PMG Engineering | Build World-Class Food Factories | Technology

Fat hardening and hydrogenating plants

Fat hardening and hydrogenation plants are industrial facilities that are used to modify the chemical composition of fats and oils, primarily for use in food production. These processes involve the addition of hydrogen gas to unsaturated fatty acids, which results in the conversion of these acids into saturated fats.

Fat-hardening plants typically use a process called partial hydrogenation, which involves the addition of hydrogen gas to unsaturated fats at high temperatures and pressure. The resulting fats have a higher melting point, making them more solid and stable at room temperature. Partially hydrogenated fats are commonly used in the production of margarine, shortening, and other baked goods, as they help to improve texture and increase shelf life.

Hydrogenation plants, on the other hand, use a process called full hydrogenation, which involves the complete saturation of unsaturated fatty acids with hydrogen gas. The resulting fats are even more stable and have a higher smoke point, making them suitable for use in deep frying and other high-temperature cooking applications. Fully hydrogenated fats are commonly used in the production of snack foods, fried foods, and other processed foods.

Both fat hardening and hydrogenation plants involve complex chemical processes that require specialized equipment and expertise. However, there is growing concern about the health impacts of consuming partially hydrogenated and fully hydrogenated fats, as they have been linked to an increased risk of heart disease and other health problems. As a result, many food manufacturers are now using alternative fats and oils that are not subjected to these processes.

The raw materials for fat hardening and hydrogenation plants are typically edible oils, such as soybean oil, cottonseed oil, palm oil, or canola oil, which are sourced from agricultural producers. These oils are typically refined to remove impurities before they are used in the hydrogenation process. Additionally, a catalyst is required to facilitate the hydrogenation reaction, and this is typically a metal catalyst such as nickel.

In terms of packaging formats, the raw materials for these plants are typically transported in large tanker trucks or railcars and are stored in bulk tanks at the plant site. The finished products are typically packaged in a variety of formats, depending on the intended use. For example, partially hydrogenated fats may be packaged in large drums or totes for use in industrial applications, while fully hydrogenated fats may be packaged in smaller containers for retail sale to consumers.

Additionally, some products may be packaged in flexible packaging such as bags or pouches, while others may be packaged in rigid containers such as cans or jars. The packaging materials used for these products may include plastic, metal, or paper-based materials, depending on the specific product and packaging requirements.

Fat hardening and hydrogenation plants require a variety of specialized equipment to carry out the chemical processes involved in modifying the chemical composition of fats and oils. Some of the major equipment used in these plants include:

1. Reactors: These are vessels where the hydrogenation process takes place. They are typically made of stainless steel and are designed to withstand high temperatures and pressure.

2. Catalyst systems: These are used to initiate and control the hydrogenation reaction. Catalyst systems typically consist of metal catalysts, such as nickel, that are supported on a carrier material.

3. Heat exchangers: These are used to control the temperature of the reaction mixture and to recover heat from the process streams.

4. Distillation columns: These are used to separate the desired products from the reaction mixture. Distillation is often used to remove unreacted starting materials and to separate the different types of products that are formed during the hydrogenation process.

5. Filters: These are used to remove any solid impurities that may be present in the starting materials or reaction mixture.

6. Storage tanks: These are used to store the finished products before they are packaged and shipped.

7. Pumps and valves: These are used to transfer fluids and control the flow of materials throughout the plant.

The key manufacturers of Fat hardening and hydrogenizing plants are as follows:

1. Crown Iron Works Company

2. Desmet Ballestra

3. Alfa Laval

4. GEA Group

5. Bühler Group

6. KMEC Engineering

7. Nuberg Engineering