Emulsifier solutions for margarine Making your business

we are
e x p e r t s in
e mul s i f i e rs and
stabilizers for bakery,
confectionery, dairy, ice cream,
margarine and fine foods - and we
happy to share our expertise. our
company values can be defined
are
in just three
words :
loyalty, responsibility and
we aim to be the preferred partner
commitment.
and supplier of quality
products, application service and knowhow to regional and m u l t i - n a t i o n a l food companies. to Palsgaard
l o y a l t y means that we act as a reliable and honourable business
partner for our customers. we treat information confidentially and know
how to keep a business secret. to Palsgaard r e s p o n s i b i l i t y
means caring about the environment and being aware of our corporate
social responsibility; we have a goal to be CO 2 neutral by 2020 and
are members of SEDEX and RSPO. to Palsgaard c o m m i t m e n t
means we are dedicated to getting the best results for our customers’
products - to the benefit of their customers. we care about our
employees and have a declared aim that Palsgaard must be
a pleasant place to work. Palsgaard we know that our
most important resource is the k n o w - h o w and d e d i c a t i o n
found in our employees.
we are committed to
getting the best results with our products in our pilot plants
and in your facilities.
at Palsgaard we
don’t sell standard solutions - we start with your needs.
Palsgaard - Heart Working
heart work is
the best way to achieve success - let us help you
get it. our products are produced according to the
Heart
Working
People
strictest quality criteria. we are experts
in emulsifiers and stabilizers
and we are happy to share our
Emulsifier solutions for margarine
Making your business come together
Aeration
Crystallization
Fat reduction
expertise with you. let our
pilot plants help you shorten
the step between idea
and
your new product.
heart work is the best
way to succeed
- let us help
you do
so.
Plastification
Emulsifying nature and industry
to evolve your business
Experience never gets old
Global spread – local knowledge
The history of commercial emulsifiers is the history of
Our global approach, however, is more than just a mindset.
Palsgaard. In 1920 Danish entrepreneur and former CEO
Palsgaard maintains production facilities in Denmark, Mexico,
of the world’s largest margarine factory, Einar Viggo Schou,
China, the Netherlands as well as a new factory in Malaysia.
invented the world’s first commercial emulsifier in the trial labs
Furthermore we operate application centres in Denmark,
he had set up around his home in the beautiful 12th century
Singapore, China, Mexico and Dubai and a sales organization
Palsgaard Manor.
covering more than 100 countries around the world.
Since then Palsgaard has continued to grow as an industry
Our global presence allows us to meet the local challenges
pioneer. We remain dedicated to aiding our customers in
of our customers. We know that there is so much more to
developing their businesses and products by means of ours
margarine production than the ingredients: Local conditions
– not only within margarine but also in bakery, confectionery,
and the production line itself all play a critical role – as do the
dairy, ice cream, mayonaise and dressings.
availability and demand for any given ingredient. Besides our
innovative emulsifiers, this knowledge makes us an invaluable
Team up and experience Innovation by Doing
partner to our customers around the world.
We take great pride in creating new products, solutions and
production processes in close cooperation with our customers,
Driven by innovation – owned by a foundation
many of whom are frequent visitors to our margarine pilot
We are driven by innovation and curiousity on the behalf of
plants at Palsgaard in Denmark, Mexico and Singapore. Here,
our customers, and our ownership structure allows us to be.
we test our way forward in both products and processes. We
Palsgaard is owned by the Schou Foundation, whose purpose
call it Innovation by Doing. The process of co-creation is at
is to support research and development as well as to ensure
the very heart of Palsgaard along with our dedication to a
that Palsgaard is a good place to work. This is what makes us
sustainable, ethical and genuinely global business conduct.
a company of heart working people.
Palsgaard offers
• Products manufactured according to ISO/FSSC
22000 and ISO 9001 (HACCP)
• Kosher and Halal certified products
• Non-GMO emulsifiers
• RSPO (Roundtable on Sustainable Palm Oil)
SCCS Mass Balance certified emulsifiers
• CSR commitment, supports the UN Global
Compact
• SEDEX (Supplier Ethical Data Exhange) member
Our pilot plants allow us
to test new ideas. They
also enable us to offer our
customers access to hightech application installations
in order to simulate both the
composition and the exact
production conditions of any
margarine product anywhere
in the world, making sure
that the recipe matches their
facilities.
The Palsgaard factory in Denmark
is located in scenic surroundings
proving that nature and industry
can emulsify and remain in stable
harmony.
The 12th century Palsgaard estate
was the home and trial lab of
founder Einar Viggo Schou and still
remains the heart of Palsgaard.
Emulsifiers for margarine
– getting down to basics
Palsgaard has been helping margarine manufacturers for almost a century. Today we produce close to
100 different emulsifiers for margarine, with even more in development. We continue to be a leader and
innovator in emulsifiers for frying margarine, liquid margarine, table margarine, low-fat spreads, cake and
cream margarine, puff pastry margarine and shortenings. All these types of margarine require the optimal
combination of emulsifiers and process parameters – and we can help you find them. In addition Palsgaard
offers an extensive database of recipe suggestions available for your inspiration.
Aeration
Crystallization
Makes your product rise to the occasion
Makes your product come together
Aerated margarine products include cake margarine, cream
Since margarine is a water-in-oil emulsion, crystallization is
margarine and fillings. Emulsifiers must ensure a stable emulsion
absolutely crucial to production. Crystallizers and emulsifiers
in the margarine during both manufacturing and baking. These
ensure a stable emulsion during both production and use of the
emulsifiers impart a fine and stable water distribution to the
margarine products.
margarine and improve the creaming and whipping properties
to deliver higher volume and increased softness.
Your business potential is crystal clear
The benefits of teaming up with us are crystal clear. At
Cooperation is aeration to your business
Palsgaard we are committed to helping you release the full
Partnering with Palsgaard gives you more than the best aeration
potential of your products and your business. Our emulsifiers
emulsifiers on the market. You also benefit from the innovation
and the extensive knowledge of our experienced staff are what
and creativity that we pursue in our unique pilot plants and from
make it all come together.
expert advice on both products and production.
Fat reduction
Plastification
What customers are requesting
Helps your products down the stretch
Consumers are continuously challenging the food industry to
Good plasticity is essential to puff pastry margarine. The
reduce fat in many products, not least in margarine and the
plasticity of the finished margarine depends on emulsifiers,
foods in which margarine is an ingredient. This increases the
crystallizers, the composition of the fat blend and on processing
call for further innovation of emulsifiers that can help ensure the
conditions. Palsgaard helps you improve the functionality and
stability and properties of margarine products while reducing
plasticity of your puff pastry margarine, so your customer’s
their fat content as much as possible. Palsgaard is constantly
puff pastries get better lamination, lift and mouth feel.
striving to help our customers meet these demands.
Stretch the boundaries of your business
Make your production as lean as your products
Palsgaard emulsifiers let you stretch five kilos of margarine
The demand for leanness does not only apply to margarine
across 500 square metres. But they also let you stretch
products. It also applies to margarine production. Partnering
the boundaries of your product, innovation and your entire
with Palsgaard gives you access to our extensive knowhow
business.
in margarine production processes so you can produce your
products efficiently and with consistent high quality.
Aeration
Cake margarine
Makes a voluminous difference
Good structure in crumb and cooperation
Cake margarine is specifically designed to incorporate air and
We do more than just supply you with the right emulsifiers. At
impart stability to the batter and the final product. Palsgaard
Palsgaard we can optimize emulsifier and fat compositions in
emulsifiers – alongside optimal fat composition – let you create
our pilot plants, and recommend adjustments to the processing
highly functional margarines with the qualities you desire.
equipment. We know how emulsifiers work in cake systems,
and we focus on:
The purpose of a high functional cake margarine is to provide:
• high volume in the baked cake
• good, homogenous crumb structure
• soft and delicious cake.
• increasing the creaminess of the margarine, so that it
is easier to incorporate more air and increase the fat
distribution in the batter
• increasing batter viscosity so it retains more air
In order to obtain this, it is crucial that the margarine has a
• protecting air bubbles to ensure expansion during baking
very short and creamy structure. The ideal structure is best
• ensuring a high number of small air bubbles to deliver
achieved by using the right types of oils, the right processing
homogenous crumb structure.
conditions, proper tempering – and the right emulsifier.
Our facilities allow us to simulate exact production equipment
In addition to our margarine pilot plants we also have test
and conditions, but we are also used to working with customers
facilities for both craft and industrial bakeries. This allows us to
and processes at their local production sites.
test final consumer products baked with margarines containing
Palsgaard emulsifiers – so you’re sure to get the results you
need for your business-to-business.
Cream margarine
A nice touch
Make your products look great
Cream margarine is used for cake fillings and decoration.
Palsgaard offers you the right emulsifier solution for your
While cream composition varies, it is generally produced by
margarine so that you can create creams that:
whipping margarine together with powdered sugar, syrup or
other ingredients. This places different demands on the quality
• have high overrun
of the cream margarine.
• are highly stable so they do not collapse during
production, cake decoration or shelf life
The role of an emulsifier for cream margarine is to provide:
• absorb liquid ingredients so they do not leak after
production
• high volume in the cream or filling
• provide pleasant mouth feel
• good, homogeneous cream that is easy to use in
• maintain sharp, stable edges on cake decoration.
confectionery production and in fine bakery
• absorption of liquid ingredients so there are no
subsequent leaks.
In order to obtain this, it is crucial that the margarine has a
very short and creamy structure. The ideal structure is best
achieved by using the right types of oils, the right processing
conditions, proper tempering – and the right emulsifier.
Crystallization
Crystallizing
The potential of your product
Making product and process come together
Palsgaard offers a variety of crystallizers for promoting the
Oil separation during storage is a typical problem for very
crystallization process, oil absorbing ability and thermostability.
soft, oil-rich products such as liquid margarine and spreads.
Add to that our substantial know how in terms of production
Elevated temperatures make the problem even worse, and it is
conditions and facilities required to obtain the desired
difficult to solve without changing the viscosity of the finished
crystallization of your products.
product.
Palsgaard crystallizers and oil absorbers are used in:
Our range of oil absorbers and crystallizers entrap liquid oil
• liquid margarine
and attach it to a net of very small crystals that are created
• table margarine
during cooling. This means no oil separation in the finished
• low fat spreads
product – even when it is stored at elevated temperatures. In
• cake and cream margarine
simple terms, these features make your product come together
• puff pastry and Danish pastry margarine
and stay that way.
• shortenings.
Much like the way that Palsgaard makes your products
and production processes come together. Our extensive
knowledge of the right ingredients and the optimal conditions
for creating the products your customers demand help you
make it all come together.
Crystal clear
Advantages of cooperation
When demands and solutions come together
At Palsgaard we continue to build on the groundbreaking
At Palsgaard we are determined to help our customers meet
innovations of our founder Einar V. Schou, who revolutionized
increasing consumer demands for e.g. liquid margarine without
the margarine industry by inventing the Palsgaard Emulsion
compromising product quality. It’s all about making your product
Oil. Ever since our pilot plants and other extensive testing
come together in the form your customers are asking for.
facilities have provided both Palsgaard and our customers
with the unique opportunity of Innovation by Doing.
We know that there is much more to the crystallization process
than the crystallizers. That is why we provide you with worldclass advice on how to secure the right processing conditions
in terms of temperature, pressure and other conditions that
crystallization processes in your production facilities demand.
Liquid margarine with
Palsgaard crystallizer
Liquid margarine without
Palsgaard crystallizer
Fat reduction
Fat reduction
In high demand
When consumers want less, we do more
The pioneering spirit of Palsgaard grows even more important
Palsgaard continues to help customers meet growing
day by day, as consumer demands for specific properties of
consumer demand for products with lower fat content.
food products continue to increase.
Our emulsifier solutions for low-fat and very-low-fat spreads
Reducing fat content in margarines places several demands
provide key advantages:
on emulsifiers, as less fat and more water affects both
• Fine and stable water distribution
emulsion stability and crystallization. In bakery margarine,
• Reduced surface tension between water and fat phases
for example, lowering fat content without properly introducing
• Stabilized water-in-oil emulsion during emulsification and
counter measures such as the right emulsifiers impacts
margarine performance both in dough preparation and in the
baked goods.
For years Palsgaard has focused on creating successful
solutions for fat reduction in:
• low-fat spreads
• liquid margarine
• household margarine
• frying margarine
• cream margarine
• puff pastry margarine
• baking compounds.
crystallization.
Wide spread innovation
Amazing products
A truly low-fat spread
At Palsgaard we continue to push the boundaries of emulsifier
We successfully manufactured a high quality spread with only
properties so customers can grow into profitable new
10 percent fat. Results-oriented innovation is at the heart of
product categories. One innovation project has resulted in
Palsgaard, and we never stop pursuing it.
the manufacture of high-quality, low-fat spreads with only 10
percent fat.
Our solution meets these demands:
80% fat
40% fat
10% fat
• As low as 10% fat content
• No hydrogenated emulsifiers
• No hydrogenated oils or fats
100
• No allergenic ingredients
90
• Non GMO
80
• No trans fatty acids (<1 percent).
Changing customer demands and lower production costs are
70
60
50
40
challenges that we face every day. What are the challenges
30
that make up your day? Team up with Palsgaard and let us find
20
a solution together.
10
0
FAT
WATER
Plastification
Plastification
What it’s all about
Putting the puff in your pastry
Stretching five kilos of margarine across 500 square metres
Palsgaard offers a wide range of emulsifiers that are particularly
places extreme demands on plasticity. Breakage is not
well suited for margarines used in high-fat and fat-reduced puff
an option. Good lift is a must, as is perfect flake structure.
pastries and yeast-raised products. Palsgaard’s emulsifiers
Add to this the growing demand for low-fat content, and the
give you the following advantages:
challenges look daunting. This is where Palsgaard steps in –
and creates value for our customers.
• Fine and stable water distribution
• Improved plasticity
Even the best emulsifier systems for pastry margarine can’t
ensure correct margarine plastification or good baking results
without the proper processing conditions and fat combinations.
• Stable emulsion during both manufacturing
and baking purposes
• Good lamination and expansion in the laminated
baked pastry.
Emulsifiers do more than add emulsion and product stability.
They also affect the crystallization speed and improve plasticity
As for all types of margarine, ensuring ideal baking properties
as well as layer separation and lift in laminated dough systems.
requires more than simply developing and combining the right
ingredients. Optimizing production processes and conditions
are equally important to the quality of your end product – and
ultimately to the success of your business.
Fat reduction
The right emulsifier combination
Stretching without breaking
Choosing the right combination of emulsifiers enables you
When baking puff pastries, it is important to keep layers of
to reduce the fat content in margarine for Danish pastry and
margarine and dough separate until the proteins denaturize
croissants from 80 to 50 percent while still providing a stable,
and the starches begin to swell. The right combination of
dry and plastic Danish pastry margarine. During baking this
emulsifiers gives good, stable margarine emulsion during the
emulsifier combination ensures an expansion and lamination of
baking process and subsequent excellent baking results.
a 50 percent fat margarine similar to Danish pastry baked with
80 percent fat margarine. In fact, our emulsifier systems have
been successfully tested in recipes with as little as 35 percent fat.
Good expansion
Regular layers
DOUGH
At Palsgaard’s pilot plants, we can simulate and optimize
production setups to get things right. We know how to optimize
emulifiers, ingredients, recipes and processes. Either way, it’s
H2O
STEAM
MARGARINE
H2O
DOUGH
MARGARINE
STEAM
DOUGH
all about the right combination.
H2O
Poor expansion
Hard and brittle Puff Pastry Margarine
DOUGH
MARGARINE
H2O
STEAM
H2O
DOUGH
MARGARINE
DOUGH
STEAM
H2O
Before baking
During baking
Melting point,
approx.
Shelf life,
months
Appearance
Ingredients
Rape seed
90
1
70
24
Powder/pellets
E471
Palsgaard® DMG 0093
Palm
90
1
65
24
Powder/pellets
E471
®
Palsgaard DMG 0291
Rape seed
90
60-70
52
12
Pellets
E471
Palsgaard DMG 0295
Sunflower
90
105
45
12
Paste
E471
Palsgaard DMG 0298
Sunflower, HO
90
70
40
12
Paste
E471
®
Palsgaard PGE 1105
Vegetable
*
*
38
12
Paste
E475
®
Palsgaard PGE 1117
Vegetable
*
*
25
12
Paste
E475
Palsgaard PGE 1155
Vegetable
*
*
15
12
Liquid
E475
Palsgaard 1388
Vegetable
30
*
20
12
Liquid at 25°C
E471, E475
Palsgaard® 6111
Rape seed
0
3
60
24
Powder/pellets
None
Palsgaard 6112
Vegetable
0
2
57
24
Powder/pellets
None
Palsgaard 6115
Vegetable
0
3
59
24
Powder
None
Palsgaard 6118
Vegetable non hydro.
0
16
60
24
Pellets
None
Palsgaard® 6120
Vegetable
10
3
60
24
Powder
E471
Palsgaard® 6151
Vegetable
10
3
62
24
Powder
E471
Palsgaard® DMG 0291
Rape seed
90
60-70
52
12
Pellets
E471
Palsgaard DMG 0298
Sunflower, HO
90
70
40
12
Paste
E471
Palsgaard® DMG 0295
Sunflower
90
105
45
12
Paste
E471
Palsgaard® PGPR 4110 Castor oil
*
*
*
24
Liquid
E476
Palsgaard® PGPR 4175 Castor oil
*
*
*
24
Liquid
E476
Palsgaard 6111
Rape seed
*
3
60
24
Powder/pellets
None
®
Palsgaard 6151
Vegetable
10
3
62
24
Powder
E471
Palsgaard® DMG 0091
Rape seed
90
1
70
24
Powder/pellets
E471
Palsgaard DMG 0093
Palm
90
1
65
24
Powder/pellets
E471
Palsgaard 1302
Vegetable
30
2
57
12
Pellets
E471, E475
Palsgaard 1304
Vegetable
30
2
60
12
Pellets
E471, E475
Palsgaard 1311
Vegetable
*
*
50
12
Block
E472c, E475
Vegetable
45
*
30
12
Paste
E471, E472c, E475
®
®
Fat reductions
Crystallization
®
®
®
®
®
®
®
®
®
®
Palsgaard 1325
®
Iodine value,
max.
Lipid source
Palsgaard® DMG 0091
®
Plastification
Monoglycerides,
min. content
Product name
Aeration
Palsgaard's emulsifiers for margarine
* numbers not applicable
Margarine production
Process
Oil
Emulsifier
OIL
BLEND
EMULSIFIER
BLEND
Water
WATER
PHASE
Mayonnaise
Oil/ Water Emulsion
Margarine
Water /Oil Emulsion
Pin Rotor Machine
C1:
Initiation of crystallization.
Mixing and minimization of water
droplets.
Cylinder
Product
Cooling medium
Scraper
Rotor shaft
C1
PRM
PRM:
Mixing and agitation of the
crystallized margarine.
Resting time for crystallization.
C2
Mixing tank
C2:
Scraping off the crystallized
margarine from the surface of
the tube chillers.
C3
Final product
Resting tube
C4
C3:
Scraping off the crystallized
margarine from the surface of
the tube chillers.
SOLID
SOFT
C4:
Crystallization and removal of
recrystallization heat.
LIQUID
Time scale
Palsgaard emulsifier types
Time:
Processes:
Sec
Super cooling
0-10 min
Crystallization
1-10 min
Aggregation
3-10 min
Network compaction
Min. - month
Recrystallistaion
Polymorphic transition
Primary crystal bond
structure (firm)
Fat structure:
E471
Palsgaard ® DMG
E471
Palsgaard ® MDG
E472b
Palsgaard ® LACTEM
E472c
Palsgaard ® CITREM
E475
Palsgaard ® PGE
E476
Palsgaard ® PGPR
E477
Palsgaard ® PGMS
E481
Palsgaard ® SSL
E482
Palsgaard ® CSL
E492
Palsgaard ® STS
Secondary crystal bond
structure (plastic)
we are
e x p e r t s in
e mu ls if ie rs and
stabilizers for bakery,
confectionery, dairy, ice cream,
margarine and fine foods - and we
are happy to share our expertise. our
company values can be defined
in just three
words :
commitment.
loyalty, responsibility and
aim to be the preferred partner
products, application service and knowwe
are members of SEDEX and RSPO. to Palsgaard c o m m i t m e n t
means we are dedicated to getting the best results for our customers’
products - to the benefit of their customers. we care about our
employees and have a declared aim that Palsgaard must be
a pleasant place to work. Palsgaard we know that our
most important resource is the k n o w- h o w and d e d ic a t io n
found in our employees.
we are committed to
getting the best results with our products in our pilot plants
and in your facilities.
at Palsgaard we
don’t sell standard solutions - we start with your needs.
Palsgaard - Heart Working
heart work is
the best way to achieve success - let us help you
get it. our products are produced according to the
Heart
Working
People
strictest quality criteria. we are experts
in emulsifiers and stabilizers
and we are happy to share our
expertise with you. let our
pilot plants help you shorten
the step between idea
Heart working people
Doing a good job for our customers is something we have very
much at heart, and it has been like this for almost a century.
and
your new product.
heart work is the best
way to succeed
- let us help
Palsgaard has a unique, warm-hearted culture, which
originates from our founders, who were very socially oriented
you do
so.
people. This spirit is the way we work today with all of our
business relations – hard and with our hearts in the right place.
Jakob Thøisen, CEO, Palsgaard A/S
Palsgaard A/S
DK-7130 Juelsminde, Denmark
Phone +45 76 82 76 82
Fax +45 76 82 76 83
[email protected]
www.palsgaard.com
Climate neutralized
This CO2-neutral brochure was
produced under the auspices
of the Graphic Association of
Denmark and has been made
climate-neutral through the
purchase of CO2 quotas.
This brochure complies with the
environmental requirements
made of the Nordic Swan Mark.
Licence number: 541 309
The paper used for this brochure
complies with FSC (Forest
Stewardship Council) standards
for ethical and sustainable
forestry and wood products.
Palsgaard is a registered trademark of Palsgaard A/S. Layout: Gravity. October 2013. Print: Vest Tryk ApS, October 2013. © Palsgaard A/S, October 2013. All rights reserved.
and supplier of quality
how to regional and m u l t i - n a t i o n a l food companies. to Palsgaard
l o y a l t y means that we act as a reliable and honourable business
partner for our customers. we treat information confidentially and know
how to keep a business secret. to Palsgaard r e s p o n s i b i l i t y
means caring about the environment and being aware of our corporate
social responsibility; we have a goal to be CO 2 neutral by 2020 and