Margarine is an emulsion of water (14-35%) in oil (86-65%) with additional ingredients such as milk, salt and emulsifiers. The oil phase (along with all lypo-soluble ingredients) and the water phase (along with all water-soluble ingredients) must be prepared separately.
Oil Phase: Depending on what type of margarine is to be produced, the main ingredients should be one primary fat, one secondary fat, stearine and emulsifiers. All of them are pre-melted (if necessary) and mixed.
Water Phase: Water, powder milk, salt, other minor ingredients all mixed together.
Preparation of the emulsion:The two phases are then mixed together into an emulsion in Soren’s ASA-R dissolver.
Buffer Tank: Once the mixing process is over and the mix is ready, the product is pumped to a buffer tank, after which the process will swith from batch to continuous. The buffer tank keeps the product under gentle agitation.
Thermal process 1 – Pasteurization: The product is continuously pumped from the buffer tank to a Plate Heat Exchanger (PHE) which, through the passage of 90°C water, takes the product to pasteurization temperature.
Thermal process 2 – Crystallization: A high pressure pump feeds the pasteurized emulsion to one or more Soren’s XHD Crystallizator where the emulsion is crystallized and plasticized, then processed in a Soren’s W series pin worker for tub filling.
Recirculation and re-melting: A tubular heat exchanger continuously remelts any possible overfeed from the filling machine and returns it to the buffer tank. The re-melting system is designed to handle the entire production rate during shutdowns of the filling or packaging sections.