Production of Margarine

PLAN

Design

Build

Maintain

Confidential – For Internal Use Only

CONTENT
• Definition of Margarine
• Raw Material
• Ingredients or Food Additives
• Packaging
• Crystallization
• Equipments & Texturizing Process
• Pattern of Process Margarine
• Tempering & Aging
• Releasement Test : Texture, Application, Creaming
• Summary
• FAQ : All about trouble shooting and problem solving
• Data and Literatures

Confidential – For Internal Use Only

Definition of Margarine
• Margarine is an emulsion of the type water in oil, made from
vegetable oil which is palm oil, consisting of min. 80% fats and oils
and max. 18% of an aqueous/water phase (SNI 3541:2014), which like
the oil phase contains soluted ingredients (Fats and Oils
Handbook, 1998). Any product containing less than 80% fat and more
than 18% of water may be called spreads or margarine cream

Confidential – For Internal Use Only

Polymorphism and Crystal Structure
• Triglycerides exhibit three main crystal types, α (alpha), β’ (beta prime),
and β (beta)

• α (Alpha) = approximately 5 μm
• β’ (Beta Prime) = more than 1 μm in lenght
• β (Beta) = approximately 25 -50 μm in
lenght and can grow to
over 100 μm during extended
Stability increases
Melting Point Increases periods of product

“Margarine Processing Plants and Equipment, Klaus A. Alexandersen”

Confidential – For Internal Use Only

 β’ (Beta Prime) and β (Beta) Crystal
Beta Prime crystal:
Plastic, smooth, glossy, less post hardening, smooth mouth-
feel, and better entrapment of liquid oil. The β' crystal form
tends to structure as a fine three-dimensional network
capable of immobilizing a large amount of liquid oil
(Margarine Processing Plants and Equipment, Klaus A.
Alexandersen)
• rapid cooling
α → β’ crystal (Timms RE, 1991)
Beta crystal:
Coarse, brittle, hard, post hardening during storage. Large b
crystals do not tend to give a three-dimensional structure
(Margarine Processing Plants and Equipment, Klaus A.
Alexandersen).
β' (Beta Prime) β (Beta)
• Slow cooling
α → β crystal (Timms RE, 1991)
Confidential – For Internal Use Only
Crystal Habit of Selected Fat

β’ type β type
• Cotton Seed Oil • Canola Oil
• Butter Oil • Corn
• Palm Oil • Peanut Oil
• Tallow • Coconut Oil
• Soybean Oil
• Sunflower Seed Oil

(Klaus A. Alexander; Margarine Processing Plants and Equipment)

Confidential – For Internal Use Only

Crystal Habit of Palm oil
• Fat containing relatively low amount of palmitic acid approximately
10%, seem to be β tending. Where fats with at least twice from 10%
the amount, in general β’ (beta prime) (Gerstenberg Schroder SPX
“Crystallization Technology”, 2012)

Picture : Molecules “Biological and

Nutrional Properties of Palm Oil And
Palmitic Acid: Effects on Healt”, 2015

Confidential – For Internal Use Only

Margarine Ingridients

A. Soluble in Water
The ingridient added in water phase is only preservative. Some preservatives used
 Salt (NaCl),  EDTA-Na2
• NaCl : ≥ 98%  Citric acid
• yodium content : min 30 ppm
 Potassium sorbat

Confidential – For Internal Use Only

B. Soluble in Oil
 Emulsifier  Flavour
From the phase, divided into powder Type of flavour is divided into, natural,
and liquid. natural identical and artificial

 Antioxidant  Colourant
Divided into natural and artificial. Type of colourant is divided into, natural
Natural antioxidant is tocopherol (pro- identical (B-carotene) and artificial
vit E), and artificial antioxidant is (vegetone).
BHA, BHT and TBHQ.
 Vitamin
Vitamin which soluble in oil is vitamin A,
D, and E.

Confidential – For Internal Use Only

Ingridients Dosage
Ingridients Dosage
Potassium Sorbate 1000 mg/ kg produk
EDTA-Na2 150 mg/ kg produk
BHA 200 mg/ kg produk
BHT 200 mg/ kg produk
TBHQ 150 mg/ kg produk
Tocopherol CPPB (0,15-2 mg/ kg berat badan)
lecithins CPPB (Not limited)
Citric Acid CPPB (Not limited)

(Peraturan BPOM RI No 8, 24, 36, 38 Tahun 2013)

Confidential – For Internal Use Only

RAW MATERIAL
1. GENERAL :
• RPO (Palm Oil)
• RPOL (Palm Olein)
• RPS (Palm Stearine)
• RKO (Kernel Oil)
• RKOL (Kernel Olein)
• RKS (Kernel Stearine)
• CNO (Coconut Oil)
2. HYDROGENATED :
• RHPO (Hydrogenated Palm Oil)
• RHPS (Hydrogenated Palm Stearine)
3. IE (INTER ESTERIFICATION) :
4. SPECIAL :
• MCT (Medium Chain Triglycerides)
• VCO (Virgin Coconut Oil)
Confidential – For Internal Use Only
 Ratio Oil Blend (14/06/2019)
WATER OIL BLEND Quantity
NO NAMA PRODUCT SOFT RPO RKO PORAM RHPO RIEPOPS SOYA BEAN RKL ROL FHPS IV MP INGREDIENT
% (ppm)
%
1 BOS 63 5 32 52-53 33-35
2 FORTUNE LAMA 16 90 5 5 38-39 48-49 BHA+BHT 50
3 FORTUNE 17,5 85 13 2 38-39 48-49 BHA+BHT 50
4 FORTUNE 17,5 98 2 38-39 48-49 BHA+BHT 50
BHA+BHT 50
5 FORTUNE GHANA/AFRICA 16,5 90 10 38-39 48-49
TOCOFEROL 250
6 FORTUNE GHANA 16,5 95 5 38-39 48-49
7 SANIA ( LAMA ) 16 40 55 5 47-48 38-39 BHA +BHT 50
8 SANIA ( BARU ) 16,5 25 71 4 47-49 38-39 BHA +BHT 50
9 SIIP 17,5 88 12 40,41 48-49 BHA +BHT 50
10 SIIP 17,5 100 40,41 48-49 BHA +BHT
11 SOVIA CREAM 21,5 88 10 2 38-39 48-49 BHA +BHT 50
12 SOVIA 17,5 90 5 5 38-39 48-49 BHA +BHT 50
13 SOVIA 17,5 98 2 38-39 48-49 BHA +BHT 50
14 GOLDEN PALM 1010 15,5 93 7 51-52.2 36-39 NO ADDITIVE
15 WILCAKE 1010 15,5 93 7 51-52.2 36-39 TOCOFEROL 200
16 WILCAKE 1010 15,5 15 85 51-52 36-39 TOCOFEROL 200
17 WILCAKE 1011 15,5 93 7 45-55 36-39 TOCOFEROL 200
18 WILCAKE 1100 15,5 83 17 48-49.5 40-42 TOCOFEROL 200
19 WILCAKE 1020 15,5 100 45-55 36-39 BHT 50
20 WILCAKE 1020 15,5 80 20 45-55 36-39 BHT 50
21 WILCAKE 1110 15,5 85 15 49-50 40-42 BHA 150
22 WILCAKE 1012 15,5 92 7 1 52-54 36-39 NO ADDITIVE
23 WILCAKE 4200 15,5 75 25 40-50 43-47 BHT 100
RIEPSKOL 7%
24 RIKI 16,5 85 3 5 48-49.5 35-39 BHA + BHT 50
RPS 75%+RPKOL 25%
RIEPSPOKO 97.5% VCO 0.125%
MCT 0.375% mono
25 SANIA ROYALE 16,5 RIEKLPS(RKL +P ) virgin coconut 2 48-50 36-37 BHA +BHT 50
crude triglycerida
16%+RPO 80%+RKO 4% oil
IERKLPS 19%
26 SANIA PREMIUM 16,5 77 4 48.5-50 36-38 BHA + BHT 50
(RKL 25%+P. 75%)
Confidential – For Internal Use Only
Margarine Production Process
The production of margarine divided into the
following parts:
 Preparation of :
– Fat Blending
– Water Phase (Salt, Preservative)
– Oil Phase (Emulsifier + Fat blend)
– Mixing tank (Flavoring, Coluring, Water
phase, and oil phase)
 Pasteurization
 Cooling, Crystallization and Kneading
 Filling, Packing and Tempering

Confidential – For Internal Use Only

 PREPARATION SECTION

Confidential – For Internal Use Only

Fat Blending Preparation
• The various fats and oils, either as fat blend or single oils, are stored in oil
storage tanks placed outside the production facility. These are kept at
stable storage temperature above the melting point of the fat and under
agitation.
• Tank Capacity : @170 MT (Line 7) ; @ 70 MT (line 4)
• Operating Condition :
– Temp : 55-60oC or 10oC above MP
– Circulation : 3 Hour (after all ingridients adding into tank)
– Agitation Speed : ±290 RPM
• During the storage period (before in line margarine process), nitrogen (N 2)
injected into oil blend to prevent the oxidation process. N 2 valve opened
50%
• Variable Control :
MP, Iodine Value (IV), Peroxide Value (PV),

Confidential – For Internal Use Only

AO/Emulsion Tank (Tank Farm Preparation)
• Steps of adding antioxidants. The
purpose is to prevent oil and fat (raw
material) oxidized and rancid
• Capacity of tank : @ 4 MT
Ingridients :
 Butylated Hydroxy Anisole (BHA)
 Butylated Hydroxy Toluene (BHT)
 Tertiary Butyl Hydro Quinone (TBHQ)
 Tocopherol (Organic Compound)
Operating Condition :
• Temperature : 70 – 75oC (adding antioxidant)
• circulation : 45 minute
• Agitation Speed : ± 202 RPM

Confidential – For Internal Use Only

Confidential – For Internal Use Only
Water Phase and Oil Phase Preparation
• The Water Phase Consist of salt, potassium sorbate, citric acid,
EDTA. That ingridients are dissolved in Reverse Osmosis (RO) Water.
The water phase adding after colourant, flavor and oil phase added into
mixing tank
• Operating Conditions :
• Temperatur : 70 – 75oC
• Agitation : 10 minutes
• Agitation Speed : 1450 RPM (Motor Spec)

• The oil phase consists minor of fat to dissolve ingredients such as

emulsifier. The ingredients (emulsifier) are dissolved in the fat blend
before the water phase is added, thus before the emulsification process
in mixing tank
• Operating Conditions :
• Temperature : 65 - 70oC
• Agitation : 10 minutes
• Agitation Speed : 1450 RPM (Motor Spec)
Confidential – For Internal Use Only
Confidential – For Internal Use Only
Mixing Tank
Tank Volume : 7 MT
Agitation speed : 15 – 25 Hz
• Adding sequence :
• Fat Blend (above Agitator level, so that the oil
Jacke
t not aeration)
• Colourant and Flavor
• Oil Phase
• Water Phase
• After all entered, Circulation 40
Minute
• To homogenized all ingridients including oil phase
and water phase to getting emulsification process.
Confidential – For Internal Use Only
 PASTERURIZATION SECTION

Confidential – For Internal Use Only

Unit Pre Heat – Pasteurization - Pre Cooling

 Pre Heat - Pasteurization

From the Mixing tank the fat blend is
continuously pumped through a Plate Heat
Exchanger (PHE) for pasteurization section
before entering the crystallization line. Heating
for loosing a crystal memory and holding
sequence of the fat blend at 75-85oC for ±12-
13 sec, pipe pasteurization ± 13-15 m

 Pre – Cooling
Cooling after pasteurization with setting point ±
10oC above melting point to help the cooling
process in cooling section
Confidential – For Internal Use Only
 COOLING, CRYSTALLIZATION
and KNEADING SECTION

Confidential – For Internal Use Only

The emulsion is pumped to the
crystallization line by means of a High
Pressure Pump (HPP).

The crystallization line for the

production of margarine and related
products consists of a high pressure High Pressure Pump Scraped Surface Heat
Scraped Surface Heat Exchanger (HPP) Exchanger (SSHE)
(SSHE) which is cooled by refrigerant
(ammonia) type cooling media.

Pin Rotor machine and Plasticator are

often included in the line in order to
add extra kneading intensity and time
for the production of plastic products.
Pin Rotor Plasticator
Confidential – For Internal Use Only
Perfector (Scraped Surface HE)
• Perfector Type : (1+1+1+1) 150
• Media : (fluid Emulsion) & R717 (Ammonia)
• V = 11 L (emulsion) & 185 L (Ammonia)
• Blade : Floating Scrappers (4 Rows)
• Retention time : 8 - 9 sec (if flowrate 4500 kg/hr)
• Motor Speed
• Tube 1 & 2 = 1455 RPM / 50 Hz
• Tube 3 & 4 = 1460 RPM / 50 Hz
Cooling Media
• Shaft Temperatur Setting point 5-8oC above Cylinder
melting point so that the product not stick to Product
Rotor Shaft
shaft Scraper

Confidential – For Internal Use Only

Pin Rotor & Plasticator

• Main Purpose : to kneading crystals and forming crystal so that the

crystal structure is more stable and plastic
• Spesification of Pin Rotor: • Spesification of Plasticator:
• Volume = 100 & 200 liter • Volume = 25 L
• Retention Time : 100 L = 80 Sec • Retention Time = 20 sec (4500 kg/hr)
200 L = 160 Sec • Motor Speed = max 970 RPM
• Motor Speed : 100 L : 50 – 300 RPM
200 L : 15 – 220 RPM
Confidential – For Internal Use Only
Homogenizer Valve
• The standard flat valve (SV) is used in a variety of food,
dairy and chemical applications (Homogenizer Handbook
Processing of Emulsions and Dispersions)
• Homogenization has become a standard industrial process,
universally practised as a means of stabilizing the fat
emulsion against gravity separation. The homogenization
reduces fat globule size from an average of 3.5 µm in
diameter to below 1 µm (Dairy Processing Handbook).
• Effect of Homogenization on the physical
structure :
– Smaller mean fat droplets
– Whiter (or shiny)
– Physical stability of the emulsion

(Chem. Eng. Technol. 2004,27,No.4)

(Dairy Processing Handbook)
Confidential – For Internal Use Only
Filling, Packing and Tempering
After margarine packed into box,
margarine will stored in :
• Tempering F (23-28oC) for
margarine low MP
• Aging (ambient Temperature) for
Margarine high MP

Filling temperature set point is 10 - 15oC

below MP of product, Filling Step :
• Case Erecting (pembentukan karton box)
• Flexim (bag inserting)
• Mechanical Plunger
• Filling
• Top bag sealing
• Top box cartons sealing
Confidential – For Internal Use Only
Process Utility

Hot Water System (HWS)

• HWS 45 (jacketing line) : from perfector –
filling line
• HWS 65 (SP 65oC) : for mixing tank
• HWS 95 (SP 95oC) : for Oil phase tank, PHE
pasteurization, PHE
remelt, Remelt holding
tank

Confidential – For Internal Use Only

Ammonia Refrigeration System
• Type : Screw Compressor
• Media : Ammonia (R717)
P = ± 2 bar
T = ± -9.1oC

Confidential – For Internal Use Only

Margarine Finish Good Product Parameter
• Smooth Not lumpy
Range PenV margarine for local
Not Grainy distribution
• Hardness (PenV in Range) • Fortune Mgr, Fortune Cream
• Plasticity Not Brittle • Sovia Mgr, Sovia Cream 100 - 140
• Specific Gravity (SG) • Siip Mgr
– For local margarin distribution • Sania Mgr 140 - 200
have SG = 0,65 max
• Sania Premium Mgr 160 - 220
• Shiny / glossy

Confidential – For Internal Use Only

Margarine Process Concept

Cooling Working Cooling Working Plasticizing

A1 A2 B1 B2 A3 A4 B3 B4 C1 H

Crystallization & Kneading Crystallization & Kneading

To Getting Smoothness & Hardness To Getting Hardness & Plasticity

(Sandy, Grainy, Lumpy, Smooth, Soft & Hard) (Soft, Hard, Plastic & Brittle)

Confidential – For Internal Use Only

• The primary purpose of the cooling step in perfector A1 is to form the many
nucleation sites from which crystallization step. The product is cooled quickly to
about 10oC under MP using a scraped surface heat exchanger which facilitates the
formation of first α and then β’ crystal (Borwankar et al., 1991)
• The crystallization process must completed in cooling tube A2 to make the
crystal in uniform size. If the crystallization process not completed and then
continued in cooling tube A3 and A4, there is a possibility that the margarine will
lumpy or brittle. So that in perfector A3 and A4 used to set the hardness.
• Pin rotor is used to kneading and forming the crystal so the structure is more
stable and plastic.

Confidential – For Internal Use Only

Analysis of Cooling Concept
• To making product softer

A2 and/or A3 A4

• To making product harder

A2 and/or A3 A4

Confidential – For Internal Use Only

 Pattern of Setting Parameter Margarine Line 7

Confidential – For Internal Use Only

Effect of Tempering After Filling 1 Hr (Observation)

Summary : If low MP margarine placed in ambient temperature, margarine

may have a harder texture than it is placed at tempering room 20 – 23oC

Confidential – For Internal Use Only

Sania BOS trial (line 4)
Production 14/05/2019
Setting Parameter
Batch Penve 20DC Penve Releas Texture
SP A1 SP A2 SP A3 SP A4 B1 B2 B3 B4 C1 Filling
4 19 13 10,5 9 140 140 150 150 600 17 224 479 smooth

Production 24/06/2019
Setting Parameter
Batch Penve 20DC Penve Releas Texture
SP A1 SP A2 SP A3 SP A4 B1 B2 B3 B4 C1 Filling
1 19 13 9 7,5 130 130 120 120 400 17 240,2 433 smooth

2 19 13 9 7,5 130 130 120 120 200 17 207,4 425 smooth

Summary : to make Sania BOS harder, setting point RPM pin rotor, plasticator
decrease (next trial : effect of decreasing A2 temperature to texture)

Confidential – For Internal Use Only

Effect of Emulsifier with Condition Parameter
Siip Margarine
Production 09/05/2019
Setting Parameter (emulsifier dimodan)
Batch Penve 20DC Penve Releas Texture
SP A1 SP A2 SP A3 SP A4 B1 B2 B3 B4 C1 Filling
1 37 32,5 32 32 190 190 207 207 854 32,9 - 33,5 158 - 175 117 - 130 smooth

Production 09/05/2019
Setting Parameter (emulsifier palsgard 1388)
Batch Penve 20DC Penve Releas Texture
SP A1 SP A2 SP A3 SP A4 B1 B2 B3 B4 C1 Filling
1 37 29,5 31 31 190 190 207 207 854 31,5 - 32,5 213 105,8 smooth

2 37 29,5 31 31 190 190 207 207 854 31,5 - 32,5 186 103 smooth

Summary : with different emulsifier, different setting point are needed

Confidential – For Internal Use Only

Penetrometer Standardization

Is there a different result between this two penetrometer??

Penetrometer Cone Angle 40 Penetrometer Cone Angle 25

Confidential – For Internal Use Only

 𝐾 .𝑊
𝐶= 𝑛
𝑃
In which C = yield Value in g/cm2
K = Factor dependent on the angle of
the cone
P = The penetration depth in 0.1 mm.
At a penetration during 5 seconds
W = The weight of the cone (grams)
n = 1.6 (for margarine, butter,
shortenings

“The Measurement of the hardness of margarine and fats with cone penetrometers”
A. J. Haighton, Unilever Research Laboratory, Vlaardingen, the Netherland
Confidential – For Internal Use Only
Packaging
Some things that need to be considered about the quality parameter
of packaging, that is :
Type of box flute CARTON BOX : PLASTIC :
• BCT ( Box Compression • thickness ( 45-70 µ)
Test) • Elongation
• Symmetrical from Join • Having 3 layer
Glue – Inner ( Metaluzing )
• Daycut ( 6-9 mm) – Colour
• Easy to bend – Outer ( HDPE )
• Distance from bending
• No blackspot
line to join glue = 1 cm
• Cartons artwork

Confidential – For Internal Use Only

 Standard of Plastic Size
X
Z

Y Y

Y
Y : Guzzette Plastic (150 mm) , tolerance +5 mm dan –0 mm
X : Plastic width (415 mm), Tolerance +5 mm dan –0 mm 4 2 4
Layer Layer Layer

Max Deviation of guzzette 5 mm

X + 2Y = S
S : Diameter Tube Plastic , Tolerance + 10 mm
S = 715 mm
Z = 115 mm
Confidential – For Internal Use Only
Standard Test of Margarine
• Hardness Test
• Organoleptic Test : Odor, taste, hand feeling
• Creaming Test (SG)
• Application Test

Organoleptic Test Creaming Test Hardness Test Application Test

Confidential – For Internal Use Only

Summary
• Pattern Process has been analyzed in slide 35, and need to do next observation. In this process especially
for perfector 4 tubes and 4 pin rotor (Gerstenberg Schroder SPX Machine). The general guideline are as
stated:
– Pre Heat = Pasteurization Temperature 75 – 80oC
– Pre Cooled = temperature +/-10oC above MP
– A1 = setting temperature +/-10oC below MP (Preparation & Nucleation)
– (A2-A4) (B1-B4) ( C ) = adjust to get texture which are expected
– Filling temperature = 10 – 15oC below MP
• Fine Tune Process
– To make margarine harder : A2 decrease and A3 A4 increase temperature
– To make margarine softer : A2 increase and A3 A4 decrease temperature
– To make Sania BOS harder, decrease setting point RPM pin rotor, plasticator
– If low MP margarine placed in ambient temperature, margarine may have a harder texture than it is
placed at tempering room 20 – 23oC
• With different emulsifier, different machine, have a uniqe characteristic (set point, texture, etc)

Confidential – For Internal Use Only

 THANK YOU
FOR YOUR
Confidential – For Internal Use Only
ATTENTION