Detailed Project Report (DPR) on Margarine Butter from Vegetable Oil

MARGARINE BUTTER FROM VEGETABLE OIL

[EIRI/EDPR/0835] J.C.: 9453

INTRODUCTION

Margarine is a complex system essentially containing on the one hand a mixture of triglycerides which are either crystallized or non-crystallized at ambient temperature, and aqueous ingredients on the other hand. Minor ingredients, e.g. emulsifiers, flavours, colouring matter, vitamins etc. are dissolved or dispersed in either the fatty or the aqueous phase. Depending on the content of crystallized triglycerides in the fatty phase, the margarine is either pourable or more or less shape-retaining at ambient temperature. Since in conventional margarines the aqueous ingredients are dispersed in the form of small droplets in the fatty ingredients, margarines are generally water-in-oil type emulsions. 

Upon melting, which takes place in the initial stage of the frying process, the margarine separates essentially into two layers, i.e. an oily and an aqueous layer. When the temperature is further increased, e.g above the boiling point of water, spattering may occur, since the water tends to escape from the bottom of the frying pan and entrainment of oily ingredients will thereby take place. 

The present method  provides margarines comprising proteins in the aqueous phase, the weight ratio of proteose-peptone proteins to proteinaceous material of an isoelectric point within the range of pH 4-6 being at least 0.5. 

In this Specification the term "proteinaceous material of an isoelectric point within the range of pH 4-6" includes non-proteose-peptone proteins of such an isoelectric point and organic nitrogen containing non-proteinaceous material, e.g. urea, peptides, etc. Consequently the percentage of "proteinaceous material of an isoelectric point within the range of pH 4-6" is N×6.38 minus percentage proteose-peptone, in which N is the percentage nitrogen determined by the Kjeldahl method. 

Proteose-peptone is defined as that proportion of the milk protein system not precipitated by heating at 95° C. to 100° C. for 20 minutes and subsequent acidification to pH 4.7, but precipitated by 12% (weight/volume [W:V]) trichloroacetic acid. The proteose-peptone proteins have been found to account for about 8-25% of the whey- and/or serum proteins and about 2-6% of the total proteins in milk. 

Conventional ingredients, e.g. phosphatides, phosphatide fractions and partial glycerides are preferably present as well. 

Particularly phosphatides are of importance, since they effect a synergistic action on the proteose-peptone proteins in respect of anti-spattering action. 

Suitably 0.05-1.0%, especially 0.1-0.6% phosphates are present. 

Both animal and vegetable phosphatides can be used, e.g. the phosphatides derived from egg-yolk, soyabeans, rapeseed, maize etc. 

Soyabean phosphatides are particularly preferred and both whole soyabean phosphatides (which may include up to about 30% of soyabean oil) and their fractionated or hydrolysed derivatives (e.g. those containing 15-35% of monoacylglycero phosphatides) can be used. 

Preferably the previously mentioned weight ratio of proteose-peptone to non-proteose-peptone proteins in the margarines of the present method  is from 0.8 to 1.2. Particularly dairy proteins and especially proteins derived from cow's milk, more particularly proteins derived from cheese whey are used in the margarines of the present method. 

Suitably the margarines of the present method  are of a proteose-peptone content of at least 0.005%, particularly at least 0.03% by weight of the margarine product. 

A suitable upper limit for the proteose-peptone content is 1.5% by weight of the margarine, preferably at most 1.0%. 

COST ESTIMATION

Plant Capacity            500 Ton/Year

Land & Building (6000 sq.mt.)    Rs. 53.40 Lac

Plant & Machinery                    Rs. 75.00 Lac

Working Capital for 2 Months    Rs. 1.96 Cr

Total Capital Investment          Rs. 3.34 Cr

Rate of Return                          32%

Break Even Point                      46%

CONTENTS

MARGARINE

EXAMPLES I-V

MARGARINES WERE PREPARED AS FOLLOWS:

THE PROTEINACEOUS MATERIALS THAT WERE INCORPORATED IN THE AQUEOUS PHASE WERE:

THE FRYING TESTS WERE PERFORMED AS FOLLOWS:

THE EQUIPMENT USED FOR THE SPATTERING TEST CONSISTED OF:

PRIOR TO STARTING THE FRYING TESTS, THE APPARATUS WAS HEATED UP AS FOLLOWS:

THE MEASURED DEGREE OF SPATTERING AND THE VISUAL ASSESSMENT CORRELATE AS FOLLOWS:

EXAMPLES VI-XIII

EXAMPLE XIV

EXAMPLES XV-XVII

METHODS FOR AN ACCELERATED PROCESS OF MARGARINE

THE PRIOR INFORMATIONS

REPRESENTATIVE PRIOR-ART TEACHINGS ARE SET FORTH BELOW.

METHODS

THE ENTIRE PROCESS COMPRISES THREE IMPORTANT STAGES.

THE CATALYST

THE SAFFLOWER OIL USED IN THE EXAMPLES IS IDENTIFIED AS FOLLOWS:

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

EXAMPLE 5

EXAMPLE 6

EXAMPLE 7

EXAMPLE 8

EXAMPLE 9

EXAMPLE 10

EXAMPLE 11

EXAMPLE 12

EXAMPLE 13

EXAMPLE 14

EXAMPLE 15

EXAMPLE 16

EXAMPLE 17

EXAMPLE 18

EXAMPLE 19

EXAMPLE 20

EXAMPLE 21

MARGARINE FAT

EXAMPLE I

EXAMPLE III

EXAMPLE V

EXAMPLE VI

MARGARINES WERE PREPARED FROM THE FAT COMPOSITIONS OF EXAMPLES I-V AS FOLLOWS:

PROCESSING MARGARINE OR BUTTER FOR SQUEEZE PACKET CONTAINERS

METHODS

THE DRAWINGS

DESCRIPTIONS

MARGARINE PRODUCT

METHODS

THE DRAWINGS

DEFINITIONS

DESCRIPTIONS

(A) COMPOSITION OF EMULSIFIED SPREADS AND MARGARINES

1. OIL PHASE

A. STRUCTURAL FAT

B. SOFT OIL

C. OTHER OIL PHASE INGREDIENTS

2. AQUEOUS PHASE INGREDIENTS

(B) METHOD FOR MAKING EMULSIFIED SPREADS AND MARGARINES

(C) POST HARDENING

METHODS FOR MEASURING PROPERTIES OF OILS USED IN EMULSIFIED SPREADS AND MARGARINE PRODUCTS

(A) DIFFERENTIAL SCANNING CALORIMETRY

(B) SPREADABILITY

EXAMPLE I

EXAMPLE II

EXAMPLE II WAS MADE WITH THE FOLLOWING INGREDIENTS:

EXAMPLE III

IMPROVED MARGARINE COMPOSITIONS/CONTAINING SOLID SUCROSE POLYESTERS

DESCRIPTIONS

SOLID SUCROSE POLYESTER

EDIBLE OIL

EMULSIFIER

OTHER COMPONENTS

MANUFACTURE

EXAMPLE I

PREPARATION OF TETRABEHENYL TETRACAPRYLYL SUCROSE

PROCEDURE

EXAMPLE II

PREPARATION OF TETRABEHENYL TETRACAPRYLYL SUCROSE

PROCEDURE

STEP A--PREPARATION OF POTASSIUM BEHENATE

STEP B--PREPARATION OF SUCROSE OCTACAPRYLATE

STEP C--PREPARATION OF C 8 -C 22 SUCROSE POLYESTERS

EXAMPLE III

EXAMPLE IV

C. PROCEDURE

EXAMPLE V

BOTTOM OF FORM

LOW-FAT BUTTER OR MARGARINE SPREAD

DESCRIPTIONS

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

EXAMPLE 5

EXAMPLE 6

MARGARINE AND THE LIKE SPREAD WITH NATURAL BUTTER FLAVOUR

METHODS

DESCRIPTIONS

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

EXAMPLE 5

EXAMPLE 6

EXAMPLE 7

EXAMPLE 8

EXAMPLE 9

EXAMPLE 10

PROCESS FOR PRODUCING A BUTTER/MARGARINE BLEND PRODUCT

METHODS

THE DRAWINGS

MARGARINE INGREDIENTS

MARGARINE INGREDIENTS

MARGARINE NUTRITION FACTS

METHOD OF FORMING A BUTTER/MARGARINE BLEND

THE DRAWING

DESCRIPTIONS

PROPERTY ANALYSIS AND CHARACTERIZATION PROCEDURE

MOISTURE DETERMINATION

FAT ANALYSIS

SALT ANALYSIS

SOLIDS NON-FAT DETERMINATION

GENERAL COMMENTS ABOUT THE FAT, MOISTURE, SALT, AND SOLIDS NON-FAT DETERMINATIONS

PHOSPHOLIPIDS DETERMINATION

EXAMPLES

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

COMPARATIVE EXAMPLE NO. 1

INSTALLATION FOR CONTINUOUS PRODUCTION OF EDIBLE FATS, MOSTLY BUTTER AND MARGARINE

MARGARINE

MARGARINE MANUFACTURE

PREPARATION

HYDROGENATION

COMBINING THE INGREDIENTS

AGITATION

QUALITY CONTROL

MARGARINE PRODUCTION PROCESS

PRODUCTION OF MARGARINE AND LOW FAT SPREADS

THE PROCESS

THE PROBLEM

THE SOLUTION

THE ADVANTAGES

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)