Hydrogenation is the process to change the physical characteristics of natural fats and oils. Hydrogenation of vegetable oils/fatty acids involves the addition of hydrogen, in the presence of a Nickel catalyst, to the carbon-carbon double bonds present in the fatty acid chains. Salient features
- A high degree of Automization to control flow, temperature and pressure in the Autoclave ensures selective hydrogenation and excellent quality product.
- 100% reproducibility of the product is ensured.
- Almost zero steam consumption for heating. Steam is needed only once for the first charge of oil while starting the plant operation. This is achieved with the most efficient design of an oil-to-oil Heat Exchanger.
- Practically maintenance-free due to low-speed agitation system in Autoclave.
- Low power and catalyst consumption
Interesterification can be defined as a redistribution of the fatty acid molecular present in a triglyceride oil over its glycerol molecular. Interesterification has become the alternative fat modification technology to partial HYDROGENATION.
Interesterification is the process of re-arranging the fatty esters within and between tri-glycerides resulting in most cases a change in the physical properties of the oil/fats. Interesterification is the intra- and inter-molecular exchange of fatty acids on the glycerol backbone of triglycerides. In the chemical Interstification process commonly used catalysts are sodium methylate and ethylate followed by sodium methoxide.
In the enzymatic Interstification process, the enzyme commonly used is lipozyme TL1M.
The simple procedure of hydrogenation in the presence of a Nickel catalyst is carried out with such perfection that MECTECH has become one of the top Hydrogenation Process Machine manufacturers and a trendsetter organisation vis-a-vis turnkey projects for Vanaspati Ghee.
The simple procedure of hydrogenation in the presence of a Nickel Catalyst is carried out with such perfection that Mectech has become a trendsetter.
- A low iodine value i.e., up to 0.5 is achieved.
- Nickel catalyst consumption is minimized with high flow rate circulation in Reactor.
- Temperature Control is achieved with a high degree of automation.
Semi Continuous Hydrogenation
The unique design of the agitation system enables the hydrogenation cycle to be reduced to a minimum.
The high degree of automation to control Flow, temperature and pressure in the autoclave ensures selective hydrogenation and excellent quality product.
100% reproducibility of product ensured.
- Zero steam consumption. (Steam is required only once for the first charge of oil while starting the plant operation). This is achieved with the most efficient design of an oil-to-oil Heat Exchanger.
- Practically maintenance free – due to low-speed agitation system in Autoclave.
- Low power and catalyst consumption.
Loop Reactor for Hydrogenation of Oils / Fats
A candle filter with an auto-wash arrangement is used for the filtration of the catalyst.
Hydrogenation of Oil / Fats is one of the largest modification processes in the oil & Fats Industry. It consists of the direct addition of a Hydrogen atom at double bonds in the Fatty Acid chain. The degree of Hydrogenation is directly related to the Iodine number. Hydrogenation is a means of converting Liquid Fats to Plastic Fats or, in other words, reducing the Iodine value by reducing the double bonds in the fatty acid chain.
Benefits of Hydrogenation of Fats and Oils
Hydrogenation of fats and oils is a process that involves adding hydrogen to unsaturated fats and oils, resulting in the creation of saturated fats. This process has been widely used in the food industry to improve the stability, texture, and flavor of various products. Here are some of the benefits of those are:
- Improved shelf-life: Hydrogenation of fats and oils increases their stability, preventing them from going rancid and extending their shelf-life. This is particularly useful for products that have a long shelf-life, such as baked goods and snack foods.
- Texture and mouthfeel: Oils and fats hydrogenation can improve the texture and mouthfeel of food products. This is because the process results in the creation of solid fats that can provide a creamy or smooth texture to food products.
- Reduced oil separation: Hydrogenation of oils and fats can reduce oil separation in products such as peanut butter and chocolate. This helps to improve the appearance and texture of the products.
- Increased heat stability: Hydrogenation of vegetable oil and fats can increase their heat stability, making them suitable for frying and baking. This is because the process results in the creation of fats that are less likely to break down under high temperatures.
However, it is important to note that hydrogenated vegetable oil and hydrogenated fats are not always the healthiest option. They are high in trans fats, which have been linked to an increased risk of heart disease. Therefore, it is important to consume them in moderation and to choose products that are labeled as "partially hydrogenated" rather than "fully hydrogenated."
The Process of Hydrogenation of Edible Oils
The resulting hydrogenated fats and oils are more stable and solid at room temperature, which improves the texture, shelf-life, and flavor of various food products. Here are the basic steps involved in the hydrogenation process:
- Selection of raw materials: The hydrogenation process starts with the selection of suitable fats and oils, such as soybean oil, palm oil, or canola oil.
- Preparation of the oil: The oil is cleaned, filtered, and heated to a specific temperature to remove any impurities and make it more suitable for hydrogenation.
- Addition of hydrogen: Hydrogen gas is then added to the oil under pressure and in the presence of a catalyst, such as nickel or platinum. This causes the unsaturated bonds in the oil to break and hydrogen atoms to bond with the carbon atoms.
- Monitoring the process: The temperature, pressure, and hydrogen flow rate are monitored throughout the process to ensure optimal conditions for the desired level of saturation.
- Finishing the product: The hydrogenated oil is cooled and filtered to remove the catalyst and any remaining impurities. It can then be further processed and used as hydrogenated vegetable oil or fats in a variety of food products, such as baked goods, snack foods, and margarine.
It's important for consumers to be aware of the presence of hydrogenated oils in their food and to make informed choices.