Optimization and pilot-scale validation of steam distillation for fresh turmeric essential Oil: Process modelling, bioactive profiling, antibacterial activity, and mass–energy balance

Turmeric (Curcuma longa L.) is a high-value botanical widely utilized in food, pharmaceutical, and cosmetic industries, with essential oil being one of its most economically important derivatives. However, optimization of steam distillation parameters for fresh turmeric remains limited, particularly regarding the effects of steam pressure and distillation time on oil quality and yield. This study employed Response Surface Methodology (RSM) with a Central Composite Design (CCD) to investigate the influence of steam pressure (0.79–2.21 atm) and distillation time (3.17–8.83 h) on extraction performance at laboratory scale, followed by validation under pilot-scale conditions. The optimized conditions—1.26 atm and 8 h—yielded 0.911% essential oil with density (0.973 g/mL) and refractive index (1.510) values consistent with high-quality turmeric oils. GC–MS analysis identified 69 volatile compounds dominated by ar-turmerone (11.67–11.99%), α-turmerone (14.49–18.70%), and α-terpineol (8.00–9.10%). Antibacterial assessment using the total plate count (TPC) method (SNI 7388:2019) showed <10 CFU/mL, indicating strong antimicrobial potency against E. coli. Mass and energy balance evaluations confirmed efficient material conversion and thermal performance, with pilot-scale distillation achieving 88.24% oil recovery and 92.72% energy utilization. Economic analysis further demonstrated strong financial feasibility. The findings provided a validated and scalable framework for optimized steam distillation of fresh turmeric rhizome, offering technical and economic justification for industrial implementation.

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