Copra Expeller

Infobox on Copra Expeller
Example of Copra Expeller
Facts
Origin	This Table shows only a selection of the most important countries of origin and should not be thought of as exhaustive. Europe Africa: Mozambique Asia: India, Philippines, Indonesia America: USA Australia
Stowage factor (in m3/t)	1.70 - 2.00 m3/t In order to ensure better utilization of transport volume, copra expeller should be compressed. Storage in silo cells is risk-free.
Angle of repose	approx. 42°
Humidity / moisture	Copra expeller requires particular temperature, humidity/moisture and ventilation conditions (SC VII) (storage climate conditions). Relative humidity: 70% Water content: 5 - 10% Maximum equilibrium moisture content: 70%
Oil content	1.5 - 7.0%
Ventilation	Copra expeller requires particular temperature, humidity/moisture and ventilation conditions. Recommended ventilation conditions: surface ventilation. See text for further details.
Risk factors	Self-heating / Spontaneous combustion Oil content: 1.5 - 7.0% Copra expeller is liable to the risk of self-heating/spontaneous combustion. Copra expeller is assigned to class 4.2, pursuant to the IMDG Code. All types and varieties of pellets, expellers and extracts fall within the class "Seed Cake" under UN numbers 2217 and 1386.

Copra Expeller

Copra expeller comprises pressing residues arising from oil extraction from copra (coconut flesh).

Depending upon how the oil is extracted, the following distinctions are made:

• pressure filtration (pressing: cold and hot pressing)
• solvent extraction
• pelletization

In the case of pressure filtration, oil cakes are obtained by cold pressing (expeller pre-pressing) and subsequent hydraulic pressing, while expellers are produced by hot pressing (expeller final pressing) (Manufacture of vegetable pressing residues).

The finished expellers leave the production plant while still hot and with a variable moisture content. After pressing, the expellers are cooled and, since they are in large pieces, they are ground and adjusted to a water content suitable for storage and transport. The ground products are then held in intermediate storage in silo cells or sent for transport.

Recently, however, the word "expeller" has come to mean homogeneous pressing residues, while "oil cake" is used to describe mixed pressing residues.

Oil content: 1.5 - 7.0%

Applications

Due to its high protein content, copra expeller constitutes a valuable concentrated feed additive for mixed livestock feed. It is a particular favorite of dairy cattle, increasing the fat content of their milk and giving it a sweetish, nutty flavor and a yellow color.

Shipment/storage

Product intended for shipping must be adequately matured. The time required for maturing is determined by the oil content. On the other hand, stored product from the previous year's harvest should not be accepted.

The consignor must provide certificates relating to the moisture and residual oil content and the maturing time of the product. It should also be determined that the product really is expeller and not extraction meal (extracting agent/solvent content). Oil contents of < 1.5% are indicative of extraction meal.

Copra expeller consists of light gray to yellowish pieces (flakes) of variable size with a smooth, somewhat curved cut surface, which is the result of processing in an extruder.

Upon acceptance of a consignment, brown or reddish to black discoloration of the goods must be looked for, since this indicates overheating during production or excessively long storage.

Expeller is mainly transported as bulk cargo. Only exceptionally is the product transported as bagged cargo (in very small quantities).

Bulk containers subject to compliance with lower and upper limits for water and oil content and the maturing time of the product and water content of the container floor (see RF Self-heating).

Do not unload very hot product with hydraulically operated grabs as the hydraulic lines are not capable of withstanding such elevated temperatures. Use only cable-operated grabs for spontaneously heated product.

Stow cool, dry. Mechanical ventilation of the stowage spaces must be possible. Do not stow over heated double bottom tanks, close to the engine room bulkhead and pipework which may become hot.

In the case of maritime transport, the IMO (International Maritime Organization) "Code of Safe Practice for Solid Bulk Cargoes" must be complied with.

Risk factors

Temperature
Copra expeller requires particular temperature, humidity/moisture and ventilation conditions.

Favorable travel temperature: 5 - 25°C

Up to a temperature of 25°C, expeller may be loaded irrespective of the external temperature. At elevated external temperatures, the product temperature must be no more than 10% higher than the external temperature. Continuous temperature measurements should be taken during loading of the cargo. In tropical ports, temperatures of 25 - 55°C may occur in the products to be loaded.

The temperature must accordingly also be measured at various depths in the hold during the voyage. If the temperature rises above 55°C and any further increase is observed, countermeasures must be taken, e.g. tight closing of all hatch openings and injection of CO2 or inert gas.

The product is best stowed in the coolest possible locations. Avoid stowage spaces close to the engine room or over heated double bottom tanks.

The enzymes which initiate and intensify fat degradation and thus the self-heating process reach optimum levels of activity at temperatures of 35 - 40°C, i.e. temperatures which are easily reached within the heaped cargo. The travel temperature should thus be between 5 and 25°C. Temperatures of up to 30°C are also admissible for short periods. However, these conditions are difficult to maintain during an ocean voyage, as a consequence of which very careful attention must be paid to ensuring that the critical water content of the product is not exceeded in order to avoid self-heating to the greatest possible extent.

Humidity/Moisture Copra expeller requires particular temperature, humidity/moisture and ventilation conditions (SC VII) (storage climate conditions).

Designation Humidity/water content Relative humidity 70% Water content 5 - 10% Maximum equilibrium moisture content 70%

Expellers must be protected from all forms of moisture (seawater, rain and condensation water), since moisture encourages mold, mustiness and self-heating.

Moisture promotes self-heating brought about both by hydrolytic/enzymatic degradation and by microorganisms and may be the result of an excessively high product water content (critical water content 10.5%) or alternatively of external influences (excessively high relative humidity (critical equilibrium moisture content 75%), seawater, rain).

At a water content of < 5%, there is a risk of oxidative fat cleavage, dust formation/dust explosions and self-heating.

Ventilation Copra expeller requires particular temperature, humidity/moisture and ventilation conditions.

Recommended ventilation conditions: surface ventilation.

"Bulk" expeller is frequently carried without ventilation as the elevated oil content may otherwise give rise to autoxidation and thus self-heating.

Due to the principal causes of self-heating in vegetable pressing residues, two problems arise with regard to ventilation:

At an excessively high product water content (copra expeller > 10%), localized overheating caused by enzymes or bacteria results in self-heating. The resultant heat must be dissipated by constant ventilation by means of a good ventilation system. Drying by ventilation is useful, but its effectiveness is questionable because, as heating proceeds, increasingly large quantities of water vapor are released. The activity of the initiating microorganisms is not suppressed by nonventilation of the hold as some of the thermophilic (= heat-loving) bacteria are anaerobic organisms (which require no oxygen supply to stay alive). In a product with an excessively low water content (copra expeller < 5%), which must be expected to undergo oxidative fat cleavage, the supply of oxygen must be interrupted as this process would otherwise be accelerated. Any attempt to cool the cargo by ventilation supplies air, so further promoting the oxidation process.

Ventilation is helpful in the first case, but hazardous in the second. The correct ventilation measures may only be implemented if the characteristics (loading temperature, water content, duration of prior storage) of the cargo are known. However, if a large batch is made up of various sub-batches, it is entirely possible for both the above-stated causes to occur in the same heap of cargo.

In order to avoid moisture damage on the surface of the cargo, ventilation must not be performed with cold external air. The ventilation system must then be switched to return air.

A certificate stating residual oil content, water content and maturing time should be demanded from the consignor.

If the oxidation processes under way in the hold are vigorous, it is not possible to dissipate the quantity of heat generated by ventilation. This particularly applies if a sub-batch susceptible to oxidation with a low water content is loaded next to a sub-batch with a high moisture content.

Biotic activity Copra expeller displays 3rd order biotic activity.

It belongs to the class of products in which respiration processes are suspended, but in which biochemical, microbial and other decomposition processes still proceed.

Care of the cargo must be aimed at limiting the fat cleavage process and so preventing possible self-heating of the product.

Gases An increase in CO2 and CO content in the hold air indicates that a cargo fire has begun. CO2 has a smothering action on the seat of the fire because it displaces oxygen.

Self-heating / Spontaneous combustion Oil content: 1.5 - 7.0%

Copra expeller is liable to the risk of self-heating/spontaneous combustion.

Copra expeller is assigned to class 4.2, pursuant to the IMDG Code. All types and varieties of pellets, expellers and extracts fall within the class "Seed Cake" under UN numbers 2217 and 1386.

Smoking/open flames are prohibited during loading, discharge and access to holds.

Causes and promoting factors of self-heating are moisture, oxygen, elevated residual oil content, high fiber content and grain size.

Oxygen promotes oxidative fat cleavage. The principal cause underlying self-heating caused by oxidative fat cleavage is an excessively high oil content. An expeller oil content in excess of 7 - 10% promotes oxidation processes. An elevated unsaturated fatty acid content in the residual oil constitutes a very serious storage risk as such fatty acids have a strong tendency to undergo autoxidation with (atmospheric) oxygen, plentiful supplies of which are also available in a feedstuff cargo, to form saturated fatty acids. This autoxidation, as a kind of flameless combustion, results in considerable evolution of heat which may result in a hazardous build-up of heat in the feedstuff cargo if the heat cannot be dissipated.

The maturing time before ocean transport is of great significance to the promotion of self-heating processes in pressing residues, with both excessively short and excessively long maturing times possibly being disadvantageous. On acceptance, expeller should thus exhibit temperatures which are only insignificantly (approx. 10%) above external air temperature. It must be ascertained whether the batch is from the previous year's production. Unfavorable storage conditions over the period prior to shipping may mean that the product is already at elevated temperature when it arrives on board. Continuous temperature measurements are thus required during loading of the cargo.

The main risk for transport of any cargo which has heated ashore is that the product is loaded at temperatures of above 55°C and retains this temperature in the hold and, due to the poor thermal conductivity of the product, areas with a permanent heat build-up form for the entire duration of transport. The longer the duration of transport, the greater are the consequential losses arising from heating.

In the areas with a heat build-up of above 60°C, the autoxidation process of the feedstuff containing residual oil gradually begins and continues as the unsaturated fatty acids oxidize. The hot spots do not spread much further. The product does, however, dry out, as a result of which moisture migrates upwards from below and water vapor collects in the space between the surface of the cargo and the underside of the hatch covers or weather deck. This accumulation of water vapor combined with maximally airtight hatch covers is the most effective method of fighting fire, as any external supplies of oxygen are blocked off.

Pursuant to the IMDG Code/IMO, ships must be equipped with systems for injecting CO2 or inert gas.

The poor thermal conductivity of pressing residues is also of significance to self-heating. Self-heating may occur simultaneously at various points within the cargo and continue to such an extent that carbonization (release of hydrogen, leaving carbon behind) occurs. The resultant fine-pored carbon has the characteristic of starting to smolder when exposed to oxygen.

Due to the poor thermal conductivity of the product, temperature measurements to detect seats of risk are very difficult. Numerous measurements must be performed and some must also be taken within the heap. Surface measurements alone are not adequate.

The poor thermal conductivity also explains late detection of the seat of a fire. The particular risk is that the cargo burns within the heap without generating appreciable quantities of smoke. The seat of the fire carves out a cavity with the result that fatal accidents may occur when someone steps onto the surface of the cargo and breaks through into such cavities.

In order to be able to detect a cargo fire in good time, it is recommended to make regular gas measurements of the hold air. A rapidly rising CO2 content indicates increased microbial activity combined with evolution of heat within the cargo. This evolution of heat ultimately leads to the spontaneous combustion of the cargo, with evolution of carbon monoxide (CO). The presence of CO gas is considered the most reliable indication of a fire. Levels of 0.002 - 0.005 vol.% of CO in the air are deemed normal, with values rising to above 1 vol.% in a cargo fire.

On unloading, small flames may appear on the exposed surface of a heated cargo: volatile gases which have formed in the cargo over the course of self-heating and have a flash point of around 60°C have spontaneously ignited. These flames do not cause the remainder of the cargo to burn as the ignition temperature of most organic cargoes is of the order of 300 - 500°C. If such small flames or glowing areas of the surface occur in isolated areas, it is helpful to tip the last grab load back down into the area of the hold concerned, so smothering the flames.

The subsequent phases of self-heating possibly culminating in a cargo fire and the action to be taken are described in the article as outlined under Feedstuffs (self-heating process).

It is possible to conclude from characteristics observable in the ship's hold, such as temperatures, appearance and odor of the cargo, whether the product was loaded at too high a temperature and whether it has undergone self-heating with microbial spoilage and subsequent autoxidation.

The following features must be observed and recorded for this purpose:

• the flow behavior of the cargo in the heap (caked, free-flowing)
  
• the color of the product (normal, brown to black) and the distribution of color differences in the product in the hold
• the odor of the product (normal, healthy, fresh, musty, burnt)
  
• the temperature and appearance of the cargo at various depths in the bulk load
  
• the appearance of the cargo surface when the hatches are opened
  
• the appearance of escaping smoke/fumes (steam is white, smoke from overheated product with a temperature of above 90°C is black)

On the basis of this information, it is possible to conclude on the spot whether:

• the product was loaded too moist
  
• the product was loaded at too high a temperature after a drying process (toasting)
  
• the product was shipped shortly after production without complying with the maturing time
  
• biogenic self-heating has occurred during the voyage as a result of metabolic processes in microorganisms
  
• self-heating has occurred without a preceding biological self-heating process by chemical autoxidation of unsaturated fatty acids
  
• the product was loaded in a discolored state (brown to black) as a result of drying processes (toasting) performed during manufacture

Odor
Active behavior: Copra expeller has a slight, pleasant odor, but should not be stored together with odor-sensitive products as odor tainting may otherwise occur.
Passive behavior: Copra expeller is sensitive to unpleasant and/or pungent odors. Odor-tainted expeller is rejected by livestock (especially horses and cattle).

Contamination
Active behavior: Copra expeller causes severe dusting during cargo handling, such that there is a risk of dust explosion at dust/air ratios of 20 - 2000 g/m3.
Passive behavior: Copra expeller is sensitive to contamination by dust, dirt, fats and oils. The holds or containers should thus contain no residues of previous cargoes, such as ores, minerals, chemicals, salts, fertilizers.

Mechanical influences
No risk.

Toxicity / Hazards to health
An increase in CO2 and CO content in the hold air indicates that a cargo fire has begun. Danger: Risk of asphyxiation and poisoning on inhalation. No access is permitted to the hold until it has been adequately ventilated and the atmosphere tested with a gas detector. The CO content may rise from 0.002 - 0.005 vol.% to 1 vol.%. The lethal (fatal) dose is approx. 0.1 vol.%.

Foreign admixtures (e.g. toxic castor seeds) and poisonous protein breakdown products are harmful to animals. Levels of infestation with the mold Aspergillus flavus of 3% are very harmful, in particular to turkeys, chicks and ducks, due to the aflatoxin complex.

Shrinkage/Shortage
Slight losses (trickle losses) may occur during cargo handling.

Insect infestation / Diseases
Insect infestation, especially by various species of beetles (e.g. khapra beetle), is widespread. On extended storage, there is a risk of mite infestation, which is promoted by heat and moisture.

If required by the consignor or import regulations, fumigation (e.g. with methyl bromide) must be performed.

Class 4.2 IMDG Code

Note: (Source including Transport Information Service of the GDV)