Cocoguru ensures high-quality coconut oil by following a systematic and controlled production process. Every stage is optimized for purity, efficiency, hygiene, and safety to deliver a premium product. Below is an overview of the detailed process from raw material to final filtered oil:

1. Copra Purchase and Sorting

Raw material used is milling grade copra sourced from the coastal areas and Tamil Nadu. Only sun-dried copra with FFA around 0.2% and moisture of ~5% is selected. Copra appears in cup shapes, white inside and brown/black outside, packed in 50 kg gunny bags.
Each batch undergoes visual inspection, and foreign materials such as:

• Shells
• Plastic threads
• Jute fibres
• Poor-quality copra are manually removed to ensure uniformity and purity.

2. Copra Drying

Selected copra is loaded into a 9-ton capacity drying hopper. Hot air at 75–80°C is generated using an air heater and circulated by a centrifugal blower. The drying process continues for 10 hours.

• Moisture reduces from 5% to 2.5%.
• This drying is essential as moisture causes rancidity in oil.
• Dried copra becomes: hard, brittle and better suited for filtering and storage

3. Copra Cutting

Copra is cut into uniform 1-inch pieces using a Copra Cutter equipped with beaters and a mesh. This standardisation helps in:

• Ensuring even roasting
• Improving handling efficiency
• Facilitating smooth conveyance through a screw conveyor to the next stage

4. Copra Roasting / Cooking

The cut copra is roasted in a steam-jacketed vessel for about 1 hour with continuous agitation. A light spray of steam enhances cooking.

• Steam is generated using an IBR-compliant boiler fired by solid waste
• upplied through a seamless steam pipeline for efficiency and safety.

  Benefits of Roasting:

  • Improves oil recovery
  • Enhances flavour with a sweet aroma
  • Sterilises copra
  • Increases shelf life of extracted oil

5. Copra Crushing / Oil Extraction

Roasted copra is crushed mechanically in an expeller with screw press in two stages:

• Stage 1: Initial extraction
• Stage 2: Second crushing of the same material to maximise yield

Results:

• Approx. 63% oil in copra
• 5% moisture loss during processing
• Remaining ~32% results in oil cake (residue with 8% oil)

Oil Cake is packed in gunny bags and sold to solvent extractors or cattle feed manufacturers.

6. Coconut Oil Filtering

Expelled oil contains ~8% sediments (feet) which are removed in a three-stage filtering process:

i. Vibrating Screen

• Removes heavy sediments via vibration
• Uses a vibrating motor and mesh
• Cost-effective and eases load on downstream filters

ii. Main Filtering – Filter Press

• Oil at ~70°C is passed through a filter press
• Consists of plates and fine-pore filter cloths
• Oil is pumped in under pressure using a screw pump
• Sediments and moisture are trapped between filter plates

iii. Fine Filtering – Second Filter Press

• Oil is cooled to room temperature using a plate heat exchanger
• Slowly filtered again through another filter press
• Final product is clear, sediment-free, wax-free, and moisture-free oil

This entire process ensures that Cocoguru coconut oil is pure, aromatic, shelf-stable, and safe for consumption, maintaining the highest standards of hygiene and quality at every step.