09 Flexible Perfector Plant 10-05-06

8/3/2019 09 Flexible Perfector Plant 10-05-06

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Basic product flowRecipe suggestions

Configuration of machinery andequipment


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Conventional tabel margarine

Soft Margarine

Low fat and reduced fat spread

Liquid frying margarine

Whipped margarine

Cake and cream margarine

Puff pastry margarine

Shortening

Bakery improver

Recepies based on palm oil

Recipe Suggestions


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Table Margarine

Remelt

Packing machine

Table Margarine

Capacity 3000 kg/h Perfectortype (2+2) x 125 Pin Rotor Machinetype 2 x 50 l

Three-way valve

Resting tubetype 200 l


HP-pump

Flexible Perfector Plant


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Characteristic: Good flavour, relatively firm at refrigerator temperature, goodfrying properties.

Recipe suggestion:

16.0 % water

1.0 % salt

1.0 % skim-milk powder

0.3 % soya lecithin

0.3 % emulsifier

16.0 % hydrogenated vegetable oil, MP 41/42C


28.4 % liquid oil

Colour and flavour are normally added

Table Margarine



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Typical margarine defects connected with the processing

conditions

Recommended action

Too hard at wrapping machine - Cool more intensively in the first cooling section of thePerfector

- Use a pin rotor machine between the chilling tubes

- Ensure proper water circulation in the jacket of the pin rotormachine

- Increase the rotation speed of the pin rotor machine

Brittle - As discribed above

Grainy

(small ricw-like grains)

- Increase the remelt temperature of the return product

- Cool slightly less in the first cooling section of the Perfector

Lumpy

(lumps of different sizes)

- Ensure proper water circulation in the jacket of the pin rotormachine and the resting tube

- Ensure proper water circulation inside the knife rotors

Open structure - Ensure proper agitation in the emulsion tank, without airincorporation

Greasy - Reduce the rotation speed of the pin rotor machine

- Dismount intermediate crystallizers

- By-pass the pin rotor machine

Table Margarine



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Soft Table Margarine

Filling machine

Soft table margarine

Capacity 3000 kg/hPerfectortype (2+2) x 125 Pin Rotor Machinetype 2 x 50 l

Three-way valve



HP-pump



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conditions

Recommended action

Too hard at wrapping machine - Speed up the pin rotor machine

-Cool more intensively in the first cooling section of the Perfector

- Cool less intensively in the last coolin section of the Perfector

Grainy



- Cool slightly less intensively in the first cooling section of thePerfector

Oily / oil separation / too shiny surface - Cool more intensively in the first cooling section of thePerfector

- Reduce the rotation speed of the pin rotor machine

Lumpy


- Ensure proper water circulation in the jacket of the pin rotor

machine and the resting tube- Ensure proper water circulation inside the knife rotors

Soft Table Margarine



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Remelt

Perfector

type (2+2) x 125 Pin Rotor Machinetype 2 x 50 l

Three-way valve



Filling machine

Low Fat Spreads

Capacity 1500 kg/h

Low Fat Spreads

HP-pump



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Characteristic: Spreadable at refrigerator temperature, good flavour andgood melt-down.

Recipe suggestion:

Reduced fat spreads, approximately 60% fat content, can be producedwithout any stabilizers. Depending on the temperature at which the spreadsare supposed to be used, the fat blend can vary. Soft table margarine andtable margarine fat compositions can be used as formulations for reduced fat

spreads at application temperatures of 5 - 10C and 20 - 25C respectively.

In general, low fat spreads contains approximately 40% fat and can bedivided into two main groups: products containing milk proteins andproducts without milk proteins. Low fat spreads containing milk proteins aremore difficult to produce since the emulsion is less stable. There are a varietyof stabilizers and emulsifiers on the market which can b used for low fatspreads.

Fat blends suggestion:

25 parts hydrogenated vegetable oil 41/42C

75 parts liquid oil

Low Fat and Reduced Fat Spreads



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Low Fat and Reduced Fat Spreads

Typical margarine defects connected with theprocessing conditions

Recommended action

Loose emulsion in the finished product/free water - Cool less in the last cooling section of the Perfector

- Pin rotor machine should be placed between the

chilling tubes, if applied- Cool moderately in the first cooling section of thePerfector, targeting product temperature of 18-20C whenentering the pin rotor machine



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Remelt

Perfectortype (2+2) x 125 Pin Rotor Machinetype 2 x 50 l

Three-way valve



Filling machine

Liquid Margarine

Liquid Margarine

HP-pump



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Liquid Margarine

Features: Spreadable at refrigerator temperature, good flavour release and goodmelt-down in the mouth.

Recipe suggestion:

16.0 % water

1.0 % salt


0.2 % soya lecithin 0.2 % emulsifier

Fat blends:

3.0 % fully hydrogenated vegetabl oil

78.6 % liquid oil

or

1.5 % oiling out preventer, e. g. Grindsted PS 209 (Danisco Ingredients 81.1 % liquid oil




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Liquid Margarine


Recommended action

Separation in layers during storage - Use more intensive agitation in the emulsion tank toobtain a better water distribution

- Increase the cooling in the Perfector

- Intensify rotation in the pin rotor machine

- Use longer maturation time in the ripening tank beforefilling in bottles



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Whipped Margarine

Capacity 3000 kg/h

Remelt


Three-way valve



Whipped Margarine

HP-pump

Filling machine

HomogenizingArrangement

N2



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Features: Spreadable at refrigerator temperature, good flavour release and goodmelt-down in the mouth.

Recipe suggestion:

16.0 % water

1.0 % salt


0.3 % soya lecithin

0.3 % emulsifier



28.4 % liquid vegetable oil


Whipped Margarine



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Whipped Margarine


Recommended action

Streaks / stripes - Ensure that the homogenizing arrangement is mountedas closely as possible to the filling station and that thereare no pipe bends between the homogenizingarrangement and the filling station

- Increase the homogenizing pressure



18/30Remelt

Packing machine


Three-way valve



Cake & Cream Margarine

Capacity 3000 kg/h

HP-pump


Remelt



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Features: Good air incorporation, easy to mix in the dough, neutral in taste.

Recipe suggestion:

16.0 % water

0-2 % salt


1.0 % emulsifier 23.0 % coconut oil




Colouring agents and flavour are normally added




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conditions

Recommended action


Brittle - As discribed above

Too soft at wrapping machine - Cool more intensively in the second cooling section of thePerfector

- Cool less intensively in the first cooling section of thePerfector

Grainy




Lumpy


- Ensure proper water circulation in the jacket of the pin rotormachine and the resting tube

- Ensure proper water circulation inside the knife rotors

Open structure - Ensure proper agitation in the emulsion tank, without airincorporation

Greasy - Cool less intensively in the first cooling section of the Perfector

- Cool more intensively in the second cooling section of thePerfector



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Puff Pastry

Remelt

Packing machine

Puff pastry margarine

Capacity 1500 kg /h Perfectortype (2+2) x 125 Pin Rotor Machinetype 2 x 50 l

Three-way valve



HP-pump



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Features: Very good plasticity without being oily, good flavour.

Recipe suggestion:

16.0 % water

1.0 % salt

1.0 % sugar

pH ~3.0

0.6% soya lecithin

1.0 % emulsifier




Colouring agents and flavour are normally added

Puff Pastry Margarine



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Puff Pastry Margarine


conditions

Recommended action

Too hard at wrapping machine - Cool less intensively in the second cooling section of thePerfector


Too soft at wrapping machine - Cool more intensively in the second cooling section of thePerfector

- Reduce the rotation speed of the pin rotor machine

- Cool less intensively in the first cooling section of the

Perfector- Reduce the total volume of intermediate crystallizers and pinrotor machine

Becomes brittle after storage - Ensure proper water regulation in the jacket of the pin rotormachine and the resting tube

- Increase the total volume of intermediate crystallizers and pinrotor machine

- Cool more intensively in the first cooling section of thePerfector

The finished product is greasy -Reduce the total volume of intermediate crystallizers and pinrotor machine- Increase the throughput

Lumpy (lumps of different sizes) - Ensure proper water circulation in the jacket of the pin rotormachine and the resting tube



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Shortening

Perfector

type (2+2) x 125 Pin Rotor Machine

type 2 x 50 l

Three-way valve

Filling machine



Shortening

Capacity 4500 kg/h

Gear wheelpump

Remelt

HomogenizingArrangement

N2



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Features: Plastic and easy to mix in the dough, in the case of shorteningswith nitrogen even white colour.

Recipe suggestion:

0-6 % emulsifier 0-6 % emulsifier

25.0 % tallow, MP 41/42C 30.0 % palm stearin

25.0 % lard 20.0 % RBD palm oil

35.0 % fish oil, MP 35/36C 35.0 % hydrogenated oil, MP 35/36C

15.0 % liquid oil 15.0 % liquid oil

Flavour can be added.

Shortenings



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Shortenings



Grainy (small ricw-like grains)



- Increase the total volume of intermediate crystallizers and pinrotor machine

- The product should be attempered at approx. 28C for somedays before placing in cold store

The finished product is brittle

Ensure that the homogenizing arrangement is mounted asclosely as possible to the filling station and that there are nopipe bends between the homogenizing arrangement and thefilling station

- Increase the homogenizing pressure

Uneven colour / stripes


-Cool less intensively in the second cooling section of thePerfector


Poor filling

Recommended actionTypical margarine defects connected with theprocessing conditions



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Remelt

Packing machine

Perfector

type (2+2) x 125Pin Rotor Machine

type 2 x 50 l

Three-way valve


Resting tube

type 30 l

Bakery Compounds

HP-pump

Bakery Compounds

Remelt



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Features: Plastic and easy to mix in the dough, in the case of shorteningswith nitrogen even white colour.

Recipe suggestion:

20-60 % water

0-10 % sucrose or glucose syrup

1- 2 % emulsifier

40-80 % fat, MP 30-35C

Flavour can be added.

Bakery Compounds / Bread Improver



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Bakery Compounds / Bread Improver


Recommended action


- Speed up the pin rotor machine

- Ensure proper water circulation in the jacket of the pin

rotor machine and the resting tube

Brittle - As described above

- Increase the total volume of intermediate cristallizersand pin rotor machines

Grainy (small ricw-like grains) - Increase the remelt temperature of the return product


Lumpy (lumps of different sizes) - Ensure proper water circulation in the jacket of the pinrotor machine and the resting tube



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If you need further information please fill out theGS trouble shooting form you can find it at the

www.gs-as.com

or send

it for our technology department by mail

Mail adresse

[email protected]

Thank you for your attention

Basic product flow
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Documents

09 Flexible Perfector Plant 10-05-06