45 Years of Experience
The complete process: formulation, emulsification, pasteurization, crystallization and packaging.
The Process
Margarine is a water-in-fat emulsion, with tiny water droplets dispersed uniformly in a stable crystalline fat phase.
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The aqueous and fat phases are melted, pasteurized and emulsified. Buffer tanks ensure constant feed flow and pressure into the crystallization zone.
The emulsion is pumped at high pressure into scraped surface heat exchangers (SSHE) for rapid subcooling. Immediately, the kneading units apply intensive mechanical shearing to form and stabilize the fat crystalline network.
Adjusting the SSHE temperature and the RPM of the pin workers is what allows the line to be configured for different margarine types: table, liquid or spreadable.
Margarine Types
Different types of margarine can be produced, such as:
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For household and bakery use in bar format.
Creamy spreadable consistency, ideal for tub packaging.
Plastic, high melting point, formulated for lamination.
Reduced-fat formulations with high emulsion stability.
Storage & Dosing
Natural oils and fats are multi-component mixtures of triglycerides, and their composition determines the physical properties and characteristics of the final product.
It is therefore common to use blends of different fats to achieve the desired characteristics.
Fats are a main ingredient (85-86%) in margarine, so it is necessary to store and dose tons every day. That is why it is important to have an automatic storage and dosing system.
Each fat and oil is melted and stored in temperature-controlled storage tanks with sensors above the melting point, then automatically dosed through flow meters into the mixing tank.
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Phase Preparation
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The fat and aqueous phases must be prepared separately to ensure that all powder ingredients are properly dissolved.
Emulsification
The fat and aqueous phases are dosed into the mixing tank. A combination of mechanical force (electro-emulsifier at 1,450 rpm) and thermal/chemical cooling allows the formation of a very stable emulsion, with water droplets of approximately 3 microns dispersed in the oil phase.
Thermal Processes
Pasteurization is necessary to obtain a product free from microorganisms, by eliminating pathogens and harmful bacteria that do not form spores.
The crystallization behavior of lipids has important implications in the industrial processing of food products whose physical characteristics (consistency, plasticity and mouthfeel) depend greatly on fat crystals.
Process parameters—such as the cooling rate, composition and residence time—directly impact crystallization behavior, so the design of a successful crystallization process depends on choosing parameters that produce crystals with the required characteristics.
Crystallization occurs through a sequence of interdependent mechanisms that all contribute to the final result.
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Crystallization Mechanisms
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To initiate crystal formation from the liquid state, the emulsion must undergo severe and rapid cooling in the SSHE (Scraped Surface Heat Exchanger).
Once a crystal nucleus has formed, it begins to grow due to the incorporation of other molecules from the supersaturated liquid surrounding the crystal. The application of fats in food products requires that the average crystal size be less than 30 µm to avoid a grainy mouthfeel.
Long-chain compounds such as triglycerides can exist in different crystal forms with specific properties, referred to as the α, β' and β polymorphs. The β' (beta prime) is the crystal form with the best functionality: it is softer and provides greater aeration and creaminess properties. Palm oil has high stability in the β' form, so it is often used in the fat plastification process.
Crystallizers
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The crystallization system achieves a high level of control of process parameters and allows flexible equipment combinations to meet optimal operating conditions, thus ensuring the crystal form and texture of the required product.
Remelting
The product is kneaded in Pin Rotor Machines, where through variable rotation speed and residence time it is possible to achieve the required texture. The sequence of crystallizers and pin workers can vary depending on the line capacity and the type of margarine to be produced.
In case of a stoppage downstream of the crystallizer, the product is remelted through a Scraped Surface Heat Exchanger and recirculated to a storage tank.
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CIP System
A cleaning cycle consists of:
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First Rinse
Removes most product residues from the pipes after production. This water goes down the drain after passing through the plant.
Cleaning with alkaline or acid detergent
This solution can be reused more than once and is recycled back to the soda/detergent tank. The optimal detergent concentration is maintained automatically by a conductivity meter and a dosing pump.
Neutralization with acid solution
Optional, depending on the product.
Final Rinse with fresh water
Necessary to remove chemicals that may remain in the pipes. At the end of this phase the water is recycled back to the first rinse tank for the next cycle.
Factors that affect cleaning cycle efficiency:
All these parameters can be configured and controlled with the automatic CIP system to ensure the same cleaning effectiveness in every cycle.
