Batching Process for Margarine
For the production of Shortening, Margarine and Table Spread, different raw materials (different oils and water) are taken in different quantities as per a pre-defined recipe, to which emulsifiers, anti- oxidants and other ingredients are added manually to make a homogenous emulsion ready to be fed to the processing section.
For batching, two tanks mandatory for all products are the Premix tank and the Buffer tank. The premix tank stands on three live load cells while the batching system automatically transfers different oils from different tanks as required by the recipe selected. Buffer tank continuously supplies the blend to the processing section while the next batch is prepared in the Premix Tank. Shortening can be prepared with the help of only the Premix and the Buffer Tank.
However, for the production of Margarine, it is required to add at least two more tanks of smaller capacities namely the Emulsifier Tank and the Water Phase Tank. Both these tanks also stand on live load cells and are integrated into the batching system to optimize production. Furthermore, for the manufacture of products with SMP or Cocoa optionally an additional would be required with a High Shear Blender will be required to blend SMP and form a homogeneous solution before transferring it to the Premix Tank.
Though these is the minimum requirement for the production of Margarine, it is sometimes preferred to have a Water Storage Tank with a dedicated hot water circulation system, twin tanks for Emulsifier and Water Phase and a Fat remelter.
A sample Flow chart for Batching Systems for Margarine supplied by SIPEPL is as below, however the Batching system is made as per the requirement of the Customer after evaluating the different products he wishes to produce.
Features of SIPEPL’s Batching Systems
Batching Tanks
The batching tanks are stainless steel SS316L grade tanks mirror finished from the inside with limpet coils for circulation of hot or cold water for accurate temperature control of the product in the tank. The tanks are insulated and cladded on the outside to prevent heat loss and surface finished with glass bead blasting.
As a standard all tanks shall comprise of a Temperature Transmitter, High Level and Low Level Switches and DIN Union Fittings for Inlet and Outlet, Lifting Hook and a CIP Nozzle.
Agitator Configuration
Since the product is an emulsion of oil and water it is becomes imperative to keep it agitated at all times to ensure a stable emulsion. Agitation to also be selected to ensure the water-oil emulsion is even across the length of the tank. Thus the agitator plays a very important role in the final quality of the product. At SIPEPL, the agitators are designed as per the requirement of the product and the moisture content in the product. For some products, a cost effective single agitator with narrow hydrofoil is selected, however for other sensitive and high moisture content products, a two agitator system is preferred. The anchor agitator and the propeller agitator. While the anchor keeps the emulsion stable, the propeller agitator is used for mixing during the batching process.
As a standard all tanks shall comprise of a Temperature Transmitter, High Level and Low Level Switches and DIN Union Fittings for Inlet and Outlet, Lifting Hook and a CIP Nozzle.
Batching Automation
A load cell based batching system is used for the Batching process to ensure the set quantity of oil is accurately transferred into the tanks. The load cell system shall comprise of 3-4 live load cells with weight indicator.
The batching automation is achieved by controlling the various transfer pumps and actuator valves in the Batching system by a pre-programmed weighing controller.
These batching controllers shall be connected to the Batching logic of SIPEPL’s SCADA Package in which the Recipes and the sequence of operation are pre-programmed.
Platform Structure and Pipe Support for Batching Systems
The Pipe Supports and Platform for Batching Systems are Pre-fabricated in either Stainless Steel or Mild Steel and the piping for the Batching system is done in-house with tie-in points as an option to reduce site activities.
Duplex Filter
The Duplex Filter shall be of Stainless Steel AISI 316L construction and equipped with strainers with the option of inserting Bag Filters. The filter consists of 2 single filters with 4 manual butterfly valves with DIN connections for bypassing one of the filters for cleaning while the other is in operation.
The filter will be furnished with:
- 1 set Strainer with 1 mm perforation
- Heating Jacket
- The manual valves will be of butterfly valves.
- Filter Bags – 2 no’s
- Drain Valves – 2 no’s
Single Agitator Tank
The batching tanks are stainless steel SS316L grade tanks mirror finished from the inside with limpet coils for circulation of hot or cold water for accurate temperature control of the product in the tank. The tanks are insulated and cladded on the outside to prevent heat loss and surface finished with glass bead blasting.
As a standard all tanks shall comprise of a Temperature Transmitter, High Level and Low Level Switches, pneumatically controlled valves for water circulation in jackets, bottom legs with provision to mount the tanks on load cells, isolation and drain valves and flexible hose connections wherever the load cells are used. These tanks shall be equipped with Sanitary Din Union Fittings for Inlet and Outlet, Lifting Hook and a CIP Nozzle.
Since the product is an emulsion of oil and water it is becomes imperative to keep it agitated at all times to ensure a stable emulsion. Agitation to also be selected to ensure the water-oil emulsion is even across the length of the tank. Thus the agitator plays a very important role in the final quality of the product. At SIPEPL, the agitators are designed as per the requirement of the product and the moisture content in the product. The single agitator with narrow hydrofoil is preferred for products with moisture content up to 60-65%,
This agitator is linked with batch weighing system with VFD receiving signals from batch weighing system and is programmable and automatically adjusting the speed with the level in the tank. The agitator shall have 4 blades and is freely supported at the bottom.
Two Agitator Tank
The batching tanks are stainless steel SS316L grade tanks mirror finished from the inside with limpet coils for circulation of hot or cold water for accurate temperature control of the product in the tank. The tanks are insulated and cladded on the outside to prevent heat loss and surface finished with glass bead blasting.
As a standard all tanks shall comprise of a Temperature Transmitter, High Level and Low Level Switches, pneumatically controlled valves for water circulation in jackets, bottom legs with provision to mount the tanks on load cells, isolation and drain valves and flexible hose connections wherever the load cells are used. These tanks shall be equipped with Sanitary Din Union Fittings for Inlet and Outlet, Lifting Hook and a CIP Nozzle.
Since the product is an emulsion of oil and water it is becomes imperative to keep it agitated at all times to ensure a stable emulsion. Agitation to also be selected to ensure the water-oil emulsion is even across the length of the tank. Thus the agitator plays a very important role in the final quality of the product. At SIPEPL, the agitators are designed as per the requirement of the product and the moisture content in the product. The two agitator tanks shall comprise of a mixing agitator and an anchor agitator. While the mixing agitator shall be used at the time of batch preparation, the anchor agitator shall ensure a stable emulsion throughout the length of the tank during processing. This combination is normally preferred for manufacture of low fat spreads.
This agitator is linked with batch weighing system with VFD receiving signals from batch weighing system and is programmable and automatically adjusting the speed with the level in the tank.
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