Margarine
Margarine
Margarine
Margarine and related products contain a water phase and a fat phase and can thus be
characterized as water-in-oil (W/O) emulsions in which the water phase is finely dispersed as
droplets in the continuous fat phase. Margarine is a blend of around 80% vegetable oil or
animal fat, and 20% water with added salt, flavorings, color, and preservatives. In many
countries these proportions are controlled by legislation. Low fat spreads have similar
ingredients, however the oil content can be as low as 20%. Gums and thickeners such as
gelatin, alginates, and most commonly, caseinates are used to replace the viscosity and
bulking effect of the fat and to ensure that a stable water-in-oil emulsion is formed. Blends of
margarine/low fat spread and buttermilk, or other dairy ingredients e.g. milk powder and
whey powder are increasingly common. These combine the taste of butter with low fat
content
The major ingredients in the fat phase, the fat blend, normally consist of a blend of different
fats and oils. In order to achieve margarine with the desired characteristics and
functionalities, the ratio of fats and oils in the fat blend is decisive for the performance of the
final product. The various fats and oils, either as fat blend or single oils, are stored in oil
storage tanks typically placed outside the production facility. These are kept at stable storage
temperature above the melting point of the fat and under agitation in order to avoid
fractionation of the fat and to allow easy handling. Apart from the fat blend, the fat phase
typically consists of minor fat-soluble ingredients such as emulsifier, lecithin, flavor, color
and antioxidants. These minor ingredients are dissolved in the fat blend before the water
phase is added, thus before the emulsification process.
Processing:
1. Buffering/Emulsion making:
The emulsion is prepared by transferring various oils and fats or fat blends to the emulsion
tank. Usually, the high melting fats or fat blends are added first followed by the lower
melting fats and the liquid oil. To complete the preparation of the fat phase, the emulsifier
and other oil-soluble minor ingredients are added to the fat blend. When all the ingredients
for the fat phase have been properly mixed, the water phase is added and the emulsion is
created under intensive but controlled mixing. Typically, a two-tank system is used for
preparing the emulsion in order to be able to run the crystallization line continuously. A
solution where the emulsion is prepared in one tank and when ready is transferred to a buffer
tank.
2. PASTEURIZATION
From the buffer tank the emulsion is normally continuously pumped through either a plate
heat exchanger (PHE) or a low pressure scraped surface heat exchanger. For full fat products
a PHE is typically used.
The pasteurization process has several advantages. It ensures inhibition of bacterial growth
and growth of other microorganisms, thus improving the microbiological stability of the
emulsion. In addition, pasteurization of the complete emulsion ensures that the emulsion is
fed to the crystallization line at a constant temperature achieving constant processing
parameters, product temperatures and product texture. In addition, occurrence of pre-
crystallized emulsion fed to the crystallization equipment is prevented when the emulsion is
properly pasteurized and fed to the high pressure pump at a temperature 5-10°C higher than
the melting point of the fat phase. A typical pasteurization process after preparation of the
emulsion at 45-55°C include a heating and holding sequence of the emulsion at 75-85°C for
16 sec. and subsequently a cooling process to a temperature of 45-55°C. The end
temperature depends on the melting point of the fat phase: the higher the melting point, the
higher the temperature.
The emulsion is pumped to the crystallization line by means of a high pressure piston pump.
The crystallization line for the production of margarine and related products typically consists
of a high pressure Scraped Surface Heat Exchanger (SSHE) which is cooled by ammonia or
Freon type cooling media. Pin rotor machine(s) and/or intermediate crystallizers are often
included in the line in order to add extra kneading intensity and time for the production of
plastic products. [The pin rotor machine is a kneading unit that gives flexibililty to work the
product under high and low pressure and at variable speeds, allowing to achieve consistently
superb results].
A resting tube is the final step of the crystallization line and is only included if the product is
packed. The heart of the crystallization line is the high pressure SSHE in which the warm
emulsion is super-cooled and crystallized on the inner surface of the chilling tube. The
emulsion is efficiently scraped off by the rotating scrapers, thus the emulsion is chilled and
kneaded simultaneously. When the fat in the emulsion crystallizes, the fat crystals form a
three-dimensional network entrapping the water droplets and the liquid oil, resulting in
products with properties of plastic semi-solid nature.
Depending on the type of product to be manufactured and the type of fats used for the
particular product, the configuration the crystallization line (i.e. the order of the chilling tubes
and the pin rotor machines) can be adjusted to provide the optimum configuration for the
particular product.
The crystallization process, the processing conditions and the processing parameters have a
great influence on the characteristics of the final margarine and spread products. When
designing a crystallization line, it is important to identify the characteristics of the products
planned to be manufactured on the line. To secure the investment for the future, flexibility of
the line as well as individually controllable processing parameters are necessary, since the
range of products of interest might change with time as well as raw materials.
1. Additives designed to thicken the product tend to form agglomerates which common
agitators cannot easily break down, thus pin rotor machine is preferred.
2. Poor hydration may lead to unsatisfactory “mouthfeel”, and an unstable product
leading to storage problems once the product has been opened.