Trends in Margarine and Shortening Products and Processing
Trends in Margarine and Shortening Products and Processing
Trends in Margarine and Shortening Products and Processing
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<strong>Trends</strong> <strong>in</strong> Margar<strong>in</strong>e <strong>and</strong> Shorten<strong>in</strong>g<br />
<strong>Products</strong> <strong>and</strong> Process<strong>in</strong>g<br />
by<br />
Jesper Hansen<br />
Gerstenberg Schröder, Denmark
Outl<strong>in</strong>e of Presentation<br />
• Focus on low trans fatty acid products<br />
• Trans fatty acid issue<br />
• Reformulation for low trans products<br />
• Process<strong>in</strong>g technology for low trans products<br />
• Other market trends
Trans Fatty Acids Issue<br />
Ma<strong>in</strong> reasons for change away from us<strong>in</strong>g partial hydrogenation<br />
• Inexpensive hard stock of trans free palm oil fractions<br />
• Health f<strong>in</strong>d<strong>in</strong>g that trans FA are implicated <strong>in</strong> development of<br />
coronary disease<br />
Trans FA <strong>in</strong><br />
Partially Hydrog. Oil (
Trans Fatty Acids Issue<br />
Global trend towards a reduction of trans<br />
fats<br />
Market drives<br />
• Large food suppliers have moved towards<br />
low trans products<br />
• January 2006 – FDA fat labell<strong>in</strong>g<br />
• January 2004 – Danish legislation
Trans Free <strong>Products</strong><br />
Reformulation: Match<strong>in</strong>g fat properties<br />
• Melt<strong>in</strong>g profile<br />
• Crystallization behavior<br />
Fractionation Interesterification<br />
Optimal<br />
Physical <strong>and</strong> Chemical<br />
Properties<br />
Full Hydrogenation
Interesterification<br />
• Alter melt<strong>in</strong>g property<br />
SFC [%]<br />
40<br />
20<br />
0<br />
Alternative Methods<br />
• Can alter the crystallization habit of fat blends<br />
Palm stear<strong>in</strong> : Coconut : Rape seed oil<br />
Oil Blend<br />
Enzymatic IE<br />
Chemical IE<br />
10 20 30 40<br />
Ref: Novozymes A/S,<br />
Denmark<br />
Temperature [°C]
Functionality of fats:<br />
• Loose structure<br />
• S<strong>and</strong><strong>in</strong>ess<br />
• Oil<strong>in</strong>g off<br />
Crystallization Habit<br />
• SFC profiles do not tell the whole story<br />
_ crystals _’ crystals<br />
Source: Danisco A/S, Denmark<br />
• Smooth texture<br />
• Plasticity<br />
• High crystal surface
Alternative Methods<br />
Palm oil<br />
• Alternative source of hard stock for trans free products<br />
• Raw material available at low price<br />
• Fractionated <strong>in</strong>termediates:<br />
– Palm ole<strong>in</strong><br />
– RBD palm<br />
– Palm stear<strong>in</strong><br />
– Hydrogenated products<br />
Crystallization properties<br />
• Good performance: tends to crystallize <strong>in</strong> the β’ crystal form<br />
• Slower crystallization rate than trans fats<br />
• Tendency to post harden<strong>in</strong>g: formation of large crystal<br />
compounds<br />
• Implicate adjustment of process<strong>in</strong>g conditions
Process<strong>in</strong>g Trans Free <strong>Products</strong><br />
Set special dem<strong>and</strong>s for optimal product properties<br />
Fat Properties<br />
Melt<strong>in</strong>g Profile (SFC)<br />
Crystallization habit<br />
Crystallization rate<br />
Process<br />
Conditions<br />
Plant Layout<br />
Capacity <strong>and</strong><br />
retention time<br />
Chill<strong>in</strong>g Intensity<br />
Knead<strong>in</strong>g Intensity<br />
Temper<strong>in</strong>g<br />
Free Trans Product<br />
Firmness<br />
Spreadability<br />
Texture<br />
No Oil<strong>in</strong>g out<br />
No gra<strong>in</strong>y texture
Flexible Perfector Plant<br />
• Configuration of mach<strong>in</strong>ery <strong>and</strong> process<strong>in</strong>g equipment<br />
• Dimension<strong>in</strong>g of the plant
Process<strong>in</strong>g trans Free <strong>Products</strong><br />
• Generally no problems with filled products<br />
• For packed products: tendency to overwork<br />
easily <strong>and</strong> less p<strong>in</strong> volume is normally required<br />
for<br />
• Lower capacity <strong>and</strong> pack<strong>in</strong>g temperature<br />
• Need longer temper<strong>in</strong>g time at different<br />
temperature<br />
• Often different plant configuration<br />
• Pilot plant trials are required to optimize<br />
process<strong>in</strong>g of specific reformulations of fat
Market trends:<br />
Other Market <strong>Trends</strong><br />
• Low fat products (<strong>in</strong>clud<strong>in</strong>g butter)<br />
• Functional foods<br />
• Pumpable shorten<strong>in</strong>g process<br />
• Butter blends
Low Fat <strong>Products</strong><br />
• Less than 40% fat (veg. oil or butter)<br />
• Very low fat products - 20% fat<br />
• Special Dem<strong>and</strong>s<br />
Ingredients Process Features Low Fat Product<br />
Emulsifiers<br />
Stabilizers<br />
Fat blend<br />
Preparation unit<br />
In l<strong>in</strong>e pasteurizer<br />
Chill<strong>in</strong>g Intensity<br />
Knead<strong>in</strong>g Intensity<br />
Remelt system<br />
Phase Inverter<br />
Viscosity<br />
Food safety<br />
Firmness<br />
Texture<br />
Spreadability<br />
Water droplet size<br />
No free water
Functional Foods<br />
• Foods conta<strong>in</strong><strong>in</strong>g <strong>in</strong>gredients that provide health<br />
benefits<br />
• Increase dietary <strong>in</strong>take of functional <strong>in</strong>gredients<br />
by fortification of common foods<br />
• Margar<strong>in</strong>e fortified with essential oils has been<br />
on the market <strong>in</strong> Europe <strong>in</strong> the past decade<br />
• Cholesterol lower<strong>in</strong>g spreads with sterol<br />
• Margar<strong>in</strong>e fortified with calcium <strong>and</strong> vitam<strong>in</strong>s
Pumpable Shorten<strong>in</strong>g<br />
• Larger bakeries go toward pumpable shorten<strong>in</strong>g as<br />
alternative for traditionally used bag-<strong>in</strong>-box plastic<br />
shorten<strong>in</strong>gs<br />
• Delivered or on-site production of pumpable shorten<strong>in</strong>g<br />
• Advantages:<br />
– compliance with recycl<strong>in</strong>g regulations<br />
– improved hygiene st<strong>and</strong>ards<br />
– more flexibility for oil selection<br />
– capable for reformulations: e.g. low trans<br />
shorten<strong>in</strong>gs<br />
– reduce costs: work force, raw materials, h<strong>and</strong>l<strong>in</strong>g<br />
– easy to <strong>in</strong>corporate <strong>in</strong>to product mix
Pumpable Shorten<strong>in</strong>g<br />
• Important function is to <strong>in</strong>terrupt the gluten<br />
network <strong>and</strong> <strong>in</strong>corporate air dur<strong>in</strong>g mix<strong>in</strong>g<br />
• Process l<strong>in</strong>e:<br />
– Preparation: Oil blend + Emulsifier<br />
– Crystallization: Perfector plant + Matur<strong>in</strong>g<br />
tanks
Butter Blends<br />
• Spreadable butter<br />
• On the market s<strong>in</strong>ce early 1980’s<br />
• Consists of: Butter + liquid oil<br />
• Additional <strong>in</strong>corporation:<br />
– Water phase<br />
– Oil <strong>and</strong> butter fractions<br />
– Hydrogenated oils<br />
– Other <strong>in</strong>gredients<br />
• Margar<strong>in</strong>e or butter blend process
Butter Blend Process<br />
• Phase dos<strong>in</strong>g: Butter + Crystallized oil phase + Water phase<br />
Fill<strong>in</strong>g
Blend<strong>in</strong>g Process for Low Fat<br />
• Full fat _ low fat products<br />
• Same water droplet size distribution<br />
• Same stability<br />
• New possibilities for <strong>in</strong>corporation of<br />
<strong>in</strong>gredients
Gerstenberg Schröder<br />
We offer technological-commercialtechnical<br />
<strong>in</strong>teraction<br />
• www.gerstenbergschroeder.com
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