Basic product flow

Recipe suggestions

Configuration of machinery and equipment

Recipe Suggestions
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

Flexible Perfector Plant

Table Margarine Capacity 3000 kg/h
Perfector type (2+2) x 125

Pin Rotor Machine type 2 x 50 l

Table Margarine

HP-pump
Three-way valve

Resting tube type 200 l

Packing machine

Resting tube type 30 l Remelt

Flexible Perfector Plant

Table Margarine
Characteristic: Good flavour, relatively firm at refrigerator temperature, good frying properties. Recipe suggestion:

16.0 % 1.0 % 1.0 % 0.3 % 0.3 % 16.0 % 37.0 % 28.4 %

water salt skim-milk powder soya lecithin emulsifier hydrogenated vegetable oil, MP 41/42C hydrogenated vegetable oil, MP 35/36C liquid oil

Colour and flavour are normally added

Flexible Perfector Plant

Table Margarine
Typical margarine defects connected with the processing conditions Too hard at wrapping machine Recommended action

- Cool more intensively in the first cooling section of the Perfector - Use a pin rotor machine between the chilling tubes - Ensure proper water circulation in the jacket of the pin rotor machine - Increase the rotation speed of the pin rotor machine - As discribed above - Increase the remelt temperature of the return product - Cool slightly less in the first cooling section of the Perfector

Brittle Grainy (small ricw-like grains)

Lumpy (lumps of different sizes)

- Ensure proper water circulation in the jacket of the pin rotor machine and the resting tube - Ensure proper water circulation inside the knife rotors
- Ensure proper agitation in the emulsion tank, without air incorporation - Reduce the rotation speed of the pin rotor machine - Dismount intermediate crystallizers - By-pass the pin rotor machine

Open structure

Greasy

Flexible Perfector Plant

Soft table margarine Capacity 3000 kg/h

Perfector type (2+2) x 125

Pin Rotor Machine type 2 x 50 l

Soft Table Margarine

HP-pump Three-way valve

Resting tube type 200 l Filling machine

Resting tube type 30 l

Flexible Perfector Plant

Soft Table Margarine
Characteristic: Spreadable at refrigerator temperature, good flavour release and good melt-down in the mouth. Recipe suggestion: 16.0 % water 1.0 % salt 1.0 % skim-milk powder 0.2 % soya lecithin 0.2 % emulsifier 16.3 % hydrogenated vegetable oil, MP 41/42C 16.3 % hydrogenated vegetable oil, MP 35/36C 49.0 % liquid oil Colour and flavour are normally added

Flexible Perfector Plant

Soft Table Margarine
Typical margarine defects connected with the processing conditions Too hard at wrapping machine Recommended action

- 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 (small ricw-like grains)

- Increase the remelt temperature of the return product - Cool slightly less intensively in the first cooling section of the Perfector

Oily / oil separation / too shiny surface

- Cool more intensively in the first cooling section of the Perfector - Reduce the rotation speed of the pin rotor machine
- Ensure proper water circulation in the jacket of the pin rotor machine and the resting tube - Ensure proper water circulation inside the knife rotors

Lumpy (lumps of different sizes)

Flexible Perfector Plant

Low Fat Spreads Capacity 1500 kg/h
Perfector type (2+2) x 125 Pin Rotor Machine type 2 x 50 l

Low Fat Spreads

HP-pump Three-way valve

Resting tube type 200 l

Remelt Filling machine

Resting tube type 30 l

Flexible Perfector Plant

Low Fat and Reduced Fat Spreads
Characteristic: Spreadable at refrigerator temperature, good flavour and good melt-down. Recipe suggestion: Reduced fat spreads, approximately 60% fat content, can be produced without any stabilizers. Depending on the temperature at which the spreads are supposed to be used, the fat blend can vary. Soft table margarine and table 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 be divided into two main groups: products containing milk proteins and products without milk proteins. Low fat spreads containing milk proteins are more difficult to produce since the emulsion is less stable. There are a variety of stabilizers and emulsifiers on the market which can b used for low fat spreads.

Fat blends suggestion: 25 parts hydrogenated vegetable oil 41/42C 75 parts liquid oil

Flexible Perfector Plant

Low Fat and Reduced Fat Spreads

Typical margarine defects connected with the processing 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 the Perfector, targeting product temperature of 18-20C when entering the pin rotor machine

Flexible Perfector Plant

Liquid Margarine
Perfector type (2+2) x 125

Pin Rotor Machine type 2 x 50 l

Liquid Margarine

HP-pump Three-way valve

Resting tube type 200 l Remelt Filling machine

Resting tube type 30 l

Flexible Perfector Plant

Liquid Margarine

Features: Spreadable at refrigerator temperature, good flavour release and good melt-down in the mouth. Recipe suggestion: 16.0 % water 1.0 % salt 1.0 % skim-milk powder 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 Colour and flavour are normally added

Flexible Perfector Plant

Liquid Margarine

Typical margarine defects connected with the processing conditions Separation in layers during storage

Recommended action

- Use more intensive agitation in the emulsion tank to obtain 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 before filling in bottles

Flexible Perfector Plant

Whipped Margarine Capacity 3000 kg/h
Perfector type (2+2) x 125

Pin Rotor Machine type 2 x 50 l

Whipped Margarine

HP-pump Three-way valve

Resting tube type 200 l

Homogenizing Arrangement

Remelt

Filling machine

N2

Resting tube type 30 l

Flexible Perfector Plant

Whipped Margarine
Features: Spreadable at refrigerator temperature, good flavour release and good melt-down in the mouth. 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 37.0 % hydrogenated vegetable oil, MP 35/36C 28.4 % liquid vegetable oil Colour and flavour are normally added

Flexible Perfector Plant

Whipped Margarine

Typical margarine defects connected with the processing conditions Streaks / stripes

Recommended action

- Ensure that the homogenizing arrangement is mounted as closely as possible to the filling station and that there are no pipe bends between the homogenizing arrangement and the filling station - Increase the homogenizing pressure

Flexible Perfector Plant

Cake & Cream Margarine Perfector Capacity 3000 kg/h type (2+2) x 125

Pin Rotor Machine type 2 x 50 l

Cake & Cream Margarine

HP-pump Three-way valve

Resting tube type 200 l Remelt

Packing machine

Resting tube type 30 l Remelt

Flexible Perfector Plant

Cake & Cream Margarine
Features: Good air incorporation, easy to mix in the dough, neutral in taste. Recipe suggestion: 16.0 % water 0-2 % salt 1.0 % skim-milk powder 1.0 % emulsifier 23.0 % coconut oil 15.5 % hydrogenated vegetable oil, MP 41/42C 23.0 % hydrogenated vegetable oil, MP 35/36C 20.5 % liquid vegetable oil Colouring agents and flavour are normally added

Flexible Perfector Plant

Cake & Cream Margarine
Typical margarine defects connected with the processing conditions Too hard at wrapping machine Recommended action

- Cool more intensively in the first cooling section of the Perfector - As discribed above - Cool more intensively in the second cooling section of the Perfector - Cool less intensively in the first cooling section of the Perfector - Increase the remelt temperature of the return product - Cool less intensively in the first cooling section of the Perfector - Ensure proper water circulation in the jacket of the pin rotor machine and the resting tube - Ensure proper water circulation inside the knife rotors - Ensure proper agitation in the emulsion tank, without air incorporation - Cool less intensively in the first cooling section of the Perfector - Cool more intensively in the second cooling section of the Perfector

Brittle Too soft at wrapping machine

Grainy (small ricw-like grains)

Lumpy (lumps of different sizes)

Open structure

Greasy

Flexible Perfector Plant

Puff pastry margarine Capacity 1500 kg /h
Perfector type (2+2) x 125 Pin Rotor Machine type 2 x 50 l

Puff Pastry HP-pump

Three-way valve Packing machine

Resting tube type 200 l Remelt

Resting tube type 30 l

Flexible Perfector Plant

Puff Pastry Margarine
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 32.0 % hydrogenated vegetable oil, MP 41/42C 28.0 % hydrogenated vegetable oil, MP 35/36C 20.4 % liquid vegetable oil

Colouring agents and flavour are normally added

Flexible Perfector Plant

Puff Pastry Margarine
Typical margarine defects connected with the processing conditions
Too hard at wrapping machine

Recommended action
- Cool less intensively in the second cooling section of the Perfector - Increase the rotation speed of the pin rotor machine - Cool more intensively in the second cooling section of the Perfector - 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 pin rotor machine - Ensure proper water regulation in the jacket of the pin rotor machine and the resting tube - Increase the total volume of intermediate crystallizers and pin rotor machine - Cool more intensively in the first cooling section of the Perfector -Reduce the total volume of intermediate crystallizers and pin rotor machine - Increase the throughput - Ensure proper water circulation in the jacket of the pin rotor machine and the resting tube

Too soft at wrapping machine

Becomes brittle after storage

The finished product is greasy

Lumpy (lumps of different sizes)

Flexible Perfector Plant

Shortening Capacity 4500 kg/h
Perfector type (2+2) x 125
Pin Rotor Machine type 2 x 50 l

Shortening

Gear wheel pump

Three-way valve

Resting tube type 200 l

Homogenizing Arrangement

Remelt

Filling machine

N2

Resting tube type 30 l

Flexible Perfector Plant

Shortenings
Features: Plastic and easy to mix in the dough, in the case of shortenings with nitrogen even white colour. Recipe suggestion:
0-6 % emulsifier 25.0 % tallow, MP 41/42C 25.0 % lard 35.0 % fish oil, MP 35/36C 15.0 % liquid oil 0-6 % emulsifier 30.0 % palm stearin 20.0 % RBD palm oil 35.0 % hydrogenated oil, MP 35/36C 15.0 % liquid oil

Flavour can be added.

Flexible Perfector Plant

Shortenings
Typical margarine defects connected with the processing conditions
Poor filling

Recommended action
- Increase the rotation speed of the pin rotor machine -Cool less intensively in the second cooling section of the Perfector - Cool more intensively in the first cooling section of the Perfector Ensure that the homogenizing arrangement is mounted as closely as possible to the filling station and that there are no pipe bends between the homogenizing arrangement and the filling station - Increase the homogenizing pressure - Increase the remelt temperature of the return product - Cool less intensively in the first cooling section of the Perfector - Cool more intensively in the first cooling section of the Perfector - Increase the rotation speed of the pin rotor machine - Increase the total volume of intermediate crystallizers and pin rotor machine - The product should be attempered at approx. 28C for some days before placing in cold store

Uneven colour / stripes

Grainy (small ricw-like grains)

The finished product is brittle

Flexible Perfector Plant

Bakery Compounds
Perfector type (2+2) x 125 Pin Rotor Machine type 2 x 50 l

Bakery Compounds

HP-pump Three-way valve

Resting tube type 200 l

Packing machine
Resting tube type 30 l Remelt

Remelt

Flexible Perfector Plant

Bakery Compounds / Bread Improver

Features: Plastic and easy to mix in the dough, in the case of shortenings with 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.

Flexible Perfector Plant

Bakery Compounds / Bread Improver
Typical margarine defects connected with the processing conditions Recommended action

Too hard at wrapping machine

- Cool more intensively in the first cooling section of the Perfector - Speed up the pin rotor machine - Ensure proper water circulation in the jacket of the pin rotor machine and the resting tube - As described above - Increase the total volume of intermediate cristallizers and pin rotor machines - Increase the remelt temperature of the return product - Cool less intensively in the first cooling section of the Perfector

Brittle

Grainy (small ricw-like grains)

Lumpy (lumps of different sizes)

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

Basic product flow

If you need further information please fill out the GS trouble shooting form you can find it at the www.gs-as.com
or send it for our technology department by mail Mail adresse technology@gs-as.com Thank you for your attention