Alfa Laval PowerPoint Presentation...2020/01/04 · produced TFA from the global food supply by...
Transcript of 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
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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
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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)
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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)
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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
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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
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− Effective dates starting 1st January 2021
MPOB licensing conditions takes effect
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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)
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Opportunities for TFA-free products
in Pakistan
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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
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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.
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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”
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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
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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
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Refining, fat modification and
margarine/shortening technology
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Margarine and edible fats highly versatile
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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
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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
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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
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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
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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
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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
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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)
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All in all,
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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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