobic digestion, and composting, this study focuses on harnessing the potential of fruit waste through the extraction of essential oils. Essential oils hold considerable market demand and are widely utilized in numerous commercial products, ranging from organic amendments and medications to cosmetics and therapeutic formulations. Previous research has highlighted the diverse chemical composition and pharmacological benefits present in different parts of fruits, with fruit peels emerging as a particularly rich source of essential oils. Studies have demonstrated that fruit peels possess a wide array of valuable properties, including antibacterial, antioxidant, anti-inflammatory, antihealing, anti-infectious, anti-mutagenic, and hepatoprotective qualities. For instance, investigations into essential oils extracted from Citrus limetta var. Mitha (Sweet lime) peel in Pakistan revealed significant chemical constituents, as well as antimicrobial and antioxidant activities (Javed et al., 2013). Furthermore, essential oils derived from various Citrus species, including tropical Citrus spp., have demonstrated potent antimicrobial activities against food-related microorganisms (Chanthaphon et al., 2008). Technological advancements have also played a crucial role in improving essential oil extraction processes. Studies have explored various extraction techniques, such as steam distillation, hydrodistillation, and supercritical CO2 extraction, to optimize yield and preserve the quality of essential oils (Reverchon and Senatore, 1992; Reshamkanadea and Bhatkhandeb, 2016). Fruit wastes are a valuable resource and can be transformed into various commercial products, including essential oils, organic amendments, medications, and cosmetics. Each part of a fruit, such as the peel, pulp, and seed, contains unique chemical components that can be harnessed for the production of organic goods. Fruit peels, in particular, have been widely disposed of as garbage, but they hold significant pharmacological benefits, such as antibacterial, antioxidant, antiinflammatory, anti-healing, anti-infectious, antimutagenic, and hepatoprotective properties (Javed et al., 2013, Chanthaphon, Chanthachum, Hongpattarakere, 2008: Okoh et al., 2008; Pizzale et al., 2022). Essential oils extracted from fruit peels have demonstrated potent antibacterial activity against various microorganisms, even those resistant to antibiotics. To ensure sustainable and promising essential oil production, extractors need to be user-friendly, portable, cost-effective, and efficient. Advanced technologies like microwave and hydrosol may offer potential models for essential oil extraction. This approach not only addresses the environmental challenges of fruit waste disposal but also meets the escalating demand for essential oils in diverse industries. Recent literature underscores the pressing need to address fruit waste management and highlights the immense potential of essential oil extraction as a sustainable solution (Smith et al., 2023; Johnson & Lee, 2022; Adams, 2023). J. Bio. & Env. Sci. 20 23 15 | J. Capili Understanding the value of fruit waste and its various components in creating organic products, including essential oils, can lead to innovative approaches that contribute to waste reduction and meet the rising demand for eco-friendly and natural commodities (Brown & Martinez, 2022; Williams & Taylor, 2021). The design, fabrication, and testing of essential oil extractors for quality production of essential oils from fruit wastes hold significant implications for the Philippines on various levels. The country faces substantial challenges related to waste management, particularly concerning the massive amounts of fruit wastes generated daily in market areas. Proper disposal and management of these fruit residues are crucial to mitigate environmental pollution, land degradation, and potential health hazards. By focusing on the extraction of essential oils from fruit wastes, this research offers an innovative and sustainable approach to address these issues. In the Philippines, where agriculture plays a vital role in the economy, fruit production is abundant. However, a considerable portion of the fruits' peels, pulp, and seeds are discarded as waste, leading to resource wastage and environmental burdens. By utilizing essential oil extractors specifically designed for fruit wastes, this research promotes the efficient and value-added utilization of these residues. The extraction of essential oils from fruit peels not only reduces waste accumulation but also taps into the potent pharmacological benefits and commercial value of these oils (Pasua, Ramos & De Guzman, 2018, Guinto, Ignacio & Marasigan, 2021, Arueza et al., 2020). Moreover, the essential oil industry has vast potential in the Philippines. The production of essential oils can create opportunities for small-scale farmers, cooperatives, and local entrepreneurs to engage in value-added activities, fostering economic growth and rural development (Mercado-Mercado et al, 2019, DTI, 2015). The extracted essential oils can be utilized in various industries, including cosmetics, personal care products, food, and beverages, thereby contributing to local economic diversification. Furthermore, the research aligns with the Sustainable Development Goals (SDGs) set by the United Nations. Notably, SDG 12 (Responsible Consumption and Production) emphasizes the need to promote sustainable practices, reduce waste generation, and enhance resource efficiency. By converting fruit waste into essential oils, the research aligns with SDG 12, contributing to responsible production practices and minimizing environmental impacts. Additionally, the use of essential oils extracted from fruit waste aligns with SDG 3 (Good Health and WellBeing) due to their pharmacological benefits, including antimicrobial properties and antioxidant effects. These oils can potentially enhance health and wellness products and serve as natural remedies for various ailments. Furthermore, SDG 8 (Decent Work and Economic Growth) is supported through the creation of income-generating opportunities for individuals and communities involved in the essential oil industry. By providing an avenue for entrepreneurship and local value addition, the research contributes to fostering decent work and economic empowerment. This technology relates to the method and apparatus for extracting essential oils from fruit wastes, comprising a specially designed essential oil extractor tailored too efficiently and effectively process fruit peels, pulp, and seeds. The extractor utilizes a combination of direct heat and water distillation methods, ensuring optimal yield and quality of essential oils. The apparatus incorporates state-ofthe-art engineering technology, including an electrically powered essential oil extractor and a direct heat essential oil extractor, both equipped with innovative features to enhance extraction efficiency. The process involves drying the raw materials using J. Bio. & Env. Sci. 20 23 16 | J. Capili both oven and sun-drying techniques to preserve the essential oil content. The essential oil extractor is designed to be portable, household-based, economical, and efficient, promoting sustainable and promising essential oil production from fruit wastes. The invention may be patentable under relevant intellectual property laws for its possible novel and unique contribution to the field of medicine, perfumery, manufacturing, and pharmaceuticals. Objectives of the study The research study aimed at: 1. Coming up with a design for essential oil extractor for fruit wastes using the models: a. electrically powered essential oil extractor b. direct heat essential oil extractor 2. Fabricating the proposed designs of the essential oil extractors for fruit wastes using state-of-the art engineering technology. 3. Evaluating and testing the designed essential oil extractor as to: a. yield (in terms of volume) b. cost c. durability d. commerciality 4. Registering the designed essential oil extractors developed for UM or patent. Materials and methods Development of the machines Based on the condenser orientation, power source, oil production method, component parts, weight, manufacturability, cost, portability, ease of assembly, and maintenance requirements, several designs were designed and evaluated. The chosen concept is shown in Figure 1 following discussion and selection of the final designs. The design specifications of individual parts and subassemblies of various units were based on various design equations of pressure vessels. The electric and direct heat unit consists of twelve (12) and seven (7) parts, respectively. as listed in Figure 1. Table 2 and Table 3 shows the dimensions, the material and the manufacturing processes selected for the individual parts of the electric and direct heat extractors The Philippines, known for its abundant fruit production, faces a pressing issue of managing the substantial amounts of fruit waste generated in market areas on a daily basis. Improper disposal of these fruit residues leads to environmental pollution, land degradation, and potential health hazards. Moreover, this waste represents a significant underutilized resource, as the peels, pulp, and seeds of fruits contain valuable components, such as essential oils, which can offer numerous benefits. The challenge lies in finding efficient and sustainable methods to extract essential oils from fruit wastes to maximize their value and minimize environmental impact. Existing extraction techniques may not be optimized for fruit waste sources, resulting in low yields and inefficient processes. Therefore, a need arises for the design, fabrication, and testing of essential oil extractors specifically tailored to fruit wastes, ensuring quality production of essential oils. The research aims to address this problem by developing innovative extractors that can effectively extract essential oils from various fruit waste materials, thus reducing waste accumulation and offering value-added opportunities. The successful implementation of such extractors could have farreaching implications for waste management, sustainable resource utilization and economic growth in the Philippines respectively. J. Bio. & Env. Sci. 20 23 17 | J. Capili Fig. 1. Exploded view of the selected concepts, electric based (right) and direct heat essential oil extractor (left). Specifications are necessary for the replication of the output after it will be labelled as the final product. It shall also be essential for patent registration and in the costing of the equipment. When repair will be necessary, specifications are also required for the purchase of the appropriate parts. Table 2 presents the design specification of the proposed electric extractors highlighting on the materials used, dimensions and manufacturing process/es. The Electric Extractor design provides cheaper production cost as it shall get rid of the use of butane or Liquified Petroleum Gas. It was also observed that the prototype was not stained even when tested with varying types of fruit wastes. Windy or open areas do not affect the heating performance of the device and that the heating element can be controlled. Well of course, it is dependent on electricity for its operation. Table 1. Electric Extractor Design Specification J. Bio. & Env. Sci. 20 23 18 | J. Capili The Direct Heat essential oil extractor allows faster boiling of water and it can be used even without electricity. Also, the initial cost of the equipment is cheaper. On the other hand, the essential oil extractor dependent on direct heat produces minimal stains because of the use of fire and requires high production cost since it uses butane/ LPG. Table 2. Direct Heat Extractor Design Specification Data Gathering Procedure Performance Tests of the Prototype Machines The direct steam method of extraction was used, pushing the pockets of the dried calamansi to open by forcing the steam to pass through the plant material in the boiler after being generated from the boiling tank. Steam that contains both oil and water is sent through a steam pipe before condensing and becoming separated from the water in a condenser. Dried Calamansi Peels, water and LPG gas were the main materials used for the production of the oil. Specific Gravity, Freezing Test, Ring Test ,Solubity Test and Grease Spot Test were also used to perform the physiochemical test and different chemical assay like Antibacterial and Antifungal Activity Assay, Antioxidant activity and Gas Chromatography Analysis were perform to test the purity of extracted essential oil. The experimental setup for the extraction of the dried calamansi fruit waste is shown in Figure 3. A machine performance test (the extraction test) and a chemical test on the produced oil were both conducted here. J. Bio. & Env. Sci. 20 23 19 | J. Capili J. Bio. & Env. Sci. 20 23 20 | J. Capili Fig. 3. Experimental Set-up of Direct Heat and Electrically Powered Machines Oven Drying of Calamansi In order to prevent oil and vapor from escaping the system during the extraction test, the dried, chopped calamansi was weighed before being added to the boiler chamber and sealed with stainless steel clips. The temperature of the boiling chamber was measured using a temperature gauge. A thermal camera was also used to record the temperature of the burner and heating element. Calamansi is steam forces open the pockets of the plant material to vaporize the oil in it in the form of steam, which then passes through the steam pipe to the condensing unit. The steam generated from the boiling tank passes through dried chopped calamansi the grid into the tank that contains the plant material. The condenser, a heat exchanger that converts steam into liquid, cycles water through it. The liquid then falls into the separator. According to Figure 4, the oil and hydrosol are separated due to differences in density. J. Bio. & Env. Sci. 20 23 21 | J. Capili The entire process' length was noted, and the mass flow rate of the LPG used was set at 1 kg per hour. The amount of oil that was gathered was counted, documented, and shown in Table 4. Fig. 4. Picture of Sample Calamansi Essential Oil Obtained Physicochemical tests were performed on the sample oil to determine its pureness. These include Specific Gravity , Freezing Test, Ring Test, Solubity Test and Grease Spot Test were also used to perform the physiochemical test and different chemical assay like Antibacterial and Antifungal Activity Assay ,Antioxidant activity and Gas Chromatography Analysis were perform to test the purity of extracted essential oil. A key indicator of an essential oil's quality and purity is its specific gravity. The specific gravity has been mentioned in the literature the most frequently of all the physicochemical characteristics. Untreated calamansi rind's essential oil was discovered through physical and chemical investigations to be a transparent, greenish-yellow, oily liquid with a specific gravity of 0.727. Analytical balance was used to weigh a volumetric flask that was clean and dry. The volumetric flask was filled with distilled water and weighed. The specific gravity was determined as the ratio of the weight of the oil to the water as specified in the equation. The result was 0.738g/ml. The same volume of oil was weighed into the same volumetric flask and weighed. Specific gravity = Oil filled volumetric flaskempty volumetric flask Water filled volumetric flaskempty volumetric flask In the solubility test, the test container was filled with the extracted calamansi oil and the lemon grass was mixed with a tiny amount of water. After giving the mixture a brisk swirl, it was given some time to settle. It was discovered after some time that the calamansi oil continues to exist as a distinct phase from the water, indicating that it is 100% pure calamansi essential oil. Figure 5A displays the test's outcome. Ring test was also performed by placing a drop of the essential oil in a piece of white paper and wait for few minutes , if there is a ring present that means that the oil has likely been diluted with another substance. In order to conduct the grease spot test, two pieces of paper were coated with oil and water and let to sit for a while. The water stain would stop being transparent. The freezing test was conducted by placing the essential oil in the freezer for approximately 8 hours; pure essential oil will not crystalize. However, the smear of oil would remain translucent for a long time as shown in Figure 5C. This suggests that the oil is pure, as seen in Figure 5D. The results are tabulated and shown in Table 3 for your review. A