alfa laval powerpoint presentation...2020/01/04 · produced tfa from the global food supply by...

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Bent Sarup

Vice President, Edible Oil Systems,

Alfa Laval, Copenhagen,

Denmark

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Presented at the 5th Pakistan Edible Oil Conference

Saturday 11th January 2020, Karachi.

Bent Sarup

Alfa Laval Copenhagen A/S

Soborg, Denmark

13/01/2020 | © Alfa Laval 2 |

Margarine technology and related

upstream fat modification technologies

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• From a health perspective

• Opportunities for TFA-free products in Pakistan

• Refining, fat modification and margarine/shortening technology

• Conclusion

In the next 30 minutes,

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From a health perspective

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The future of margarine and shortening influenced by

world trends

Population

increase

Significant rise in vegan and

vegetarian population

Footprint in Asia, Africa

and Europe

Increase in demand for

plant-based food products

Health and

wellness

More health-conscious

consumers

More low-fat, low-calorie

and trans fat free products

More affordable, raw

plant-based materials

Environmental

footprint

Focus on image, legislation

and utility cost

Water and

energy savings

Continued investments

in plant infrastructure

Industrial

margarine market

Increased use of

plant-based margarines

Demand for low-fat bakery and

confectionery products

More affordable, raw

plant-based materials


Health and Trans-fatty acids (TFA)- In focus for regulation since the beginning of millennium

• TFA intake is currently estimated to be

responsible for more than half a million

deaths from coronary heart disease each

year around the world

• In May 2018, the World Health

Organization (WHO) launched the

REPLACE action package to support

governments to eliminate industrially

produced TFA from the global food

supply by 2023.

Ref: Countdown to 2023: WHO Report on Global Trans Fatty Acid

Elimination (2019)

Estimated number of annual deaths from

coronary heart disease due to TFA intake in

adults 25 years and older (2010)


Denmark the first country to ban industrial TFA’s

– yielded great results

• In 2004, industrially produced TFA were

eliminated in Denmark – the first national

policy globally

• During the past 15 years, 28 countries

have implemented mandatory TFA limits,

covering 2.4 billion people (31%) across

the globe

• According to a American Journal of

Preventive Medicine study: After a decade,

cardiovascular disease mortality rates in

Denmark plummeted. Ref: https://time.com/4025570/denmark-trans-fat-ban/

Ref: Countdown to 2023: WHO Report on Global Trans Fatty Acid Elimination (2019)

https://time.com/4025570/denmark-trans-fat-ban/


TFA consumption in everyday food

Ref: Countdown to 2023: WHO Report on Global Trans Fatty Acid Elimination (2019)

• Vanaspati ghee, bakery shortening, hard margarines

and fat spreads, along with food products made with

these fats as ingredients, are the major sources of TFA

consumption in Pakistan

• Increased focus on introducing TFA limits, but complex

since both national and provincial food safety bodies

are involved, and considerable variations found at the

provincial level

• Many opportunities exist for achieving TFA elimination,

including ”technical assistance to replace

industrially produced TFA with healthier oils and

fats, and create a toolbox for replacement.”

- Situation in Pakistan


Potentially harmful trace compounds in palm oil- Not present in crude palm oil, appear during refining

3-MCPDE (3-monochloropropanediol esters)

• Possible effect on kidney & male fertility*

• Formed >140 oC in the presence of acidity and chloride ions**

• Difficult to remove after formation

GE (Glycidyl Esters)

• Genotoxic and carcinogenic (can damage DNA & cause cancer)*

• Formed rapidly >220 oC at long retention time

• Main pre-cursor Diacylglycerides (DAG)

• Can be removed by direct stripping or post-refining

* European Food Safety Authority (EFSA)

** Institute of Food Science & Technology, UK (IFST)

>140°C

DAG GE

Deodorizing Time

H+

>220°C

TAG/DAG + Cl ̄ 3-MCPDE

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EU legislation on GE affects supply chain

COMMISSION REGULATION (EU) 2018/290, of 26 February 2018

1.0 ppm

0.5 ppm

10 |13/01/2020 | © Alfa Laval

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− Effective dates starting 1st January 2021

MPOB licensing conditions takes effect

11 |13/01/2020 | © Alfa Laval

Parameters Processed

palm kernel oil

Processed

palm oil

Effective date

GE (max) 1.0 ppm 1.0 ppm 1st Jan 2021

3-MCPDE (max) 1.25 ppm 2.5 ppm

1.25 ppm*

1st Jan 2021 until 31st Dec 2021

1st Jan 2022

Palm oil refinery category (RF)

Palm oil product exporter category (PX)

Palm oil product importer category (PM)

* Effective date for Integrated Refinery, Exporter & Importer (Effective date for Independent Refinery is 1st Jan 2023)


Opportunities for TFA-free products

in Pakistan


Pakistan edible oil market – key figures

Edible oil consumption (2017) 1)

4.1 mill ton (17 kg/capita/year)

Palm oil import (Jul 18 to Jun 19) 2)

2.9 mill ton

Vegetable ghee (2018 – 19) 2)

1.4 mill ton

Consumer cooking oil price June 2019 (2.5 ltr) 2)

415 – 550 Rs (~ 3.1 USD/ltr)

Consumer vegetable ghee price June 2019

(2.5 Kg, tin) 2)

505 – 520 Rs (~3.3 USD/kg)

Sources:

1) http://www.blackseagrain.net/novosti/pakistan-jump-in-edible-oil-imports,

2) Monthly Bulletin of Statistics, July 2019, Pakistan Bureau of Statistics


Pakistan standard PS:221 (4th Edition, 2010)

Related to fat modification technologies it is noted that technologies and products used

elsewhere to replace hydrogenated fats are not allowed:

• Interesterified products.

• Only the soft fraction (olein) from the dry fractionation of palm oil allowed, the

”naturally hydrogenated” TFA-free part (stearin fractions) as pure blending

component is not.


Introduction of palm oil in Vanaspati Ghee increased

over time (1970 – 1994)

Ref: ”Market acceptance of Palm Oil based Vegetable Ghee in Pakistan”, Iftikhar Ahmad, Palm Oil Developments, 21, p 35-37 (1994)

Period Palm Oil Share (%)

1970 - 75 5 - 20

1975 - 80 20 - 40

1980 - 85 40 - 60

1985 - 90 50 - 65

1990 - 91 65 - 80

1991 - 94 80 - 100

”Due to no or very little hydrogenation

required for conversion of palm oil

vegetable ghee, it can be conveniently

used to produce low-trans or

trans-free products”

”The latest nutritional concerns on the

risks of trans-isomers in hydrogenated

products will encourage the greater

incorporation of palm products in

vegetable ghee”


Moves to adopt the WHO recommendation117th Oil Seeds & Their Allied Products Technical Committee, Pakistan Standards & Quality Control

Authority (PSQCA) in Karachi, Pakistan on 10 April 2019.

• PSQCA decided to reduce the level of trans fatty acid from the previous, 10 percent to

be 5 percent and the melting point to be 39°C in Vegetable Ghee (up from 36 ± 2 °C in

PS:221)

• PSQCA also proposed to eliminate the trans-fat according to the mandate of World

Health Organization (WHO) in 2023

• It is recognized that TFA-free hard fats from palm oil may potentially replace TFA

containing hard fats achieved by partial hydrogenation.

Ref: https://www.palmoilmagazine.com/news/7389/palm-oil-trade-to-pakistan-is-open-after-vanaspati-ghee-has-license


TFA-free Vanaspati Ghee already available

in other markets

Promoted as:

• Trans fat-free

• Hydrogenation-free

• Cholesterol-free

• GMO Free

• Rich in natural antioxidants (tocopherols & tocotrienols)

Ref: *) http://www.simedarbyplantation.com/our-businesses/downstream/our-products/delico-100-vegetable-ghee


Refining, fat modification and

margarine/shortening technology

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Margarine and edible fats highly versatile

13/01/2020

Margarine and edible fats

• Table margarine

• Low fat margarine

• Industrial margarine

• Puff pastry margarine

• Anhydrous margarine

• Shortening and vanaspati ghee products

Applications

• Table consumption – spreads and cooking

• Industrial application – cakes and biscuits

• Industrial application – croissants

• Other food industrial applications

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Margarine and shortening

– raw materials from upstream processes

13/01/2020

Crush and

extract

Clarify and

water degum

Seed oil clarification

Water degumming

(lecithin drying)

Neutralization

Degumming (acid/enzymatic)

Dewaxing

Soapstock splitting

Degum/

neutralize/

dewax

Bleaching

(absorption)

to remove

impurities

Deodorization

(continuous or semi-

continuous) to remove

volatile components

and thermally

stabilize/bleach the oil

Bleach Deodorize

Modify by dry

fractionation,

interesterification or

hydrogenation to

produce liquid oils and

fats with specific cloud

point or melting

behaviours

Modify

Margarine and

shortening lines

Margarine and

shortening

Seed oil extraction

CPO mills


Margarine and shortening plant systems – an overview

• Producing an edible oil blend or stable

water-in-oil emulsion

• Margarine is typically with 80%

vegetable oil and 20% water with added

salt, flavourings, colours and

preservatives

• Shortening including vegetable ghee is

100% vegetable oil with oil soluble

additions such as flavourings,

emulsifiers, antioxidants, vitamins

• Manufacturing processes vary

according to the product formula and

ingredients used

Oil phase

Emulsifier Portable water Powder ingredients Brine solution

Water phase

Oil

Emulsion pre-mix tank Emulsion buffer tank

Re-melt unit

Pasteurization

Crystallization unit

Pin worker unit

Packing machine


Consistent product quality requires quality plantsComplete plants delivered with key components from Alfa Laval and RONO https://ro-no.com/en/

Oil phase and emulsifier preparation

Water preparation Emulsion preparation Pasteurization Crystallization

Contherm for

pre-cooling

before

crystallizationHygienic pumps

Equipment Agitators and mixers

Hygienic valves

Pasteurizers

Pin workers

Scraped surface

heat exchanger

Hygienic pumps

Heat exchangers

Hygienic fittings Hygienic valves with

control tops

https://ro-no.com/en/


RONO Maschinenbau GmbH – a company with

long history in margarine and shortening technology

• The manufacturing of the company Schröder placed in

Lübeck, Germany since 1958

• After the merge of Schröder Germany and Gerstenberg

Denmark in 2004 the plan was to outsource the workshop

• In 2005 the Schroeder workshop was sold to their

managers Carlos Romero and Stefan Nolte => RONO was

founded *)

• Since July 2014 in a new facility with 3200 m2 production

area and 700 m2 office space

• Based on proven technologies launched own improved

scraped surface HE in 2015 (80/120 bar)

• Since 2018 in partnership with Alfa Laval

*) About 100 SSHE & components were fabricated for Gerstenberg Schröder by RONO


Pilot plant for product development

• Complete and versatile continuous pilot plant,

designed for 50 to 100 bar working pressure

• The RONO and Alfa Laval specialist teams with

their partners available to support

• Due to the modular system all machines,

aggregates and control components can be

combined individually

• Adaptable to any customers demand for an

innovative product development facility.

- Useful for development of new TFA-free products


Examples of TFA-free Vanaspati formulations using

interesterification

Reference: „Palm Oil and Food Fats“, KG Berger,

Global Oils and Fats Magazine, p 55ff, Vol 5 (2008)

Reference: Pocket Book of Palm Oil Uses, MPOB, 7th Edition (2017)

https://www.palmoilmagazine.com/news/7389/palm-oil-trade-to-pakistan-is-open-after-vanaspati-ghee-has-license

https://www.palmoilmagazine.com/news/7389/palm-oil-trade-to-pakistan-is-open-after-vanaspati-ghee-has-license


All in all,


Advances in health and nutritional research guides the industry

The food industry responds with facility and product formulations upgrade

Changes are gradually and responsibly implemented to ensure healthy,

safe and affordable products

Alfa Laval and partners are committed to assist via development and

applications of technology and services

Let us work together to reach the 2023 WHO target based on all the good

work already done

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alfa laval powerpoint presentation...2020/01/04 · produced tfa from the global food supply by...

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