A) The RBD oils are blended using the product oil blend recipe into a Blend Tank inside the Oil & Aqueous Room. The oil blending is done either by mass flow meter or load cell for correct composition.
B) A small portion of the blended oil is first pumped into a mix tank where the oil is heated up and all oil soluble additives are added. The mix tank content is pumped back into the blend tank and is now called the oil phase. Milk/whey powder is dissolved in potable water and pumped into an Aqueous phase tank. All aqueous soluble additives are added and dissolved to make up the aqueous phase. Heating to pasteurization temperature and hold for a minimum time is recommended for meeting local regulation prior to use.
C) The oil and aqueous phases are metered into one of the two production/emulsification tanks. Each production tank is equipped with a high shear mixer to emulsify the oil and aqueous phases. The mixer is equipped with variable speed drive to reduce the speed for gentle agitation after emulsification is done. The two tanks will be used as production tank and emulsification tank alternatively. The production tank will also function as product recycle from the production line.
The oil emulsion from the production tank will pass through a twin filter/strainer to ensure no solid will pass into the final product (GMP requirement). The filter/strainer operates alternatively for filter cleaning. The filtered oil emulsion is then passed through a pasteurizer (GMP requirement) which consists of three sections of two plate heaters and one retention pipe. The first plate heater will heat the oil emulsion up to pasteurization temperature prior to passing through the retention pipe to provide the necessary holding time. Any oil emulsion heat to less than the required pasteurization temperature will be recycled back to the production tank. The pasteurized oil emulsion will enter into the cooling plate heat exchanger to cool down to approximate 5 ~ 7degree C above the oil melting point to minimize chilling energy. The plate heater is heated by central hot water system with temperature control. The plate cooling is done by cooling tower water with automatic temperature regulation valve and PID loops.
The oil emulsion pumping/transfer, up to this point, is done by two centrifugal pumps in tandem. Nitrogen metering and injection point is done at the oil emulsion stream after pasteurization and cooling. The nitrogen injection head is a custom sanitary design with build in non-clogging check valve. The nitrogen injection is done at high pressure to ensure gas dissolving completely in the product stream instead of bubbles of different sizes. This gas injection technology originated from the Unilever Canada Toronto plant, after years of process improvement. The tandem centrifugal pumps are sized to provide sufficient head and flow volume to satisfy the line CIP requirements.
The oil emulsion is fed into the first chilling SSHE (Ftherm A unit) to lower the temperature to the desired exit temperature. Each A unit is equipped with individual flooded direct evaporative cooling system using USA made Parker components. The cooled oil emulsion is pumped via a positive piston high pressure pump to the first pin worker unit (Ftherm C unit) for proper conditioning for further chilling. The second chilling cylinder chills the oil emulsion to the desired exit temperature to ensure proper solid content in the product. There are three downstream
1. The product passes to the large volume resting tube for puff pastry product.
2. The product passes into the small volume resting tube for table/stick margarine.
3. The product passes into another pin worker (Ftherm C unit) and texturizing valve to provide the necessary texture for tub or bulk margarine fill. We have sold many bulk box (10 ~ 30 kg box) filling system. Each box is filled from a sanitary filler head and weigh controlled by load cell using high resolution custom PLC computer with touch screen.
The Nominal Capacity Of The Plant---1000~4000kg/hr
The plant proposed by us is a universal plant suitable for the manufacturer of the various specialty fats as mentioned below.
The capacity of manufacture of various products depends on various parameters such as type of oil, type of premix, melting point, physical properties, operating pressure & temperature, sequence of connections of equipment, oil technology / application etc, and will vary from product to product.
Emulsified, Non-Emulsified and aerated shortenings
Fat Spread with or without milk fat
Cocoa butter substitute and equivalents
Cream Margarine & Shortening(both aerated & non aerated)
Raw Material--- palm oil ,vegetable oil, animal oil, etc.
Total Power---About 80kW
Production process：Measuring——Ingredients Configuration——Filtration——Emulsification——Flash Cooling——Kneading——Filling & Packing