EDIBLE OILS

FATS
REFINING
AND

BASIC TECHNICAL INFORMATION

GIANAZZA
nternational

INDEX
INDEX

EDIBLE OILS & FATS REFINING

ALKALI REFINING
COMBINED NEUTRALIZATION & DEWAXING
BLEACHING
DEODORIZING
PHYSICAL REFINING
WATER DEGUMMING & LECITHIN DRYING
DEWAXING BY FILTRATION
WINTERIZATION
DRY FRACTIONATION
HYDROGENATION
CHILLING & PLASTIFYING
SOAPSTOCKS ACIDULATION

EDIBLE OILS & FATS REFINING

PROCESS

1. EDIBLE OILS & FATS REFINING

EDIBLE

OILS
AND

FATS
REFINING

The most frequent and important application of

oily seeds and natural fats is by far in the field of
edible products.Gianazza International has been
active in the manufacture of edible oil refining
plants for over one century and now it is
engaged in the development of advanced
technologies and optimization of the ones
already available, in terms of energy saving,
pollution control and process automation.This
booklet is aimed at giving information about the
solutions that can be proposed according to the
process block diagram on the previous page
(from single plants to complete oil mills on turnkey basis).
Two refining methods are available basically:
- ALKALI REFINING (or classic chemical refining)
- PHYSICAL REFINING

In comparing the two refining systems, the

following facts should be considered:
REFINING METHOD

CHEMICAL

PHYSICAL

Applicability

Almost no limit

Not recommended for

some oils and fats

Final quality
and keepability

Good to excellent

Some reserves on keepability

Oil yield

Standard

Higher

Degumming requirements

--

Bleaching agent
requirements

Standard

Higher

By-products

Diluted soapstocks

Fatty acids and deodorizing distillates

Effluents waters
(quantity/quality)

Higher quantity/
Heavy pollution

Lower quantity/Minor pollution

Very critical

In modern oil mills, where different types of oils

and fats are processed, the best solution is often
represented by an universal refining system
suitable to perform, to the Customer's option,
both chemical and physical refining process
(the investment for an universal plant is only
slightly higher than the cost of a standard
chemical or physical refining line).

1 - Multipurpose refining plant - (Turkey)

Capacity: 300 t/d
2 - Continuous deodorizing plant

2. ALKALI REFINING
This refining process can treat almost any kind of edible oils and fats but it involves the production of soapstocks and has a refined oil yield lower than the one physically obtainable even if of
more stable quality in the time. The standard steps in this refining process are:
- NEUTRALIZATION
- COMBINED NEUTRALIZATION AND DEWAXING (for sunflowerseed, corn and a few other oils)
- BLEACHING
- DEODORIZING
NEUTRALIZATION
In case of small capacities, batch or semi continuous plants (based on repeated runs) are
proposed. Starting from 50 ton/d, fully continuous plants are recommended using centrifugal
separators. The ideal continuous process foresees the use of three centrifuges (one neutralization stage plus two washing stages), but modern plants normally use two separators only, with
the following process steps:
1. ACID CONDITIONING
2. REFINING (treatment with caustic lye and soapstocks removal)
3. WASHING (with water)
4. DRYING (under vacuum)
The acid conditioning is normally using food grade phosphoric acid for removing phosphatides
that will be mixed with soapstocks and discharged.
In case phosphatides have to be recovered, a preliminary water degumming is necessary.
Metering pumps with double head or flowrate controllers enable to dose the lye and the
process water at the wanted rate and concentration.
YIELD & PRODUCT QUALITY
The neutralization yield depends on the quantity of non-oil matter (FFA etc.), generally called
Wesson loss (W) or Theoretical loss (TL) according to the following formulas:
L = 0,3+ 1,25 TL
L = 1,35 TL
where:

for TL
for TL

L = Refining loss
TL
TL = (FFA + phosphatides +
Typical quality parameters that
can be obtained are:
100 ppm after one washing
50 ppm after two washings
Line of centrifugal separators
for neutralizing/degumming plant

ALKALI

REFINING

3. COMBINED NEUTRALIZATION & DEWAXING

COMBINED

NEUTRAL

IZATION

AND

DEWAXING

Some vegetable oils, mainly sunflowerseed oil and corn oil, contain waxes that give the oil an
unpleasant cloudiness when cooled down to temperatures available in domestic refrigerators.
In order to avoid this problem, it is necessary to submit the oils to a DEWAXING treatment.
The WET DEWAXING, carried out in fully continuous operation by using centrifugal separators
and combined with the neutralization step, can be made in two different ways:
- COLD REFINING
- WET DEWAXING
COLD REFINING
Generally used for good quality
sunflowerseed oils with low acidity,
it involves the following steps by
using two centrifugal separators
only:
- ACID CONDITIONING
- COOLING & CRYSTALLIZING
- COLD REFINING & DEWAXING
- HOT WASHING
- VACUUM DRYING (optional)
In this process the soapstocks and
the waxes are mixed and removed
at the same time.

2
1 - Line of centrifugal separators for neutralizing plant
2 - Neutralizing plant (schematic drawing)

3.1 COMBINED NEUTRALIZATION & DEWAXING

WET DEWAXING
Generally used for poor quality sunflowerseed and corn oils, it involves the following steps by
using three centrifugal separators:
- ACID CONDITIONING
- HOT REFINING (soapstocks removal)
- COOLING & CRYSTALLIZING
- DEWAXING (WAX REMOVAL)
- HOT WASHING
- VACUUM DRYING
In this process the soapstocks and the waxes are separately removed by means of two
centrifugal separators.
In both systems (cold refining and wet dewaxing) the oil is cooled at 7 8C and then sent to
crystallizers where it remains from 8 to 12 hours.
In order to reduce the oil viscosity without dissolving the formed crystals, a light increase of the
oil temperature up to 15C is carried out before sending it to the dewaxing separator.
A typical flowdiagram of the dewaxing stage is shown below: by coupling the same with the
flowdiagram of the refining plant on the previous page, a typical combined hot refining and
wet dewaxing plant is obtained as final result.
YIELD & PRODUCT QUALITY
Different formulas have been proposed to express the loss of oil in combined refining &
dewaxing processes.
In COLD REFINING the acid oil obtained from soapstocks generally has an acidity in the range
of 3050% FFA or lower.
In case of crude oil with acidity higher than 11,5%, the process of WET DEWAXING (combined
with hot refining) is preferred since it reduces the total losses of neutral oil.
As to cold stability, both systems are unable to remove the waxes entirely; the cold test is,
therefore, generally 24 h at 5C (or 5,5 h at 0C).
Whenever a more stringent cold test is requested, the process should be completed by a
FINAL POLISHING DEWAXING to be carried out on the refined oil by filtration of cold oil with filteraid or on paper.

Wet Dewaxing plant (schematic drawing)

COMBINED

NEUTRAL

IZATION

AND

DEWAXING

4. BLEACHING
BLEACHING

Bleaching basically consists

of impurities and colouring
matter adsorption by means of
bleaching agents: this operation
is carried out under vacuum.
Bleaching earths (acid activated
or not) of different grades and
types are typically used as
adsorbing agents.
Although the purpose of bleaching is to improve the colour of
the oil, it is actually a refining step that removes many impurities, mainly soaps remained in the
oil after alkali refining and phosphatides.
Fully continuous plants are available for capacities of 25 t/d upwards: the operation is rigorously
continuous in the bleaching step proper, while filtration is semi-continuous in the sense that there
is one filter in operation while the second one is being regenerated (sometimes one filter only is
used, stopping the plant during the regeneration phase of the filter).
The filters are generally of vertical shape, equipped with stainless steel pressure leaves and
discharged automatically by a vibrator (the whole operation can be automated, of course).
The flowdiagram of a typical continuous bleaching plant is shown here below.

YIELD & PRODUCT QUALITY

The bleached oil is practically free from solid
impurities, moisture and soaps; phosphatides
and heavy metals will be drastically
reduced.Concerning yield, the loss of oil
in the spent cake depends on care and
modality of cake blowing: it can be as low as
2025% or less, according to the type of oil
(solid fats or hydrogenated oils may have a
higher loss).
The spent earths can be deoiled up to an oil
residual of 5% approx. by means of a particular system using solvent.

3
1 - Bleaching plant with vertical pressure leaves filters
2 - Bleaching plant with vertical filters fully made of stainless steel
3 - Bleaching plant (schematic drawing)

5. DEODORIZING
Besides batch deodorizers for small capacities, GIANAZZA International supplies fully continuous
deodorizers (of superposed trays type), in a wide range of capacities, from 20 to 1000 t/d.
Alternative technologies (packed column) are available for special cases.
The standard plant is called DOVERT CS; DOVERT CSV represents an alternative and more
sophisticated model, while the model DOVERT TR is semi-continuous, fully automatic
operating, particularly appreciated by the margarine producers.
The following features are common to all types of deodorizers:
particular care to the fine distribution and dispersion of the stripping steam into microbubbles
so that the deodorization efficiency is very high;
the oil is flowing through an obliged path (except in semi-continuous models) in order to
avoid preferential ways;
the oil layer is limited, with a great surface of the oil being exposed to maximum vacuum;
the deodorization temperature is kept to the lowest range so that the formation of transisomers is minimized and any other form of oil degradation is avoided;
the oil heating to the final treatment temperature (as well as cooling of the deodorized oil in
CSV and TR models) is carried out under vacuum and in presence of stripping steam to
avoid any overheating;
low consumptions, thanks to high heat recovery (70-75% in continuous plants);
the vertical cylindrical design grants minimum installation space requirement and low cost of
the building (the column is ground leaned);
the column is easy to install, inspect and clean.

DOVERT CS continuous deodorizing plant (schematic drawing)

DEODO

RIZING

5.1 DEODORIZING
DEODORIZING

AVAILABLE SOLUTIONS
The above-mentioned DOVERT CS plant is the standard and cheapest version but different
solutions are available.
We wish to point out the following two:
DOVERT CSV
It is similar to the standard one with the same performances and consumptions; the difference
is that pre-cooling of deodorized oil (up to 160C approx.) by heat exchange with the oil to be
deodorized is realized under vacuum and in presence of live steam inside the deodorizing
column.
DOVERT TR
The basic principle of semi-continuous deodorizing is that the oil is processed per batches under
automatically controlled operating conditions. Batches of different quality can be processed
successively with negligible contamination and no loss of production. Actually, this plant is ideal
whenever frequent quality changeovers are required (for example in the margarine industry);
for this reason the heat recovery is not so high because counter-current heat exchange is not
possible.
The typical semi-continuous plant involves
seven superposed stages respectively
destined to:

PRODUCT QUALITY & CONSUMPTIONS

The quality of deodorized oil, from any type
of DOVERT plant, is normally complying
with the best international standards.
Moisture and impurities are absent; PV is
generally zero when tested immediately after
sampling; the residual acidity is in the range
The energetic consumptions are:
heat recovery are requested;
for vacuum production the consumptions
mainly depend on: the quantity of injected
steam pressure and the cooling water
temperature.

Dovert CS continuous deodorizing plant

6. PHYSICAL REFINING
Physical refining basically consists in the removal of fatty acids by steam distillation under
vacuum, which involves the following advantages:
- higher yield of refined product;
- no soapstocks formation;
- lower quantity of polluted effluents;
- lower refining costs.
Nevertheless, it must be emphasized that not all types of oil can be satisfactorily refined by
physical system.
Generally speaking, physical refining is successful with some specific oils, typically PALM OIL,
OLIVE OIL and LAURIC OILS while, on other oils, it can be successful only provided that a very
effective pre-treatment is carried out, capable of drastically removing the phosphorus and
heavy metals.
In most cases a versatile combined alkali/physical refining plant may be the best solution.
Physical refining normally involves the following steps:

It is the most critical stage of the whole process.

By using two centrifugal separators it is generally possible to reduce the phosphorous content
down to 30 ppm or less.
The target for a successful physical refining (5 ppm phosphorus) is reached by the further treatment.
This is a modified bleaching, in which a preliminary oil treatment with a food grade acid is
carried out before the bleaching agent addition (the plant must be entirely made of stainless
steel).
From the point of view of construction and dimensions, a stripper/deodorizer is practically the
same as a simple deodorizer. Differences concern mainly the operating conditions namely:
absolute pressure, temperature and quantity of stripping steam.
The plant, called PHYSITRON, in case of physical refining is very similar to the deodorizing
DOVERT plant described in the alkali refining section.
Also for the PHYSITRON plant three models are available:
for fully continuous operation with superposed trays;
equipped with structured packing stripping COLUMN;
fully automatic semi-continuous stripper/deodorizer.

PHYSICAL

REFINING

6.1 PHYSICAL REFINING

PHYSICAL

REFINING

PHYSITRON CSF
This plant uses, combined with a column with traditional trays (CROSSFLOW system), a special
structured packing column, operating with very short contact times (COUNTERFLOW system).
This plant gives the following advantages:
it permits to better utilize the stripping steam thus involving lower quantity of stripping steam
and, consequently, lower energetic consumptions for the vacuum set;
the PHYSITRON model is particularly recommended for the physical refining of oils with high
acidity, typically PALM OIL and also OLIVE OIL with some reserves.
The plant, equipped with packed COLUMN, requires more cares and precautions in the operation and use as well as a more frequent and accurate maintenance.
The plant shown in the process flowdiagram (next page) is designed for a sophisticated type
of heat recovery available on request: the heat exchange between the incoming oil and the
deodorized oil is carried out inside the deodorization column (in the lowest tray).
In this way the deodorized oil is maintained under vacuum and it is stirred/protected by injection
of live steam, while the incoming oil is flowing into coils submerged in the deodorized oil layer,
thus granting the highest quality for the finished oil. In special cases, also precooling of the oil (by
soft water) can be carried out inside the deodorization column, in similar way.
YIELD & PRODUCT QUALITY
The Physitron plant is capable of
producing oils with final acidity lower
than 0,10% (normally 0,05%) when
starting from pre-treated oils with 5%
FFA.
The quality parameters normally
obtained from the deodorization
process are also granted in case of the
Physitron plant.
As to yield, a typical formula for the oil
loss is:
L = (K x FFA + 0,10)%
where K is depending on the incoming
FFA and ranges from 1,10 to 1,20%.
Consumption figures are similar to
the corresponding figures of the
deodorization process or slightly higher.

Deodorization/deacidification plant
(Colombia) - Capacity: 500 t/d

6.2 PHYSICAL REFINING

PHYSICAL

REFINING

2
1 - Physitron CSF (deodorizing section) (Colombia) - Capacity: 500 t/d
2 - Physitron CSF (schematic drawing)

COMPLEMENTARY PROCESSES
COMPLE

MENTARY
PROCESS

Besides the processes previously described as basic steps in any refining line, some
complementary processes are often involved in production of edible oils and fats even if they
cannot be exactly defined as refining stages. Among these processes, it is worth mentioning:

Different solutions are available according

to the product type, capacity, quality
requirements, etc.

7. WATER DEGUMMING & LECITHIN DRYING

WATER

DEGUMMING

AND
LECITHIN
DRYING

Some crude oils like soybean oil and sunflowerseed oil containing important quantities of hydratable phosphatides, are generally submitted to water degumming.
This process enables to recover, at the same time, a valuable product such as lecithin.
The product discharged from the centrifugal separator is an aqueous slurry typically containing:
- Phosphatides: 33%
- Entrained oil: 17%
- Water: 50%
It is dried under vacuum (usually in a thin film evaporator) up to a residual moisture content in
the range of 12%. A continuous plant is shown in the following diagram.

1 - 300 t/d edible oil factory (Turkey)

2 - Water degumming and lecithin drying plant (schematic drawing)

8. DEWAXING BY FILTRATION
Dewaxing by filtration is an alternative process to dewaxing by centrifugal separator (cold
refining or wet dewaxing). It is not recommended when the waxes content in the oil is rather high
(over 600 ppm) but, on the other hand, the process has a good or very good efficiency and can
grant a lower cold test (24 h at 0C or even more stringent).
The process needs to use filter aid, both for precoating of the filter pressure leaves and as
continuous addition. The oil is cooled down to 78C and grained for 8 up to 12 h in vertical
crystallizers equipped with stirring system, before filtration.
The loss is generally in the range of 2 kg of oil per 1 kg of filter aid being used (or 10 x waxes %).
POLISHING DEWAXING
Oils which have been dewaxed in the neutralizing stage (e.g. sunflowerseed, corn oil etc.)
generally require a final wax removal in order to comply with most restrictive cold test
requirements (24 h at 0C plus 72 h at room temperature or 48 h at 0C or similar).
This operation is called PolishingDewaxing. The operating principle
of the plant is similar to the
dewaxing already described,
but it is usually carried out after
deodorization and needs lower
quantities of filter aid (0,10,2%
max).
Depending on the use of one or
two filters, the plant runs in semicontinuous or fully continuous
operation respectively; in most
cases one filter only is used.

1
C

2
1 - Dewaxing plant (filters group)
2 - Dewaxing plant by filtration (schematic drawing)

DEWAXING
BY FILTRA

TION

9. WINTERIZATION
wINTER
IZaTION

This process is similar to dewaxing, but it is destined to separate the solid triglycerides contained
in the refined oil, instead of waxes. This operation involves:

This process is particularly used for cottonseed oil destined to the production of salad oil, but it

10. DRY FRACTIONATION

DRY

FRACTIONA

TION

solvent nor catalyst.

The fatty matter is cooled according to a prefixed program of temperature reduction, so that
crystals can form and grow before being filtered in a continuous rotary filter operating under

2
1 - Winterization plant (schematic drawing)
2 - Dry fractionation plant (schematic drawing)

11. HYDROGENATION
This process is used for hardening the natural oils in order to produce solid or semisolid edible fats,
in particular margarine and shortening.
Hydrogen with high purity (99,9%) and nickel catalyst are necessary.
The proposed process is normally batch, with operating pressures from 0,5 to 5 bar max and temperatures in the range of 180 to 220C.
The plant can be equipped with partial or integral heat recovery system (in this case there is no
steam consumption).
TYPES OF REACTOR
The Gianazza reactor uses a special type stirrer (particularly designed for gas-liquid reactions in
presence of suspended solid catalyst), capable of obtaining the recirculation of gas in the liquid
mass without any compressor nor any other external circulation device.
In alternative, plants based on the
Loop Reactor technology can be
supplied.
Neutral oils and fats can be hydrogenated totally or selectively to any desired I.V.
Computerized instruments are available to pre-set and automatically stop
the injection of hydrogen as soon as
the prefixed quantity and therefore
the wanted I.V. are reached.
In order to completely remove the
nickel catalyst, a post bleaching treatment is normally carried out.
Standard capacities cover the range
from 10 to 200 t/d.

2
1 - Fatty acids hydrogenation plant (China) - Capacity: 250 t/d
2 - Hydrogenation plant Loop reactor type (schematic drawing)

HYDRO
GENATION

12. CHILLING & PLASTIFYING

CHILLING

AND
PLASTI

FYING

The Gianazza TURBOFRIGOR is a continuously operating cylindrical scraped

cooler/crystallizer, in which the product
flows into an annular section, the outer
surface being permanently scraped by
several knives mounted on a central
rotor.
The external jacket is cooled by an
evaporating frigorific fluid.
One or more cooling tubes can be used
in series, normally combined with one or
more plastifying tubes (equipped with a
special type comb stirrer).
The Turbofrigor is used for a wide range
of plastified fats, shortening, ghee, etc.

2
1 - Turbofrigor shortening production plant - Capacity: 50 t/d
2 - Shortening production plant (schematic drawing)

13. SOAPSTOCKS ACIDULATION

Soapstocks are transformed into
acid oils by means of acidulation
with sulphuric acid.
According to the capacity, batch or
fully continuous plants can be
proposed.
In some cases (mainly for cottonseed
soapstocks) it is recommended to
carry out a total and complete
saponification of the fatty matters in
order to obtain, after acidulation,
crude fatty acids with 9095% FFA.

SOAPSTOCKS

ACIDULA

TION

ACIDS OILS obtained by a standard acidulation are normally submitted to splitting in high
pressure vessels, in order to produce crude fatty acids with a FFA content ranging between 94
and 96% or more, to be sent to final distillation.
The main problems of this process are:
- corrosion due to the use of sulphuric acid: for this reason the vessels are made of plastic material;
- effluent water with very low pH and high C.O.D. levels.

2
1 - Soapstocks acidulation plant - Capacity: 75 t/d
2 - Soapstocks acidulation plant (schematic drawing)

We are pleased to inform you that Gianazza International has acquired the rights to Gianazza Technology. We have over 250 successfully
operating plants for edible oils and fats refining as well as more than
300 plants for oleochemicals throughout the world.
Considering the world continuous evolution, Gianazza International is
determined to continue Gianazza's century old commitment to quality
and focus on core business of introducing new technologies, plants
and facilities as well as providing the necessary parts needed to
maintain a first class production.
We are confident to appraise our customers that the Gianazza International has the technology and the know-how of Gianazza under a
new structure in order to offer reliable services for years to come. We
have the support of skillful personnels from Gianazza who trust in
more than 120 years of experiences our company has gained since
1892. Gianazza International is devoted to provide long term satisfaction to our customers.

GIANAZZA
nternational
GIANAZZA INTERNATIONAL srl

Via Piranesi, 26 20137 Milano (MI) - Italy

Phone +39.030.2425051 - Fax +39.02.36215805
e-mail: [email protected]
www.gianazza.eu

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