Reduced and Low Fat Spreads

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Reduced and Low Fat Spreads

Table of Contents

Executive summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Introduction to SPX Flow Technology - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Vision and commitment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Customer focus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

Introduction to spreads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Spreads production - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Recipes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Evaluation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

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 Reduced and Low Fat Spreads

EXECUTIVE SUMMARY INTRODUCTION TO

SPX FLOW TECHNOLOGY

Food companies today are like other manufacturing VI S ION AN D COM M ITM E NT
businesses not only focusing on the reliability and quality of SPX's Flow Technology segment designs, manufactures
the food processing equipment but also on various services and markets process engineering and automation solutions
which the supplier of the processing equipment can deliver. to the dairy, food, beverage, marine, pharmaceutical and
Apart from the efficient processing lines we deliver, we can personal care industries through its global operations.
be a partner from the initial idea or project stage to the final
We are committed to helping our customers all over the
commissioning phase, not to forget the important
world to improve the performance and profitability of
after-market service. SPX Flow Technology has Gerstenberg
their manufacturing plant and processes. We achieve this
Schröder installations in more than 110 countries around the
by offering a wide range of products and solutions from
world.
engineered components to design of complete process
plants supported by world-leading applications and
development expertise.

We continue to help our customers optimize the

performance and profitability of their plant throughout its
service life with support services tailored to their individual
needs through a coordinated customer service and spare
parts network.

C U S TO M E R F O C U S
SPX Flow Technology develops, manufactures and installs
modern, high efficient and reliable processing lines for
the food industry. For the production of crystallized fat
products like margarine, butter, spreads and shortenings
SPX offers Gerstenberg Schröder solutions which also
comprise process lines for emulsified food products such as
mayonnaise, sauces and dressings.

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 Reduced and Low Fat Spreads

I N T R O D U CT I O N T O S P R E A D S a fat phase and a water phase. The major ingredients in the fat
During the last decades, low fat spreads have become very phase, the fat blend, normally consist of a blend of different fats
popular in the Western World due to an increasing awareness and oils in order to achieve a defined solid fat content curve.
in the population in respect to minimizing the fat intake. Back In regard to reduced fat products, the fat phase constitutes
in the late 60’s, the first margarines with a fat content reduced less than 60% of the total emulsion. Reduced fat spreads are
to approximately 40% were produced. Thus, these products usually formulated from the same oil blends as those used for
contained 50% of the normal fat content and consisted of only the manufacture of the corresponding soft table margarines,
fat, water, salt, emulsifier, flavor, vitamins and preservatives. These however these products contain less than 60% fat.
products showed poor melting and flavor release properties
Minor ingredients such as emulsifier, lecithin, flavor and color are
due to very tight water-in-oil emulsions. This tight emulsion was
dissolved in the fat phase before emulsification. Lecithin is not
required in order to have the needed stability.
used in 40% spreads since it destabilizes the emulsion.
In general, margarine contains minimum 80% fat, and products
Emulsifiers are surface-active compounds and are used to
with a fat content of less than 80% are called spreads. Low fat
reduce the interfacial tension between the water and the
spreads have approx. 40% and reduced fat spreads contain
fat phase, usually monoglycerides or mixtures of mono- and
typically 60% fat.
diglycerides. The emulsifier stabilizes the liquid emulsion before
In the early 80’s, 40% fat products containing very high amounts crystallization to secure a homogeneous product and to achieve a
of milk solids were marketed in the US. These products exhibited, finely dispersed and stable water distribution in order to improve
however, very poor microbiological stability. Consequently, these the microbiological keeping properties in the spreads.
products did not have the 4 to 6 months’ shelf life that other
Fat-soluble flavor and color, butter flavor and β-carotene,
spreads have and were therefore withdrawn from the market.
respectively, are added to achieve products which taste and look
Today, higher quality products containing less fat, usually with like butter. In addition, β-carotene has pro-vitamin A activity.
milk proteins and stabilizer systems, are being produced with
For reduced and low fat spreads, the water phase has a great
great success in many countries. However, the great demand
influence on the finished product in regard to taste and mouth-
for low fat food products has been and still is a big challenge
feel. It mainly consists of water in which the minor ingredients
for the food industry, since a number of low fat products require
are dissolved. Apart from salt and preservative, whey powder,
development of new technologies and processes.
skimmed milk powder or other types of milk can be added. Due
to the high water content, a stabilizer system is needed in the
S P R E A D S P R O D U CT I O N case of spreads in order to have the necessary stability in the
In general, like production of ordinary margarine the production final crystallized product. Water-soluble flavor and color can also
of spreads can be divided into the following parts: be added, but are primarily used in low fat spreads.

• Preparation of the water phase and fat phase Salt is added primarily to improve taste, but also to prevent
• Emulsion preparation growth of micro-organisms. In frying margarine, salt helps to
• Pasteurization prevent spattering.
• Crystallization
Preservatives often used in reduced fat spreads are benzoates
• Filling
and sorbates. They are most active at a pH around 4.5, which
• Remelt
makes the advantage of adding them doubtful due to the fact
The emulsion consists of a fat phase and a water phase. Minor
that pH in low fat margarine emulsions is often close to neutral.
ingredients such as emulsifiers, salt, preservatives or additives,
color, flavor and vitamins are dispersed in the phases according Milk proteins have an o/w emulsifying effect, which means that

to solubility. Consequently, the raw materials used in the emulsion they work against the w/o emulsifier system of the margarine or

preparation prior to processing of spreads can be divided into spread and thus de-stabilise the margarine emulsion. However,

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 Reduced and Low Fat Spreads

this enhances the flavour release and thus milk proteins are care should be taken not to incorporate air during emulsification.
added to the emulsion when producing spreads to influence the SPX Flow Technology has developed special tanks to fulfil these
taste. demands. Prior to entering the crystallization equipment, the
emulsion is pasteurized, preferably in a scraped surface heat
Stabilizers can be added in order to make the low fat emulsion
exchanger (SSHE).
more stable. There is a large variety of stabilizers, such as
hydrocolloids, on the market. The water binding capacity and Low fat emulsions have been found to be sensitive to in-line
organoleptic properties have to be considered when choosing pressure and cooling rate. If too extensive chilling takes place
stabilizer or stabilizer systems. early in the process, the shearing forces might become too large
and the emulsion might break. Therefore, low fat products should
Alginates, pectin and carrageenans have a good water binding
be produced by high-liquid, low SFC profile blends to minimize
effect and gives stable emulsions. These stabilizers are today
this problem. Usually a lower throughput is used when producing
widely used either alone or as mixtures.
low fat spreads than when producing corresponding 80%
In the case of low fat spreads, the water phase and the oil should margarine.
have similar temperature and should be combined slowly when
Formulation A represents a 40% fat spread without protein
forming the emulsion. Additionally, it is very important that the
and without stabilizer, whereas formulation B shows a 40% fat
emulsion is properly agitated to ensure homogeneity. However,
spread containing protein and stabilizer.

R ECI PE S

FORMULATION A, % OF THE FORMULATION B, % OF THE

EMULSION EMULSION

FAT PHASE EMULSIFIER(S) 0.5-1.5 0.5-1.5

Β-CAROTENE 4 PPM 4 PPM

FLAVOR 0.15 0.15

30 PARTS INTERESTIFIED BLEND OR HYDROGENATED
FAT BLEND UP TO 40% UP TO 40%
OIL 41°/42°C
70 PARTS LIQUID VEGETABLE OIL

WATER PHASE WATER UP TO 60% UP TO 60%

SALT 0.5-2 0.5-2

FLAVOR 0.02 0.02

WHEY POWDER - 0.5-1.5

STABILIZER - 0.5-2

However, depending on the composition of the emulsion and first chilling tube in order to make the phase inversion before the
especially the water phase, low fat emulsions can be more or less emulsion has become too crystallized.
stable. Stable, viscous emulsions are easy to crystallize. Relatively
Typically the emulsion is continuously pumped from the buffer
low cooling temperature can be applied and the product can be
tank through either a plate heat exchanger (PHE), a low pressure
produced like normal table margarine.
SSHE, the GS Consistator® or high pressure SSHE, the GS
In most cases when producing low fat spreads, a w/o emulsion Kombinator, for pasteurization prior to entering the crystallization
is made from the beginning, but if the composition is such that it line.
gives an unstable emulsion, it can be an advantage to start with
For some very stable low fat emulsions the PHE can be
an o/w emulsion. If an o/w emulsion is made from the beginning,
used for pasteurization. For the low fat versions for which the
it is necessary to make a phase inversion by the inverter during
emulsion is expected to exhibit a relatively high viscosity and is
the crystallization process. The inverter has to be placed after the
specifically sensitive to shear and for heat-sensible emulsions

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 Reduced and Low Fat Spreads

Kombinator
GS Nexus
SSHE

Pin rotor machine

Cooling water
Preparation of emulsion HP pumping HP pasteurizing Crystallization Kneading

Remelting Filling in cups

High pressure pasteurization solution with GS Kombinator 250 SHCW.

(e.g. emulsions with high protein content), the GS Consistator® In addition, pasteurization of the complete emulsion ensures
system as a low pressure solution or the GS Kombinator 250 that the emulsion is fed to the crystallization line at a constant
SHCW as a high pressure solution is recommended as shown in temperature achieving constant processing parameters, product
the process drawing. temperatures and product texture. Furthermore, occurrence of
pre-crystallized emulsion fed to the crystallization equipment is
The pasteurization process has several advantages. It ensures
prevented when the emulsion is properly pasteurized and fed to
inhibition of bacterial growth and growth of other micro-
the high pressure pump at a temperature 5-10°C higher than the
organisms and thus improves the microbiological stability of the
melting point of the fat phase.
emulsion. Pasteurization of only the water phase is a possibility,
but pasteurization of the complete emulsion is preferred since A typical pasteurization process will after preparation of the
the pasteurization process of the emulsion will minimise the emulsion at 45-55°C include a heating and holding sequence of
residence time from pasteurized product to filling or packing of the emulsion at 75-85°C for 16 sec. and subsequently a cooling
final product. Also, the product is treated in an in-line process process to a temperature of 45-55°C. The end temperature
from pasteurization to filling or packing of the final product depends on the melting point of the fat phase: the higher the
and pasteurization of any rework material is ensured when the melting point, the higher the temperature.
complete emulsion is pasteurized.
The emulsion is pumped to the crystallization line by means of a
high pressure plunger pump (HPP). The crystallization line for the
production of margarine and related products typically consists
of a high pressure SSHE which is cooled by ammonia or Freon
type cooling media. Pin rotor machine(s) and/or intermediate
crystallizers are often included in the line in order to add extra
kneading intensity and if placed at the end of the line before the
cup filler, a correct filling consistency is ensured.

The heart of the crystallization line is the high pressure SSHE,

the GS Nexus, the GS Kombinator or the GS Perfector, in
GS Kombinator 250 SHCW
for high pressure which the warm emulsion is super-cooled and crystallized on
pasteurization.
the inner surface of the chilling tube. The emulsion is efficiently
scraped off by the rotating scrapers, thus the emulsion is chilled

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 Reduced and Low Fat Spreads

If the product at filling is out of scope in regard to the

specifications, it will be diverted to the remelting system, melted
and added to the buffer tank for re-processing. Different
remelting systems are available but the most used systems are
PHE or low pressure SSHE, e.g. the Consistator®.

E VA L UAT I O N
In regard to reduced fat and low fat spreads, these products
SSHE units from the GS brand: GS Nexus and GS Kombinator.
have to exhibit the same characteristics as traditional soft table
margarine and other 80% fat spreads. In other words, the eating
and kneaded simultaneously. When the fat in the emulsion properties should be similar to those of full fat margarines in
crystallizes, the fat crystals form a three-dimensional network terms of mouth-feel and flavour release. In addition, the products
entrapping the water droplets and the liquid oil, resulting in should be spreadable directly from the refrigerator.
products with properties of plastic semi-solid nature.
The stability of the samples can be described by a spreadability
The crystallization process, the processing conditions and test. This test involves spreading of the sample with a knife on
the processing parameters have a great influence on the cardboard, and the following rating system can be used:
characteristics of the final spread product. When designing a
• 5 points: describes a highly stable and very smooth sample.
crystallization line, it is important to identify the characteristics of
• 4 points: describes a stable sample that tends to separate
the products planned to be manufactured on the line. To secure when worked intensively.
the investment for the future, flexibility of the line as well as
• 3 points: describes a sample that separates when worked.
individually controllable processing parameters are necessary,
• 2 points: describes a sample that separates immediately.
since the range of products of interest might change with time as
• 1 point: describes a sample that separates during processing
well as raw materials.
- free water is visible.

Typically, a spread line is running at lower capacity than a Water droplet size and distribution can be analyzed by Nuclear
corresponding 80% fat margarine; the line could be decreased Magnetic Resonance, NMR, using Minispec from Bruker,
to 50% of the capacity rate at which an 80% product is being Germany. The most important parameter in characterizing
produced. any emulsion is the size distribution. Two emulsions may have
the same average droplet size and yet exhibit quite dissimilar
The configuration of the process differs from producer to
behavior because of differences in their distribution of diameters.
producer but often a cooling to pin to cooling or cooling to pin
Stability of the emulsion is one of the phenomena influenced by
configuration is used. The chilling and kneading intensity in the
both relative size and size distribution. Size is an individual droplet
SSHE and the pin rotor machine, respectively, depends on the
property, but the property of one droplet is not an interesting
type of product. As a general rule, less intensive chilling is applied
value in the overall emulsion evaluation. The real interest is the
when especially low fat spreads are made. The residence time
entire size distribution of the emulsion.
in the pin rotor machine varies unfortunately also from spread to
spread but 1-2 minutes is a normal interval.
S U M M A RY
When the product leaves the last chilling section or pin rotor
There is no doubt that reduced and low fat spreads are going
machine it is ready for filling. The filling temperature is normally
to stay on the market in future. However, further developments
higher for low fat products than for the corresponding 80%
concerning stabilizer systems, emulsifier systems and perhaps
fat products since the emulsion is more viscous. If the filling
processing are still of interest in order to produce even better
temperature is too low, the final product may become crumbly
reduced and low fat spreads which have the same characteristics
with water leakage as it is filled or later spread on bread.
as full fat spreads in regard to use, taste, mouth-feel and keeping
properties.
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A B O U T S PX

Based in Charlotte, North Carolina, SPX Corporation (NYSE: SPW) is a global Fortune 500 multi-industry manufacturing leader
For more information, please visit www.spx.com.

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Denmark Germany
P: +45 7027 8222 P: +49 451 3709 0
[email protected] [email protected]

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