Esterification (Glycerolysis)/Interesterification Plants
It is well know that oil is ester of glycerol and fatty acids, which can be decomposed in to their original
constituent (fatty acid and glycerol) or synthesized in to triglycerides by fatty acids and glycerol.
Glycerolysis reaction is reverse of hydrolysis process. It is carried out by reacting fatty acids with glycerol. In addition to esters, water is also product of glycerolysis. The reaction is reversible and proceeds to completion only if water is removed from the medium. The equilibrium between the forward reaction (Glycerolysis) and the reverse reaction (Hydrolysis) controlled by water content of the reaction mixture. In the presence of excess water, hydrolysis predominates, whereas under water eliminating conditions Glycerolysis is favored.
The intra and intermolecular exchange of fatty acids is generally considered Inter-Esterification wherein the process takes place on the backbone of triacylglycerol’s. Partially hydrogenated fat contains Tran’s isomers which is detrimental for human health. Inter-Esterification is used very commonly in the production of Margarine. It is a process which is of importance when the plasticity of fat is being contemplated.
The manufactured by PEMAC can be used for:
- Production of Margarine
- Production of Oil for deep frying
- Separation of two constituting fats
Vanaspati & Hydrogenation Plants
The hydrogenation process can be performed before or after splitting. Hydrogenation is the reaction between hydrogen and the ethylenic double bond of an unsaturated fat in the presence of a catalyst. The saturated (hydrogenated) fat obtained is characterized by better stability properties and higher melting point. The typical hydrogenation process is carried out at a temperature between 160-250ºc and hydrogen pressure of 10-25 bar with the presence of a finely divided nickel catalyst supported.
The salient features of PEMAC’S HYDROGENATION PLANTS are:
- Increased heat exchange
- Maintenance of temperature
- Low contaminant ratio
- Efficient operation
- Low running and Maintenance costs leading to increase in productivity and efficiency
- Low setup cost
- Maintenance free main reaction vessel (Hydrogenation or Autoclave)
Vanaspati is Generally used as the alternative to ghee due to its cheap price. Vanaspati is vegetable cooking oil, fully or partially hydrogenated. Our expertise lies in manufacturing and developing hi- tech vanaspati plants for complete processing and production of oil.The vanaspati is either used for cooking food or as the raw compound in soap making.
We are equipped with advanced technology that facilitate us to develop special types of industrial hard oil plants, attached with hydrogenation gas generation system. This system produces hydrogen gas by the electrolysis of water. Required for the hydrogenation reaction the gas is compressed in storage cylinders in which high pressure is maintained, from where it is drawn for use in the processing plant.
- Continuous bleaching, neutralization, deodorization along with post bleaching and post neutralization sections
- Optimized process condition for proper selectivity and product consistency
- Zero wastage of hydrogen gas and nickel catalyst
- Low consumption of energy
Bakery shortening & Margarine plant
PEMAC is a leading manufactures & exporter of process equipment’s& Turnkey Projects for processing bakery shortening. The plant will be capable of producing up to1,000 kgs/hour when cooling from an inlet temperature of 45 C TO 23/25 C suitable for semi-liquid filling into cans. The capacity is dependent upon product formulations and inlet temperature of the product to be processed.
The Plant Consist of The Following
1.Essessprocessor-Heattransfer cylinder assembly.
2.Crystal distribution cum stabilizer.
3.Triplex plunger reciprocating pump.
4.Nitrogen gas purging system.
5.Interconnecting product pipeline.
Two numbers of interconnected esessprocessor consisting of a single horizontal heat transfer cylinder assembly mounted on an open frame. The cylinder is jacketed and lagged for use with glycol solution. There movable heat transfer cylinder will be internally hard chrome plated. The esssessprocessor shaft is concentrically mounted within the cylinder and has four diametrically opposed rows of floating type scraper blades and is driven by suitable motor hose proof to IP55 standard via belts and pulleys suitably guarded. All the product contact parts are made of stainless steelAISI304 materials. The scraping blades, seal parts and 'o' rings will be compatible with the product, the frame and the external product non-contact parts are in carbon steel and finished painted with metallic paint. Essessprocessor chilling jacket is suitability insulted for eliminating heat loss and cladded with stainless steel sheets for maintaining utmost hygiene.
Crystal Distribution Cum Stabilizer
Horizontally mounted and sequentially connected to the two number of essessprocessors mentioned above. The cylinder has two rows of fixed pins at 180 with a concentric shaft carrying pins in a helical arrangement which intermesh with fixed pins while rotating, driven through a gear box and a suitable motor hose proof to IP55. All product contact parts are made of stainless steel AISI 304 materials. Two numbers of heaters are provided for heating of the product in case of product solidification inside the product cylinder during power failure or production stoppage. The cylinder is suitably insulated for eliminating heat loss and cladded with stainless sheets for maintaining utmost hygiene.
Triplex Plunger Reciprocating Pump
Triplex model single acting reciprocating plunger pump is used for feeding the product to the system. The capacity of the pump is 1,690 litters/hour driven by a suitable motorhome proof to IP 55. All product contact parts are of stainless steel AISI/316 materials and the product handling compartment is suitability jacketed for hot water/steam circulation for melting the product.
Nitrogen Purging System
This consist of pressure regulating value for regulating the line pressure with two numbers gauges for reading the line pressure as well as cylinder pressure. This system has flow meter with flow regulating value for adjusting the required amount of gas to be mixed with the products.
Interconnecting Product Pipeline
The interconnecting product pipeline is jacketed for heating in case of product being solidified inside the pipeline. Further each section of the product pipeline is interconnected suitably for continuous heating of the entire length of the product pipeline.
This control panel not only enables smooth and trouble-free handling of the product but also ensures safe operation of the plant. The unique design features of the control panel prevent mishandling of the plant thereby avoiding costly damages. The unit does not start unless temperature of the product at certain specified locations is below the specified limit.
At the same time the unit does not stop even the temperature are the specific locations goes below the specified temperature during the operation of the unit. This safety factor avoids damage to the equipment’s of the plant when the product inside the equipment’s as well as pipeline is solid in case the plant is stopped due to power failure or product change over.
The bakery shortening plant enumerated above is not the only capacity limit but also, we can manufacture higher production capacity plants as may be required by the clients. We can also procure other fabricated equipment’s like fat blenders of various capacities in both stainless steel and carbon steel as per the specific requirements
PEMACs high efficiency lecithin plants are design to manufacture dry lecithin from wet gums obtained from the soybean oil. In this process moisture from the wet gums is evaporated & the resultant product is cooled in order to receive dry lecithin. It's a natural ingredient, filled with a range of stabilizers, emulsifiers and release agents.
They have a number of uses in the pharmaceutical or cosmetic industry applications. Its hydrophobic / hydrophilic character makes it an ideal food emulsifier. We are experts in manufacturing high performance Lecithin Plants for dehydration of wet gums from soybean. Our plants feature unique design which makes the drying process of the feed gentle without any burn. The soybeans are conveyed in the plant, where screening and cracking to appropriate dimensions are conducted. Beans, in the plant pass through solid fractions developing a bow wave ahead of each blade. Our Lecithin Plant can be easily clean and requires minimum maintenance.
High Flow rate
Low energy consumption
Technology based solvent extraction process
Low power consumption
Low oil residue in extracted meal.