ARTICLE
Introduction
Copra is the product obtained after drying coconut kernel, from an initial
moisture content of approximately 50 % to a moisture content which is
ideally close to 6 %. Unfortunately, the drying process is frequently
unsatisfactory, and if the copra is under-dried this can lead initially
to bacterial damage, and later to attack by moulds and insects.
The qualitative effects of deterioration in copra have been known for
many years. Work prior to 1937 has been reviewed by Cooke [1], while Child
[2], reporting in 1974, provides a useful summary of the problem. The
quantitative effects of deterioration have been examined by Nathanael
[3] who emphasised that simple measurement of oil content and free fatty
acid (FFA) before and after storage does not give an indication of true
storage loss. If copra is considered to be composed of water, oil and
proteinaceous meal, then deterioration may involve a differential loss
of both oil and meal. If, during fungal attack, the loss of meal is greater
than the oil loss, then the stored copra may show an oil content higher
than that of good quality copra originating from the same source. Indeed,
some oil millers prefer mouldy copra because of the higher oil recovery
[4]. Nathanael estimated the loss copra during the storage of under-dried
copra (at 12% moisture) over a 5 month period to be 15%, of which 10%
was avoidable. The FFA of the oil after this period was 1.5% compared
with 0.8% in well dried copra stored over a similar period.
In recent years an additional problem associated with copra deterioration
has been recognised, namely the presence of aflatoxin in copra that has
been attacked by the mould Aspergillus flavus. When copra is processed
in an expeller, aflatoxin in the copra is distributed between the oil
and cake [5]. Since the main use for copra cake is in the manufacture
of cattle feeds, the presence of aflatoxin in feeds for lactating cattle
gives particular cause for concern because of the known metabolism of
aflatoxin B1 in copra cake to aflatoxin M1 in milk
[6]. This is reflected in European Community regulations [7] which limit
the level of aflatoxin B1 in raw material imports to 20 ppb
(µg/kg) and limits levels in dairy feeds to 5ppb. Meeting this limit
requires the promotion of improvements in copra quality, for example through
a grading scheme. However, any scheme must provide a real financial incentive
to cover the increased processing costs necessary for the production of
dry, mould-free copra [8].
Copra marketing in the Philippines
Most of the copra produced in the Philippines is made by small-holder
farmers. The majority is initially traded by weight under the traditional
"Pasa" system, in which the prevailing area price of copra is adjusted
according to its estimated moisture content and other attributes. The
marketing system for copra in the Philippines has two major functions.
(a) to buy and accumulate copra in large quantities required by the
oil mills, many of which have capacities in excess of 200 tonnes per day;
(b) to allow time for the material to dry to a level at which it can
be processed by the factory for oil extraction.
The storage period between production and processing generally varies
between four and eight weeks. It is during this period, when the copra
slowly dries from 15 to 16% to around 6%, that significant damage from
both mould and insect attack is likely to occur. However, during periods
of market speculation, storage periods can be considerably longer. The
trading system is complex and may involve several different routes [9],
but in general the copra resides in a minimum of three stores before processing,
those of the primary trader, the dealer and the factory.
Purchases by the dealer, and at the factory, involve moisture content
determination using the Brown-Duvel method. This technique gives results
some 2 to 3 percentage points higher than the oven method [10]. Much of
the copra from the farmer has a moisture content well above the level
of 6% (oven method) recommended for safe storage. Estimates of the average
initial moisture content by Brown-Duvel are as high as 18% (i.e. 15 to
16% oven). When trading copra, it is usual to express moisture content
on a "wet weight basis", and all figures recorded in this paper are presented
in this form.
The work described in this paper was carried at the Davao Research Center
of the Philippine Coconut Authority (PCA) in Mindanao. The trials were
designed to provide information on :
(a) conditions which promote deterioration in copra and the development
of aflatoxin ;
(b) the effect of the method of copra drying on its stability ;
(c) the relationship between the appearance of copra and its quality
;
(d) the likely level of post-harvest losses in the Philippine coconut
industry.
Trial outline
Materials
Quality changes were monitored in copra stored at different moisture
contents and produced by three drying methods
| (a) Sun drying |
Trials Sl, S2 & S3 |
| (b) Kukum (indirect dryer) |
Trials Kl, K2 & K3 |
| (c) Tapahan (direct dryer) |
Trials Tl, T2 & T3 |
Drying was carried out on half cups. The timing of each trial was carefully
planned so as to avoid overloading the analytical facilities.
The variety of coconut used for these trials was the "Laguna Tall".
Sun dried copra was dried directly on the ground for a maximum period
of 5 days. The kukum dryer is fired by coconut husk and uses oil drums
as the heat exchanger. The tapahan is the traditional direct heat "smoke"
dryer, which also uses coconut husk as fuel. Changes in the quality of
commercial copra from various parts of the marketing chain were examined.
These were:
(d) Sun dried deliveries to a primary trader (ref. PS1 to PS5)
(e) Tapahan dried deliveries to a primary trader (ref. PT1 to PT5)
(f) Copra delivered to a large dealer (ref. BD1 to BD5, drying method
unknown)
(g) Copra being delivered to a large factory (ref. BF1 to BF5, drying
method unknown)
Sample preparation
The copra was stored in bags to allow recovery of the sample from the
store. The bags (used locally for onions or potatoes) had an open mesh
which allowed for easy transfer of moisture, mould spores and insects
during the storage period. Individual bags contained between 6 and 10
kg. With the exception of the commercial samples, the copra for each storage
set was selected to be of the same moisture content. The chosen moisture
contents were approximately 24%, 18%, 12% and 6%. These were judged from
the known period of drying and the texture of the copra. The preparation
of the 16 bags for the first trial with the kukum dryer (K1) at 24% moisture
content was as follows:
Thus the storage trial with non-commercial copra required 16 bags of
copra for any given initial moisture content, (i.e. 64 bags for the four
moisture contents selected). Commercial copra was well mixed before bagging
the replicate samples. As in the above example 16 bags were prepared for
each sample taken. The complete study involved the preparation of 896
bags of copra of which 672 were placed into store, the remainder being
the controls (storage time 0 week).
Storage conditions
The initial concept was to bury the prepared bags of copra in large
stacks of copra to allow equilibration to the environmental conditions
within the commercial stack. However in practice, such bags were extremely
difficult to recover, and deep storage was replaced by shallow storage
in which the bags were kept at the surface of the stack covered with 15-30cm
of copra.
Storage conditions were selected to approximate to commercial practice.
Bags of copra with high moisture levels (24% & 18% ) were initially
buried within a stack of copra in a primary store. When the trader sold
his stock, the copra was moved to a dealer's store and buried again. Copra
designated "12%" moisture was buried in a dealer's store, and low moisture
copra buried directly in a factory store. All copra kept for more than
four weeks was finally stored at a factory in a heap of copra that was
not required for immediate processing.
Analytical methodology
Control samples of copra (dried overnight at 60°C) were analysed
on the day when the copra was placed in store. Stored materials were analysed
at 2, 4, and 8 weekly intervals. Measurements were carried out to determine
the following
* Visual appearance by separating the copra into three types based on
the extent of mould attack
* Moisture loss over the storage period.
* Changes in oil quality (FFA and colour).
* Aflatoxin B1 levels.
* An assessment of dry matter (oil plus meal, oil loss and dust formation.
Visual appearance of the copra
The copra was separated into three types based on the extent of mould
attack
(a) Satisfactory copra, substantially free from mould attack.
(b) Copra with slight or superficial mould attack.
(c) Copra with severe mould attack i.e. attack resulting in surface
penetration. It was sometimes necessary to break the copra to see this
penetration.
Copra with any sign of mould penetration was designated "severe" while
the differentiation between copra placed in the "satisfactory" and "slight
mould" groups was less rigid. All three fractions were weighed and expressed
as a percentage of the total weight.
In addition the presence of moulds and insects was recorded together,
where possible, with their identification. Dust present in the sample
was separated and weighed.
Moisture loss
The relatively large samples of copra employed in these trials (10 to
20kg for each duplicate) were handled by the following method designed
to overcome sampling difficulties and possible excessive weight loss during
grinding. This two stage process involved drying the bulk sample at 60°C,
followed by drying a ground sub-sample at 103 ± 2°C.
The bags of copra were weighed and pre-dried in a large fan-assisted,
electrically heated, tray dryer overnight at 60°C. After cooling,
the copra was reweighed and the two bags comprising each replicate were
combined and ground in a knife mill fitted with an 8mm screen. The copra
was then passed through a sample divider and a one twelfth sample removed.
This sample was further mixed by hand prior to removing sub-samples for
the oven determination in which the moisture content was determined as
the weight loss when the ground copra (approximately 5g) was heated for
three hours at 103 ± 2°C. The weight loss of the bulk sample
together with oven method determination was used to compute the moisture
content of the original sample.
Oil content of copra
The analysis of oil content was carried out by NMR in a Mark 111 Newport
quantity analyser using crude coconut oil as standard. The method requires
a dry sample, and the combined duplicates from the oven moisture determination
were used. The results for several samples were compared with those given
by the Soxhlet method; agreement was satisfactory.
Isolation and analysis of the coconut oil from
each treatment set
The residual ground dry copra after sampling for moisture and oil content
(9.2 to 18.4kg) was processed in a small-scale expeller (throughput 40
to 60 kg/hour with an extraction efficiency of 70 to 80%) to provide crude
oil and copra cake. A small sample (100ml) of the freshly prepared oil
was clarified by filtration through a plain folded Whatman number 1 filter
paper. Oil colour was measured by the Philippine Coconut Authority standard
method on a Lovibond Tintometer using a 5.25 inch cell. The FFA of the
oil was determined by titration with 0.1N sodium hydroxide solution using
a method based on a British standard (BS 684: section 2.10: 1988). All
recorded levels of FFA are presented in terms of lauric acid.
Aflatoxin analysis
Aflatoxin analysis was conducted out on samples of cake from the expelling
process rather than the copra itself. The cake was ground in a knife mill
to pass a 2mm screen and sub-samples (approximately 2 x 50g) were obtained
using a sample divider. These were analysed for aflatoxin using an HPTLC
method combined with automatic fluorescence scanning for detection and
quantification [11].
Oil and dry matter loss
Losses of dry matter and oil were calculated by relating samples on
a "weight into store" basis. The success of this assessment relies heavily
on the initial selection of copra with homogeneous moisture content within
each storage set.
Aflatoxin in expeller
cake
A separate study [5] established that the ratio of aflatoxin in the
cake produced by the small-scale expeller to that in the copra from which
it was derived was approximately 1.5: 1. In addition, the ratio of aflatoxin
in the cake, from copra processed in commercial expellers in the Philippines
did not exceed 1: 1. Aflatoxin data presented in tables
1 and 2, figures 1, 2 and 3,
and plates 1 to 6 inclusive are calculated from the aflatoxin
in copra cake x 0.66. These can be interpreted as being the level of aflatoxin
in the copra, or the maximum that is likely to be found in cake after
commercial processing in an expeller.
Results
Visual appearance
The control samples for each series of sun-dried samples suffered mould
attack during preparation and the extent of this attack increased with
the drying period. However, all the attack was superficial. Black moulds
on the sun-dried copra were identified as Curvularia. The kukum
dryer generally produced white copra but the under-dried samples proved
to be highly vulnerable to mould attack. Tapahan copra was mould free
but tended to be dark in colour due to smoke deposition. All the high-moisture
samples suffered "severe" attack by moulds within the first two weeks
of storage, the most prevalent being Rhizopus sp. (white), A.
niger (black),A. flavus (yellow-green) and A.Glaucus
(green). Some were found to contain copra beetles (Necrobia rufipes).
At four weeks several samples were infested with flour beetles (Tribolium
castaneum) and mould mycelia was found to have broken down the copra
structure, forming dust and leaving a stained surface. In the case of
the high moisture samples, the copra surface was badly pitted. Sometimes
copra that had earlier suffered superficial attack was classified as "satisfactory".
Copra with very "severe" damage was often fragile and disintegrated easily.
The relationship between the proportion of cups by weight showing attack
by penetrating moulds, and their initial moisture content is shown in
figure 4. This is an important
relationship, since the extent of mould attack should also be related
to oil quality and aflatoxin content. The scatter of data about the "fitted"
curve in figure 4 suggests
that copra dried in a tapahan to a moisture content lower than 15% may
be less prone to mould attack than copra prepared in a kukum dryer, or
sun-dried to a similar moisture level.
The visual quality of the sun-dried copra from trial S3 (initial moisture
content nominally 6%, 12% and 24%) after eight weeks storage is shown
in plates 1 to 3 respectively.
Moisture loss
The moisture contents of all the copra samples examined fell to 5-7%
within the initial 2 week storage period (figure
5a, b and c). A separate study (figure
6) showed that copra with moisture contents as high as 20% will
dry (given good ventilation) to safe moisture levels within 10 days. However,
as indicated above, it is during this time that moulds are likely to develop.
In relation to the Philippine marketing system this approximates to the
period of on-farm storage, and drying in the primary traders' store.
Quality of extracted oil - Free fatty acid development
Changes in FFA content in relation to initial moisture content are presented
in figure 7 for the eight
weeks storage period. The data indicate that the extent of FFA formation
is related not only to the moisture content into store, but also to the
method of copra preparation. This is perhaps not surprising because
(a) sun drying was carried out under very poor conditions (intermittent
sunshine with periods of rain) and the copra had deteriorated before it
entered the store. The average FFA of oil from this control was 0.7% as
compared with 0.1 to 0.2% for the copra without deterioration.
(b) The average FFA in oil from the control kukum and tapahan copra
was 0.2% and 0.1% respectively. Tapahan copra differs primarily from copra
prepared by sun drying or in a kukum dryer due to smoke deposition on
the inner surface. In addition there is generally some case hardening
on the copra surface in the smoke-dried copra due to the high temperatures
involved.
Estimates of the average increase in FFA during 2, 4 & 8 weeks storage
intervals are given in table 3.
Sun dried copra demonstrated the highest increases in FFA. FFA increases
found in the kukum and tapahan copra are of the same order up to an initial
moisture content of 16%. Copra with good initial visual quality after
preparation in either a kukum or tapahan dryer, when placed in a store
at 10% moisture would be expected to yield an oil with a level of FFA
of less than 1% after eight weeks storage. Although not evaluated in this
trial, sun-dried copra of equivalent quality would be expected to exhibit
similar storage properties. The relationship between FFA increase and
the percentage of cups by weight with penetrating mould is shown in figure
8. As a general observation, oil present in mouldy copra will
continue to deteriorate after the copra has dried out, irrespective of
the method of preparation, although the rate of deterioration may decline
as the product ages (figure 8).
Oil quality - Colour
Oil colours at the end of eight weeks storage are summarised in table
4. Oil from well prepared kukum or sun-dried copra is water white.
However, in these trials poorly sun-dried copra produced oils with a high
red colour. Such copra was characterised by the presence of black surface
mould (Curvulavia sp.). Oils from sun-dried copra were pink to
deep red in colour. They would not normally be observed within industry
because the copra for processing is usually of mixed origin. There are
indications that the red colour in oils extracted from poor quality, sun-dried
copra diminishes with long storage. In general mould attack leads to an
increased yellow colour in oil. The colour of oils from copra prepared
by sundrying, in the tapahan and in the kukum dryer and stored for eight
weeks is shown in plates 4
to 6 respectively. With the exception of the oils from samples
S3G18 & S3G24 (plate 4)
all meet the Philippine standard for crude coconut oil (maximum 12 red
and 75 yellow).
Aflatoxin development
Levels of aflatoxin B1 for the three different methods of
manufacture are shown graphically in figure
1. The relatively high levels of aflatoxin found in some of the
controls was the result of problems in handling in the earlier part of
the trials. There was little change in the level of aflatoxin after two
weeks storage and on average, aflatoxin levels slightly declined on storage.
On the basis of these observations the aflatoxin levels in the stored
copra for any one batch is taken as the mean for the 2,4 & 8 weeks
periods.
The relationships between the initial moisture content of copra into
the store and aflatoxin B1 development for each type of copra
is shown in figure 2.
There is a strong similarity between the behaviour of kukum and sun-dried
copra although for any single moisture content the former is likely to
develop a higher level of aflatoxin. It was observed that copra from a
kukum drier appears more likely to exhibit a wide range of moisture contents
due to uneven drying [13] with the result that material with a low average
moisture can be attacked by A. flavus. Moisture in sun-dried copra
is likely to be more evenly distributed if well managed and turned regularly.
Figure 2 clearly shows
that copra prepared in a tapahan is less likely to contain high levels
of aflatoxin.
An analysis of the data, using a Statgraphics software package, indicated
that the relationship between aflatoxin levels and "into-store" moisture
content (MC) are as follows
Aflatoxin B1 (ppb) = C x % MC 2.326
where C = 0.170, 0.123 and 0.047 for copra prepared in a kukum dryer,
by sun drying and in a tapahan dryer respectively.
Therefore to achieve an average level of 20 ppb aflatoxin B1
(as required by current EC regulations), kukum and sun-dried copra should
be dried to 7.8% and 8.9% respectively, while tapahan dried copra only
has to be dried to 13.5%. However, if the average level of aflatoxin is
20ppb then around 50% of the samples will exceed this figure. To reduce
the potential incidence of aflatoxin contamination to 5% of samples it
will be necessary to dry to average marker levels of 4.6%, 5.3% and 8.8%
for kukum, sun-dried and tapahan copra respectively. The very low figures
for the kukum and sun-dried copra reflect the necessity for long drying
periods in order to overcome the effect of uneven drying.
The relationship between aflatoxin and the percentage by weight of cups
showing penetrating mould attack after eight weeks storage is presented
in figure 3 for the three
drying methods. It can be seen that for any given level of attack, tapahan
prepared copra is likely to contain lower levels of aflatoxin than that
produced in a kukum dryer or by sun drying. It is clear that any sample
of sun or kukum dried copra showing more than 20% attack by penetrating
moulds is likely to exceed an aflatoxin B1 level of 20 ppb.
The relationship between aflatoxin levels and mould attack was calculated
to be
Aflatoxin B1 (ppb) = e (0.035 x % mould + C)
where C = 2.36, 2.96 & 1.57 for copra prepared by sun, kukum and
tapahan drying respectively.
Predicted average values for aflatoxin B1 (ppb) in relation
to penetrating mould attack are as follows :
Material losses
Losses of dry matter and oil over the eight week storage period for
the non-commercial samples are presented graphically in figures
9 and 10 respectively. Linear regression analyses gives the following
relationships :
% dry matter loss = 0.28 x % moisture - 1.51 R = 0.76
% oil loss = 0.25 x % moisture - 2.09 R = 0.70
Estimates of average material losses for copra kept under the trial
storage conditions are recorded in table
5. The figures confirm the known stability of copra held under
good conditions of storage with a low initial moisture content (5 to 7%).
However, there is no evidence of an anticipated rise in the oil content
of the deteriorated copra although this is known to occur in practice.
The mean oil content of the "control" copra in these trials was 66.7%
(dry basis) while the calculated oil content after storage (based on the
data in table 5) is 66.9%
over the moisture range 10 to 20%. Measurement of dust formation was obscured
by the fact that dust was lost during the movement of the bags but could
also be gained within the store from surrounding copra. No relationship
between the initial moisture content and dust formation was observed.
Average levels of dust formation for the non-commercial samples over an
eight week storage period were 0.3%, 0.4% and 0.3% for the sun, kukum
and tapahan dried copra respectively.
Commercial samples
Quality changes in the commercial samples after eight weeks storage
are summarised in table 1.
The commercial samples taken from the dealer and factory stores showed
a wide range in quality. Oil FFA after 8 weeks storage ranged from 1.6%
to 4.6% and aflatoxin levels from 12 to 592 ppb. As the age of the samples
was unknown, only the level of severe mould attack can be applied as an
indicator of aflatoxin contamination (table
2). In nine of the twenty samples examined the aflatoxin B1
content found was much higher than that predicted.
Discussion
The study confirms the long established fact that copra containing 5-7%
moisture, which is largely free from mould attack, is a stable commodity.
When under-dried copra is placed into store, attack by A.flavus will
result in build up of aflatoxin B1 until the copra dries out
to a moisture content of approximately 8%, below which the mould is no
longer active [2]. Given good storage conditions this occurs over the
first two weeks of storage, which in the Philippines is in the early part
of the marketing chain, and approximates to the period on farm and in
the primary trader store. The study highlights the protective effect against
aflatoxin contamination imparted to copra by smoke drying in a tapahan.
This compares well with observations by de Lava in 1928 [13] and more
recently by Arseculeratne and his co-workers [14]. Arseculeratne studied
the effect of smoke from coconut shell and found an inhibitory effect
on aflatoxin accumulation rather than mould growth. Such inhibition has
been observed in the present study (figure
3) but there are indications that tapahan drying actually inhibits
mould formation (figure 4).
Whether the latter is the result of a component of the smoke, case hardening
or a combination of these two factors requires further study.
However, use of the direct fired tapahan introduces an additional quality
problem, contamination by polycyclic aromatic hydrocarbons (PAH), although
it is known that PAH can be removed from coconut oil if the refining process
includes treatment with suitable levels of activated carbon [15].
The study indicates that copra entering the marketing system with an
average moisture content of 16% and stored with good ventilation will
suffer a material loss of less than 3%. In practice copra tends to be
stored in large heaps and material at the centre could well suffer increased
loss.
The results also provide baseline data for the development of grading
schemes to limit average aflatoxin levels to 20ppb. Ideally copra should
be produced at source at 6% moisture as quickly as possible (generally
a minimum of 5 days sundrying or 24hrs in a kiln). However, a moisture
acceptance limitation at the first point of sale to 9% should provide
a satisfactory result. At this level, after drying in the store to around
5-7%, tapahan prepared copra is highly likely to meet the aflatoxin limit
while sun-dried copra should average 20ppb. However, copra prepared in
a kukum dryer would require drying to an average moisture content of 8%.
This can be attributed to the wide moisture distribution associated with
this natural draught dryer, a problem overcome in the tapahan by the protective
action of the smoke. Further down the marketing chain when the copra has
dried out, visual quality becomes important, and here the percentage of
cups showing attack by penetrating moulds is a guiding factor.
Relating visual mould attack to aflatoxin levels can be difficult. A
batch of very mouldy copra may contain little A.flavus and hence
a low level of aflatoxin. Another batch of what may appear to be good
copra, may contain small pockets of A.flavus in amounts sufficient
to create significant contamination.
In a separate study some 120 pieces of copra, each contaminated with
A.flavus were combined and found to contain 1180 ppb of aflatoxin
B1. The average surface cover of mould was 40%. At this level
of contamination one cup in fifty eight (1.7%) is sufficient to result
in a mixed sample exceeding 20 ppb of aflatoxin. Restricting mould levels
in tapahan and sun-dried copra to a level below 20% should, in theory,
eventually yield copra cake with an average level of aflatoxin B1
of 20 ppb. However, in practice, observed aflatoxin levels in some samples
are much higher than predicted so lower mould levels, say 5%, will be
required to ensure compliance. Any measure taken to control aflatoxin
levels will also improve oil quality. Using the measures described in
this paper, FFA levels in coconut oil prepared from copra stored for 8
weeks would be expected to be no greater than 1%.
CONCLUSION
Acknowledgements
The authors would like to acknowledge the practical assistance of Manuel
de Castro, Rose Balucan, Evelyn Tan, Lorna Maximo, Florante Glacio, Teodoro
Bontillao and Carlito Gestopa of the Philippine Coconut Authority and
Sarah Phillips, Clifton Gay and Phillip Drew of the Natural Resources
Institute. Aflatoxin analyses were carried out by the PCA in Manila under
the direction of Nelly Valencia. The authors are indebted to John Wood
for his valuable assistance with the preparation of the manuscript.
The study could not have been carried out without the ready cooperation
of the following organisations : The Davao Research Center (PCA), Mintal
Commercial , Solid Asia Marketing Corporation, Julu Enterprises and Legaspi
Oil Mill who are all located at Davao City Mindandao. The work constituted
part of an RP-UK technical cooperation project designed to reduce aflatoxin
levels in copra cake/meal.
The Department for International Development of the United Kingdom can
accept no responsibility for any information or views expressed in this
presentation.
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