Complete Margarine Plant - 1.500 kg/h @ 120 Bar - GEA / Gerstenberg Schröder / Oystar Benhil Ecopack

Complete industrial margarine production line with a nominal production capacity of approximately 1.500 kg of table margarine per hour with a work product pressure up to 120 bar. The processing tanks and process design is made by GEA. The High Pressure Pump, Crystalliser and Pin Rotors are made by Gerstenberg Schröder / SPX - Perfector. The consumer packaging machine is made by  Oystar Benhil Ecopack. The entire line is still installed in its original position at the factory in India, offering an excellent opportunity for inspection and evaluation in its existing production environment.

Fat spreads consist of two primary phases: a water phase and a fat phase. They are therefore classified as water-in-oil (W/O) emulsions, in which the water phase is finely dispersed in the form of small droplets throughout the continuous fat phase. Depending on the intended application and required product characteristics, the composition of the fat phase and the manufacturing process are selected accordingly. Factors such as the desired texture, spreadability, melting properties and product stability determine the formulation and processing conditions.

In addition to the crystallization equipment, the modern fat spread production facility comprises a range of process and storage equipment. This includes dedicated tanks for the storage of oils and fats, as well as separate systems for the preparation of the emulsifier phase, water phase and final emulsion. The production facility is further equipped with a pasteurization unit to ensure microbiological safety and product stability, together with a remelting system where required for controlled processing and product conditioning.

The complete manufacturing process for margarine, fat spreads and related products can be divided into the following main sub-processes:

• Reception and storage of oils and fats.
• Preparation of the fat phase, emulsifiers and water phase.
• Pasteurization.
• Emulsion preparation.
• Chilling, crystallization and resting of the product.
• Final consumer product packaging.

The complete installation consists of the following machines and equipment:

A) Oil Storage silos

• 2x Oil storage tanks for the reception of the edible oil which is used in the production process.

Manufacturer: GEA

Volume: 20.000 liter each

Year: 2011

Serial numbers: M2T01 / M2T02

The tank is made of stainless steel 316. Single jacketed. Agitator designed to keep the product in continuous motion and prevent settling. Inspection lid on top of the tank, allowing access for visual inspection of the product inside. Spraybowls for cleaning.

• All pumps / interconnecting piping / valves for receive and sending out of the edible oil.

B) Fat phase preparation

• 1x Fat phase preparation tank

Manufacturer: GEA

Volume: 200 liter

Year: 2011

Serial number: M3T01

The tank is made of stainless steel 316. Single jacketed. Agitator designed to keep the product in continuous motion and prevent settling. Inspection lid on top of the tank, allowing access for visual inspection of the product inside.

• Duplex strainer for 2.000 ltr/h.

• Set of control valves.

C) Water phase preparation

• 1x Water phase preparation tank

Manufacturer: GEA

Volume: 1.500 liter

Year: 2011

Serial number: M4T01

The tank is made of stainless steel 316. Single jacketed. Agitator designed to keep the product in continuous motion and prevent settling. Inspection lid on top of the tank, allowing access for visual inspection of the product inside. The tank is mounted on loadcells for exact weighing of the product inside the tank.

• Water phase recirculation / transfer centrifugal pump, 5.000 ltr/h.

• Plate heat exchanger of 5.000 ltr/h.

D) Powder adding system

• Turbo blender, manufacturer JEC, 500 kg/h.

• Duplex strainer for 5.000 ltr/h

E) Pasteurisation unit

• Pasteurization unit to ensure microbiological safety and product stability.

Skidmounted pasteurizer on a stainless steel frame with a plate heat exchanger (GEA Ecoflex, NT50T-75PL, year 2011, serial nr IN-110/80468, capacity 2.500 ltr/h, 4-sections), pumps, holding tube, hotwater set with expansion vat, all control valves and interconnecting piping.

• Control valves.

F) Emulsion preparation

• 2x Emulsion preparation tanks

To prepare and mix the liquid emulsion before it enters the cooling and crystallization section of a margarine production line. Inside the emulsion preparation tank, these fatt and water phases are mixed under controlled conditions to produce a stable water-in-oil (W/O) emulsion. The small droplets of the water phase are distributed uniformly throughout the continuous fat phase.

Manufacturer: GEA

Volume: 1.500 liter each

Year: 2011

Serial numbers: M5T01 / M5T02

The tanks are made of stainless steel 316. Double jacketed so the product can be heated/cooled/keep at temperature. Agitator designed to mix. Inspection lid on top of the tank, allowing access for visual inspection of the product inside. Spraybowls for cleaning. The tanks are mounted on loadcells for exact weighing of the product inside the tanks.

• Duplex strainer.

• 1x Re-melting tank

To melt and recover margarine, shortening, or other crystallized fat products so that the material can be returned to the production process.

Manufacturer: GEA

Volume: 500 liter

Year: 2011

Serial numbers: M5T03

The tank is made of stainless steel 316. Double jacketed so the product can be heated/cooled/keep at temperature. Agitator designed to keep the product in continuous motion and prevent settling. Inspection lid on top of the tank, allowing access for visual inspection of the product inside.

• All pumps such as Emulsion transfer pump, CIP return pump, Transfer pump from re-melting tank to emulstion tank / interconnecting piping / valves for sending out of the emulsion.

• Hot water hydro system of 25.000 ltr/h with control valves.

G) Margarine processing equipment

• High pressure pump

Manufacturer: Gerstenberg Schröder

Model: P-3-55/80

Year: 2010

Serial number: 4198-DK-01

Capacity: up to 2.000 ltr/h

Product pressure: up to 120 bar

• Crystalliser

Manufacturer: Gerstenberg Schröder

Model: Perfector (1+1)x125

Year: 2010

Serial number: 4198-DK-02

Emulsion: 120 bar, -25/40°C, 2x 3,5 liter

Medium: R717, 17,5 bar, -25/40°C, 2x 111 liter

Motors: 2x 11 kW - 380 / 420 V - 50 Hz - 1.470 rpm

Including separate water heating unit for the seals

• Pin Rotor Machine

Manufacturer: Gerstenberg Schröder

Model: Pin Rotor 25 + 50 liter

Year: 2010

Serial number: 4198-DK-03A and 4198-DK-03B

Pin rotor 01: Product 25 liter, 120 Bar, 0/80°C and Water 2,5 liter, 5 bar, 0/80°C

Pin rotor 02: Product 50 liter, 120 Bar, 0/80°C and Water 5 liter, 5 bar, 0/80°C

• Resting tube

The resting tube provides a controlled holding / residence time for the margarine after crystallization and mechanical working. After the pin rotor, the margarine already has a semi-solid structure, but the fat crystal network is still developing. Inside the resting tube, the product is allowed to rest under controlled conditions with little or no mechanical agitation.

Volume 30 + 20 liter.

H) Consumer foil wrapping equipment

• Foil wrapping machine

Manufacturer: Oystar Benhil Ecopack

Model: FD 120 / 753

Year: 2011

Serial number: A10-3528A

Capacity: 80 to 120 foil wrapped packages per minute

The machine is equipped with 2 format sets.

Format 01: 100 and 200 gram, size of the mould: ± 95 x ± 65 mm x height.

Format 02: 500 gram, size of the mould: ± 115 x ± 70 mm x height.

Control panel with Siemens S7 PLC and touch screen panel.

Photo cell detection for creating the correct postion of the marketing on the package.

I) Electrical and control panels of the margarine line

Main control panels with all motorgroups, PLC (Siemens S7-300), frequency converters will be delivered with the line.

J) Interconnecting product piping and valves.

Interconnecting product and utilities piping, product and utilies pumps and product and utilities valves will be delivered with the line.

K) Manuals / Software

Operation manuals, spare parts manuals, electric schemes, progam and technical drawings / P&ID will be delivered with the line.

L) Ammonia System

Ammonia system (R717) for chilling the crystalliser.

Summarized

This complete production line offers an interesting opportunity for manufacturers looking to establish or expand their margarine production capacity with an existing industrial installation of 1.500 kg per hour at a product pressure up to 120 bar.