Maximizing the value
of modified fats
Alfa Laval processes for modifying edible oils and fats
Aiming at new horizons
If you’re in the business of modifying oils into fats for the
food industry, the key to success lies in providing your
customers with high-quality products that meet their
requirements perfectly – even at short notice.
Naturally, you also want to ensure that your processing
operations remain safe while at the same time adding
maximum value to your raw materials.
Alfa Laval provides you with the fats modification solutions
you need to move up the value chain – safely and surely.
2
The benefits of
fats modification
Fats modification processes open Opportunities abound
new doors so that you can offer more Installing Alfa Laval fats modification
products, reach new customer groups equipment provides you with a low-
and increase revenues. risk path into a world of new opportu-
There are also strategic advantages to nities to:
be gained from modifying these fats. • branch out into more products
A move from the basic processing of with higher value
bulk oils and fats enables you to focus • acquire new customers
on a wider market spread. • forge new types of customer
This in turn strengthens your compa- • relationships
ny’s ability to deal with the effects of • enter new markets
seasonal demand, market fluctuations • move further up the value chain
and the worldwide commoditization of The Alfa Laval approach provides
basic agricultural products. flexible solutions that enable you
to quickly, efficiently and safely
vary production to meet changes
in customer requirements and
specifications.
Alternatives in
fats modification Feedstock
Depending on the products your
customers are interested in and the
raw materials you have available, you
can choose between several different
Alfa Laval solutions, or a combination Interesterification,
of these. Fractionation Hydrogenation
chemical/enzymatic
3
Converting oils
and fats naturally
The natural way to modify oils and fats
Cooling
If your feedstock stems from palm oil or animal fats, there is a water
direct, natural way to modify it to ensure that it acquires greater outlet
value. By separating the feedstock into liquid and solid fractions,
or by combining different fractions, you can create products that
match your customers’ exact specifications.
Fractionation consists of gently cooling oils or fats in an
accurately controlled process, making it possible to crystallize
the hard fat content. Cooling
water
intlet
In dry fractionation, the fat is kept at a temperature at which it is
in a partially liquid form. The crystals are then separated from the
liquid fraction by membrane filtration. The result is two distinct
products with different physical properties and melting points.
This can be achieved with absolutely no chemical modification, Oil in- and outlet
making this the “natural” way to produce hard fats. Alfa Laval crystallizer
Fractionation
Fractionation
Crystallizers
Compressed air
Filter press
Steam
Stearin tank
Heater
Stearin to storage
Steam
Core Olein
Steam blow tank
tank
Oil in
Cooling Olein
water out Oil to
Cooling feed tank
water in
Wash
olein
Chiller water in Chilled tank
water
Chiller water out tank
To filter press Steam
during washing
A schematic diagram of the dry fractionation process
4
Taking dry fractionation still further
The Alfa Laval dry fractionation plant at the palm oil refinery run by IOI Edible
Oils features six crystallizers and one filter press. Here, dry fractionation is
more than just a way of producing cooking oil. Advanced PLC systems have
been added for efficient control and top-quality results.
“Alfa Laval has simplified dry fractionation into a process that is easy for the
operator to interface, and thus transformed the technology,” states Kenny
Liew, Deputy Plant Manager for IOI Edible Oils Sdn Bhd in Malaysia.
The Alfa Laval advantage
Alfa Laval crystallization and filtration equipment for fats
modification processes features:
• upward flexibility – the modular design makes it
possible to increase production capacity to keep
pace with demand, by adding more crystallizers and
extending filter capacity.
• excellence in process and engineering solutions –
by designing and specifying the most suitable key
components, such as crystallizers, membrane filters,
pumps and instruments, the Alfa Laval system ensures
high process efficiency.
• highly effective crystallizer design – using the best
vessel engineering design, construction materials,
surface finishing, design of the cooling coils and
agitation that produce crystallized slurry ideally suited
for membrane filtration.
• high yields – efficient crystallization and accurate
process control result in good separation of the liquid
and solid phases as well as ensuring greater yields and
higher profitability.
• practical design – Alfa Laval equipment is designed to
be straightforward, practical and easy for you to install,
operate, clean and maintain.
• plant control – the system is available with different
levels of automation, to suit your particular
requirements.
The combination of automation and the closed loop
cooling system makes it possible to achieve a virtually
unlimited range of different cooling curves.
5
Versatile, modular
hydrogenation
The versatile way to modify fats Vacuum
Catalyst
Oils and fats from virtually all kinds of raw materials and ingredients Oil Hydrogen
can be modified into hard fats by altering their molecular structure.
This is done by hydrogenation – the name given to the process in
which hydrogen is chemically combined with unsaturated oils and Cooling
fats, by making it link up with the double bonds of the unsaturated water
outlet
fatty acid chains.
Essentially, this process consists of bubbling hydrogen gas through
the oils, normally at temperatures of 150–200°C (302–392°F),
under pressure and in the presence of a catalyst. This adds the
hydrogen atoms to the double bonds of unsaturated fatty acids,
either to reduce them or to produce fully saturated fats.
Hydrogenation raises the melting point of oils and fats and
improves a range of other properties, including taste and shelf-
life qualities.
Oil outlet Cooling
The diagrams to the right and below show two systems based on water inlet
filtration and continuous centrifugal separation that Alfa Laval provides
for catalyst removal. Alfa Laval reactor
Hydrogenation
Hydrogenatic
Vacuum
Steam Citric acid system
Steam Feed tank Filter aid Bleaching earth
Catalyst Flash
tank tank Vacuum
Vacuum Water
Reactor Post-treatment
system Cyclone
Steam
Compressed air
Hydrogen
Heater
Filter
Steam Slope oil
Vacuum
Intermediate
tank
Oil in Vacuum
Compressed air
Filter
Steam
Economizer
Drop tank Cooling water
Cyclone Final cooler
Filter
cake
Slope oil Oil out
A schematic diagram of the hydrogenation process
6
Unlimited flexibility
The Alfa Laval hydrogenation plant supplied to CALSA features a feed tank, a drop tank
and a dead-end reactor. Heat recovery is done by a highly efficient AlfaRex TM20 plate
heat exchanger. Catalyst removal is undertaken in two steps, using direct filtration followed
by a post-treatment system. The plant is fully automatic, controlled by a PLC unit.
“Alfa Laval supplied us with a highly efficient plant, with the lowest production costs
in terms of energy, hydrogen and catalyst consumption. It gives us unlimited flexibility
to produce any type of fats we want,” states Mr. Alejandro Murillo, plant manager of
CALSA – Cia Argentina de Levaduras S.A.I.C. – Argentina.
Low production costs Hydrogenation solutions using Alfa Laval equipment
Alfa Laval hydrogenation equipment significantly also make it possible to vary batch size and plant
reduces production costs by ensuring low production capacity, according to specific requirements. Feed and
costs, full energy recovery, minimized hydrogen con drop tanks contribute to increasing production and heat
sumption, good catalyst distribution and contact with recovery. In addition, the reduced oil volume in the heat
the oil, and a reduced temperature difference between exchangers makes stock changes easier and reduces
oil and water. contamination.
• Low production costs. Highly efficient heat
exchangers heat the incoming oil while simulta High degree of safety
neously cooling the hydrogenated product, thereby What’s more, the explosion-proof design of Alfa Laval
maximizing heat recovery. hydrogenation equipment keeps the hydrogen within
the reactor, ensuring plant safety. Special seals with
• Full exothermic energy recovery. Using a closed
leakage detectors ensure early detection, should any
loop cooling system ensures maximum energy
leaks occur.
recovery from the exothermic reaction.
• Minimized hydrogen consumption. Special agitation
techniques incorporate most hydrogen into the oil
before it reaches the reactor head space. Vortices
on the surface of the oil also force the hydrogen in
the head space back into the oil. The result? Use of
exactly the right hydrogen quantities.
• Good catalyst distribution and contact with the oil.
Low speed and high flow agitation ensure good
catalyst distribution and contact with the oil. The
filtration rate is improved, as the catalyst is not
converted to colloidal form. Alfa Laval spiral heat exchanger
• Reduced temperature difference between oil and
water. The use of a closed loop cooling system and
natural recirculation prevents the water hammer
effect and improves temperature control.
Greater flexibility
Alfa Laval hydrogenation equipment also lends a
greater degree of versatility to your operations. A wide
range of operating parameters makes it possible to
produce saturated or partially hydrogenated fats with
different specifications. These parameters include
hydrogen flow rate and pressure, reaction temperature,
degree of agitation and amount of catalyst.
AlfaRex® economizer
7
Transforming edible oils and
fats through interesterification
Want to combine an efficient, flexible production After drying the oil, a catalyst is introduced into
set-up with the ability to satisfy ever-changing the oil recirculation stream, using the special
customer demands? Interesterification can help. catalyst dosing device. When the catalyst
reaction is completed, the oil is discharged to
By combining different oils and fats, interesterifi
the post-treatment reactor. Here, the catalyst is
cation makes it possible to produce hard fats
deactivated with acid and the oil is treated using
from a wide range of raw materials – and in a
bleaching earth.
way that conforms to modern market demands.
As an alternative, the catalyst can be deacti-
Traditional interesterification is carried out by
vated with water in the washing tank. The soap
using a chemical catalyst (normally sodium
generated in this process is removed using a disc
methylate) to bring about a regrouping of the
stack centrifuge. The oil is then dried and sent to
position of the fatty acids on the basic glycerol
the post-treatment stage.
molecule.
Interesterification does not affect the degree
The mixture of oils and fats is pumped from the
of saturation of the fat, nor the location of the
mixing tank to a steam heater and then to the
cis-trans chemical bonds. It is largely done to
reactor under vacuum conditions for drying.
control the consistency of the oil or fat at different
To improve drying efficiency, the oil is pumped
temperatures, a parameter that is crucial for your
through a recirculation section.
customers in the food industry.
Interesterification
Interesterification
Catalyst handling unit
Catalyst
Vacuum
Oil in Steam
Polishing
filter
Compressed air Oil cooler
Filter Cooling water
Steam
Bleaching
earth
Vacuum Oil out
Filter
cake Cyclone
Post-
Citric acid
treatment
system
system
Slope oil
Filter
A schematic diagram of the interesterification process (catalyst deactivated with acid)
8
Advantages of interesterification • Post-treatment equipment includes the Alfa Laval
hermetically sealed earth transportation and
Alfa Laval interesterification equipment used in fats
dosing system and a post-treatment reactor
modification processes includes a specially designed
with steam or mechanical agitation, designed for
catalyst handling system. The system includes:
continuous or batch operation.
• A hermetically sealed catalyst handling unit,
Because of the design of the components and the
which allows manipulation of the catalyst bags
rigorous specifications used, Alfa Laval interesteri
without direct contact between the product
fication equipment keeps the consumption of energy
and the operator, thereby ensuring a safe, inert
and other utilities to a minimum, resulting in lower
environment.
operating costs.
• A catalyst dosing unit ensures the use of accurate
amounts of the catalyst, with no exposure to the
atmosphere.
• A catalyst pre-mixer doses the catalyst in a
blender where it is dissolved in the recirculation
oil stream. This ensures the introduction of the
catalyst powder to the oil occurs inside the
vacuum reactor.
• A catalyst neutralizer, using either acid or water,
to render the catalyst inactive.
Other special Alfa Laval features include:
• Oil conditioning. Recirculating the hot oil to the
reactor under vacuum conditions ensured that the
oil has a low moisture content. This results in the
best possible catalyst efficiency and consumption. Alfa Laval disc stack centrifuge
Interesterification
Interesterification
Catalyst handling unit
Catalyst
Vacuum
Steam
Citric acid
Oil in Steam
Process Vacuum
water
Citric acid Vacuum
system dryer
Filter
Condensate
Oil to
Vacuum post-treatment
Steam
Steam
Washing Disc stack centrifuge
tank Heater
Acidulation
Process water
A schematic diagram of the interesterification process (catalyst deactivated with water)
9
Expertise from a global a world
leader in heat transfer, centrifugal
separation and fluid handling
10
Process know-how reliable resettings and adjustments to meet new
One of the key advantages of working with Alfa Laval specifications. Alfa Laval can provide you with the
to install, update and extend your fats modification exact degree of automation you need to meet your
systems is our extensive practical experience. particular requirements.
Alfa Laval’s proven ability to design and configure Alfa Laval provides a wide range of straight
a wide range of process variants to meet specific forward, easy-to-operate control and monitoring
customer requirements can provide you with the systems, which easily integrate with existing plant
benefits of a vast body of accumulated know-how. control systems.
Project implementation Engineering services
Alfa Laval has a specialist group whose sole focus is Alfa Laval provides a wide range of supplementary
the design and engineering of fats and oils projects. engineering services that help ensure that your new
Our specialists have years of experience and an installation comes on line as quickly and efficiently
extensive, proven track record of plants designed, as possible.
installed and in operation.
We can also provide you with considerable savings
The process and engineering team also has constant by ensuring full compliance with the relevant national
access to the most recent technologies and solutions and international regulations for design codes, safety
implemented by Alfa Laval all over the world. This procedures and best engineering practices.
means you benefit directly from Alfa Laval’s renowned
Alfa Laval engineering services include:
know-how in the fields of thermal engineering, separa
tion technologies and fluid handling, and from the latest • installation design in full accordance with
breakthroughs in other related industrial processes. international standards
• installation supervision
Engineering for automation • commissioning and start-up
The automation of key plant operating processes • operator training
– either wholly or in part – makes it possible to • documentation
achieve new levels of flexibility when you need rapid, • operational, maintenance and service support.
11
This is Alfa Laval
Alfa Laval is active in the areas of Energy, Marine,
and Food & Water, offering its expertise, products,
and service to a wide range of industries in some
100 countries. The company is committed to
optimizing processes, creating responsible growth,
and driving progress – always going the extra mile to
support customers in achieving their business goals
and sustainability targets.
Alfa Laval’s innovative technologies are dedicated to
purifying, refining, and reusing materials, promoting
more responsible use of natural resources. They
contribute to improved energy efficiency and heat
recovery, better water treatment, and reduced
emissions. Thereby, Alfa Laval is not only accelerating
success for its customers, but also for people and the
planet. Making the world better, every day. It’s all
about Advancing better™.
How to contact Alfa Laval
Contact details for all countries are continually up-
dated on our web site. Please visit www.alfalaval.com
to access the information.
PFT00112EN 2004
