LATEST TRENDS IN DRY FRACTIONATION OF FATS

Dr. Véronique GIBONFractionnement TIRTIAUX SA

Fleurus - Belgium

Lipid Structural Properties SymposiumUnilever R&D Colworth, UK

16-17th October 02

RECENT TRENDS IN DRY FRACTIONATION

FRACTIONATION DRY FRACTIONATION EQUIPMENTS WHY FRACTIONATE ?

– Hydrogenated Soybean Oil

– Crude Fish Oil (High - 3)

– Cottonseed Oil

– Extra virgin olive Oil

– Anhydrous Milkfat

– Beef Tallow

– Palm Oil

– Palm Kernel Oil CONCLUSIONS

Fractional distillation Volatility Super-critic extraction Solubility Liquid-liquid extraction Solubility Adsorption Solubility Solvent fractionation Crystallisation Detergent fractionation Crystallisation DRY FRACTIONATION Crystallisation

KEY OF SUCCESS = SELECTIVITY

FRACTIONATION

• THE SIMPLEST AND CHEAPEST FRACTIONAL CRYSTALLISATION

PROCESS.

• “GREEN” TECHNOLOGY.

• SELECTIVITY IMPROVED BY :

•THE MASTERY OF POLYPHASIC AND THERMAL PROPERTIES OF

TRIGLYCERIDES : POLYMORPHISM, INTERSOLUBILITY,

SEEDING IN SUPERCOOLING CONDITIONS.

•DEVELOPMENT OF MEMBRANE FILTER-PRESSES

CONTROLLED CRYSTALLISATION OF THEMELTED OIL,CONDUCTED ACCORDINGTO A SPECIFIC COOLINGPROGRAM.

STEARIN :Solid fraction

OLEIN :Liquid fraction

2) SEPARATION OF THE CRYSTALLISED OIL :

DRY FRACTIONATION

1) CRYSTALLISATION :

Vacuum belt (or drum) filter :Soft stearin.

Membrane filter press :Hard stearin.Higher yield in olein.

Nozzle centrifuge :Soft stearin.Closed and smallspace.

EQUIPMENT : CRYSTALLYSERS

Crystallizing oil

Exchange plates

Agitator Type 1 :

Type 2 :

EQUIPMENT : SEPARATION

Florentine filter :

Scraping of the stearin cake

EQUIPMENT : SEPARATION

Discharge of the stearin cakes

Hermetic membrane filter press :

EQUIPMENT : SEPARATION

Nozzle Centrifuge :

Patented by GEA - Westfalia

Improvement of the oxidative stability. Improvement of the cold stability.

• PARTIAL HYDROGENATION + FRACTIONATION (Winterization) :PARTIAL HYDROGENATION + FRACTIONATION (Winterization) :Oils containing poly-unsaturated fatty acids of polyenic type : Hydro Soybean, Hydro Fish Oil, Hydro Rapeseed, … • FRACTIONATION (Winterization) :FRACTIONATION (Winterization) :Fish oil (High -3), Cottonseed Oil, Olive oil ...

• SINGLE OR MULTI-STEP FRACTIONATIONSINGLE OR MULTI-STEP FRACTIONATION : :Solid or semi-solid fats :

- Anhydrous Milkfat - Beef Tallow- Palm Oil- Palm Kernel Oil ...

WHY FRACTIONATE ?

Human imagination to tailor new products. Oriented economical policy.

FRACTIONATION (Winterization) : Hydrogenated Soybean OIl

Single fractionation

Hydrogenated soybean oilIV : 105

DP : 18°C

StearinIV : 91

DP : 32.2°C

OleinIV : 108.3

CT : 7 hours at 0°C

Salad oil

Hydrogenated soybean oilIV : 84

DP : 25.8°C

StearinDP : 34.6°C Olein

DP : 16.3°C

Multi-step fractionation

Hydrogenated soybean oilIV : 77

DP : 35°C

StearinIV : 61

DP : 45.1°C

OleinIV : 81

DP : 31.2°C

OleinIV : 88

DP : 18,2°C

Frying oil

CBR

Semi-liquid shortening for frying

SFC = f (T)

Margarines, shortenings

Margarines, shortenings

Margarines,shortenings

Second StearinIV : 73

DP : 35,0°C

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Frying oil

FRACTIONATION (Winterization) : Fish oil (High -3)

• Crude Fish Oil B : IV = 163 - EPA+DHA = 22,62% ; EPA > DHAOlein : EPA+DHA > 12 % ; Cold test at least 4 hrs at 0°C

Stearin :Temperature SFC5°C 4010°C 3515°C 2720°C 2125°C 9

Crystal type B

• Crude Fish Oil A : IV = 172 - EPA+DHA = 25,26% ; EPA < DHAOlein : EPA+DHA > 9 % ; Cold test at least 6 hrs at 0°C

Stearin :Temperature SFC5°C 3210°C 2515°C 1520°C 1125°C 6

Crystal type A

FFA (C18:1) = 2,05 %Color - Gardner - = 12

FFA (C18:1) = 1,34 %Color - Gardner - = 10,75

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Fish Oil A

Stearin A

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45

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Fish Oil B

Stearin B

FRACTIONATION (Winterization) : Cottonseed Oil

Olein : OFilter Press - IV : 114,8 - CP : - 8,5°CCentrifuge - IV 116,3 - CP : - 7,5°C

Stearin : SFilter Press - IV : 92,0 - SFC 15°C : 17°CCentrifuge - IV : 100,0 - SFC 7°C : 6°C

Cottonseed OilIV : 109,1

Neutralized and bleached Cottonseed Oil : •Winterization at 4°C •Filtration on Membrane Filter Press or with Centrifuge

Temperature SFC (MFP) SFC (Cent.)5°C 30,0 21,010°C 25,5 14,515°C 17,0 6,520°C 1,0 1,025°C 0 0

Cold test at 0°C > 6 hours

Very Small Crystals

FRACTIONATION (Winterization) : Olive Oil

First Olein : OIV : 80,5

First Stearin :IV : 74,7

DP : 16,4 °C

Olive OilIV : 79,6

Extra Virgin Olive Oil :

•Filtration on Membrane Filter Press

Second Olein : OIV : 78,5

Second Stearin : SIV : 63,4

DP : 25°C

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Temperature (°C)

SF

C (

%)

First Stearin

Second Olein

Second Stearin

Super Olein : OODP : 13°C

Stearin : OOSDP : 21°C

Top Olein : OOODP : 6°C

Second (Soft) Stearin : OSDP : 26°C

Olein : ODP : 21°C

Hard Stearin : SDP : 45°C

AMFDP : 34°C

Olein : OSODP : 24°C

Third Stearin : OSS DP : 32°C

Recycling

MULTISTEP DRY FRACTIONATION OF ANHYDROUS MILK FAT (AMF)

AMF : DROPPING POINTS BETWEEN 45°C and 6°C ...Triple fractionation : the best solution for all qualities of AMF

AMF FRACTIONS : Spreadable or soft butter

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Temperature (°C)

SFC

(%

)

Olein : ODP : 18.9°C

TopOlein : OOOCP Mettler : -3°C

ThirdStearin : OOSDP : 18.1°C

Hard fractions ;Shortenings ;Margarine ; Semi-liquid frying shortenings;Salad oils ...

SFC (%)

MULTISTEP DRY FRACTIONATION OF BEEF TALLOW

Beef TallowDP : 43.2°C ; IV : 44.2

Stearin : SDP : 49°C

Second Stearin : OSDP : 26.7°C

Recycling

Olein : SODP : 45°C

Super Hard Stearin : SSDP : 54°C

Recycling

°C0

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SSSSOBeef TallowOS

OOSOOOOOO

Super Olein : OODP : 14°C

OLEINIV : 57-59

SUPEROLEIN

IV: 64-66

HARD STEARINIV : 32-36

TOPOLEIN

IV: 70-72

SOFTPMF

IV :42-48 SUPERSTEARINIV: 17-21

SOFT STEARINIV : 40-42

“OLEINS”HARDPMF

IV : 32-36

= CBE

Recycling

= SALADOIL

= SUBSTITUTEOF HYDROGENATED PRODUCTS

= SHORTENINSG

= SALAD OIL

MULTISTEP DRY FRACTIONATION OF PALM OIL

= SHORTENINGS ;MARGARINES ;COATING ...

= FRYING OIL ;COOKING OIL ;

SHORTENINGS ;MARGARINES ;SALAD OIL ...

= BACKERYSHORTENINGS ;MARGARINES ;VANASPATI ; MANTECA

PALM OILIV: 51-53

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OLEINIV : 57-59

SUPEROLEIN

IV: 64-66

TOPOLEIN

IV: 70-72

RED PALM LIQUID FRACTIONS, RICH IN CAROTENE

DEODORISING AT LOW TEMPERATURE :REFINED PALM OIL WITH HIGH LEVELS IN - CAROTENE : “ RED PALM OIL ”

PALM OILIV: 51-53

RED COLOUROF CRUDE PALM OIL :- CAROTENE

IV CP CAROTENEAOCS (PPM) (°C)

• NB PALM OIL 51.9 21.6 382 • RED OLEIN 56.7 8.1 409• RED SUPEROLEIN 63.2 3.3 670• REDTOPOLEIN 71.3 -2.4 854

MULTISTEP FRACTIONATION : “ RED PRODUCTS ” WITH HIGH OXYDATIVE AND

COLD STABILITIES AND NUTRITIONAL LABEL

= SALADOIL

RED PALM FRACTIONS : WHICH MARKET ?

PALM OIL-Carotene : 382 PPM

OLEIN409 PPM

SUPEROLEIN

670 PPM

TOPOLEIN

854 PPM

SOFT PMF235 PPM

HARD PMF

80 PPM

• OLEIN , SUPEROLEIN , TOPOLEIN :

HIGH VITAMINIC SALAD OIL WITH HIGH COLD AND OXIDATIVE STABILITY. FRYING OIL (“LOW” TEMPERATURE).

• STEARIN AND PALM MID FRACTIONS :

RICH IN VITAMINS PRODUCTS FOR DIETETIC USE : MARGARINE, SHORTENINGS ; CBE.

STEARIN280 PPM

NUTRITIONAL LABEL :- BENEFICIAL EFFECT ON CELLULAR AGEING.-PROTECTION AGAINSTCANCER.

FRACTIONATION OF PALM KERNEL OIL : CBS

C6-C10 7% 6% 4% 4% C12 48% 53% 55% 55% C14 16% 21% 22% 22% C16 9% 9% 9% 9% C18 2% 2% 2% 9% C18:1 15% 8% 7% 0,5% C18:2 2% 1% 1% 0%

C12;C14

C18:1

PKO PKS PKS Hydrogenated PKS IV 18 IV 9 IV 7 IV 7 to 0,4 = CBS

SFC (%)

°C0

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CBS

CONCLUSIONS

It can be difficult to imagine that the mastery and the automatic control of DRY FRACTIONATION is born only 50 years ago.In 1959 in BELGIUM a 8T/day dry fractionation unit is installed for the production of Beef Tallow Olein for frying, still now commercialised as “Blanc de Boeuf”.

In the 60ies and the beginning of 70ies, such types of unit are installed in MALAYSIA, INDONESIA, AUSTRALIA, LATIN AMERICA and CENTRAL AFRICA for the fractionation of animal fats, palm oil, AMF and partially hydrogenated soybean and fish oils.

The fractionation process has been consequently developed, with a range of different companies entering the market of construction of dry fractionation equipment.

THANKS FOR YOUR ATTENTION

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Lipid Structural Properties SymposiumUnilever R&D Colworth, UK

16-17th October 02