Oils and Fats - Flanders Smart Hub

A world leader
The Desmet Ballestra Group is the world leader in the fields
of engineering and supply of plants and equipment for:
- the Oils and Fats industries,
- the Detergents, Surfactants and related Chemical industries,
- the Oleochemical and Biodiesel industries
Desmet Ballestra benefits from a worldwide
reputation of excellence, thanks to over
60 years of unequalled experience,
a strong R&D capacity and the most
extensive customer base
in the industry.
Desmet Ballestra core business
The Group is
organized around
3 Business Divisions
€ 380
million
turnover
1,100
employees
7,500
projects
in 150
countries
A
worldwide
network
of offices
OFO
Oils, Fats
& Oleo
technologies
DSC
Detergents,
Surfactants
& Chemicals plants
OSFE
Oilseeds
& Feedmill
Equipment
Group structure and organization
Technical / R&D
Europe
Mid. East Africa
South America
Detergents
& Surfactants
Sales & Marketing
Chemicals
India
Industrial Methods
Finance
Oleochemicals
Asia China
Far East
North & Central
America
Worldwide presence next to our customers
U.K.
France
U.S.A.
Spain
Russia
Belgium
Italy
Turkey
U.A.E.
China
Mexico
India
Malaysia
Colombia
Brasil
Argentina
DB office
or subsidiary
Singapore
Oils, Fats & Oleochemicals
First class engineering
With its HQ in Brussels, Desmet Ballestra’s
Oils , Fats & Oleochemicals Division
is the world specialist in oilseed and edible oil
processing plants. It delivers tailor-made engineering
and procurement services covering each step of the
industry, from crop to final product:
5 market segments
ü Seed preparation
Dehulling, Cracking, Cooking, Flaking, Expanding
ü Extraction
Mechanical and solvent extraction, Desolventising-toasting ,
Drying-cooling, Distillation, Solvent recovery
ü Refining
Degumming, Neutralization, Bleaching, Winterising, Deodorizing
ü Fat modification
Fractionation, Hydrogenation, Interesterification
ü Oleochemicals
Fatty Acids, Fatty Alcohols, Methylesters, Glycerine, Biodiesel
Oils, Fats & Oleochemicals technology platform
Oilseeds
Edible fats
Preparation
Refining
Extraction
Animal Feed
Crude oil
Fatty acids
Fatty alcohols
Biodiesel
Fat Modif.
Edible oil
Oleochemicals
Glycerine
Detergents, Surfactants & Chemicals
technology platform
Chemical Plants
Sulphuric
Acid
Phosphoric
Acid
Chemical
industry
Raw materials for
Surfactants/Det.
Oil
refining
Water
treatment
Detergents & Surfactants Plants
Fertilizers
Ore
processing
Agriculture
Sulphonation
Ethoxylation
Personal
care
Multipurpose
Detergent
bars
Laundry
Products
Detergents
Liquid
Detergents
Powder
Detergents
Oilseeds & Feedmill Equipment
technology platform
Oilseeds
Preparation
Rosedowns Pressing
Equipment platform
Sterling screw presses
Compress system
Mini presses
Oil screening tank
Mill design/ Engineering
Spare parts
Extraction and downstream edible oil processing
Bulk/powdery materials (seeds, cereals..)
Stolz Handling/Processing
Equipment platform
Destoning
Grain/powder cleaning
Sieving
Mechanical handling
Dedusting
Human Food
Grinding
Mixing
Thermal treatment
Pelletizing
Cooling
Animal Feed
Oils & Fats processes
Seed preparation
Purpose: to modify the seed into a shape that is suitable for fast and effective extraction
by mechanical pressing or solvent extraction.
It is a succession of several processes, amongst which:
ü
ü
ü
ü
ü
Dehulling :
Cracking:
Cooking:
Flaking:
Expanding:
increases the protein content of the de-oiled meal,
reduces the particle size of the seeds,
reduces the viscosity of the oil and adjust the moisture content,
ruptures the cell structure of the broken seeds,
enhances extraction parameters (used in specific cases)
preparation
175 & prepress processes
seed preparation
1,500 equipments
Oils & Fats processes
Seed preparation
Soybean
Cracking
Cooking
Flaking
20% oil
20% oil
Sunflower
Flakes
Cracking
Cooking
Pre-pressing
Cake
20% oil
45% oil
Crude
Oil
To Refining
To
Extraction
Oils & Fats processes
Extraction
Purpose: to obtain high quality oil with minimal undesirable components,
achieve high extraction yields and high value meal. Two common extraction processes
are solvent extraction and mechanical extraction using a screw press.
In order to maximize the removal of the oil contained in a seed, solvent extraction is conducted
on prepared seeds or, for high oil content seeds, on the cakes yielded by the pre-presses.
It consists of a sequence of four operations:
ü
ü
ü
ü
Physical removal of oil from the seed
Desolventising-toasting of the de-oiled seed - i.e. meal (incl. drying and cooling)
Distillation, to remove the solvent from the extracted oil
Recovery of solvent, which is reused at extractor level
full pressing
391 processes
extraction
790 units
complete
600 distillations
desolventising toasters,
700 dryer collers & DTDC
Oil extraction from oilseeds
Notable trend to larger capacity plants (‘economics of scale’)
Soybean extraction : avg. cap. = 3000 TPD
Rapeseed extraction : avg. cap. = 700 TPD
-
max. cap. = 20.000 TPD
max. cap. = 3.000 TPD
Oils & Fats processes
Solvent extraction process
Cake / Flake
Hexane
Desolventiser
20% oil
Extractor
Miscella
Meal
Steam
Distillation
Crude
Oil
To Refining
To Feed Milling
Oils & Fats processes
Refining
Purpose: to remove excess fatty acids and undesired components
which may compromise the taste, odor and appearance of the final edible oil.
Oil refining consists of a sequence of 4 main operations:
ü
ü
ü
ü
ü
Degumming, to take out gums (lecithin) from crude oil
Neutralization of crude oil, to neutralize free fatty acids (soapstock)
Bleaching, to absorb coloring matters and remove residual phosphatides,
metals, soaps and oxidation products
Winterising, to preserve limpidity and refined oils brightness
Deodorizing, to remove odoriferous material, free fatty acids and other
undesired minor components to produce a bland oil with a good shelf life.
250
degumming
units
738
bleaching
plants
neutralizing
200 units
winterising
121 plants
1,237
deodorising
plants
Oils & Fats processes
Refining process
Bleaching earth
Crude
Oil
Caustic Soda
Filtration
Deodorising
Gums
(Lecithin)
Degumming
Soapstock
Neutralising
Bleaching
Refined
Oil
Steam
Oils & Fats processes
Fat modification
Purpose: to chemically or physically modify oils in order to change their properties
and extent possible applications.
Market increasing demand for low trans fats and «green» products influence modification
processes. A combination of available technologies opens up other venues of investigation,
especially in the field of tailor-made fats for well-defined applications.
The prominent processes are:
ü
ü
ü
Fractionation, to separate «oleins» (liquid fraction ) from «stearins» (crystallised fraction)
Hydrogenation, to improve oil’s melting properties by reducing its degree of unsaturation
Interesterification, to create an oil more suitable for deep frying or making margarine with
good taste and low content of saturated fatty acids
333
fractionation
plants
hydrogenation
94 plants
interesterification
58 plants
Oils & Fats processes
Fat modification process
Hydrogenation
Catalyst
Refining
Refined
Oil
Hydrog.
oil
Fractionation
Cristallisation
Filtration
Olein
Filtration
Margarine
Ghee
Pastry Fat
Stearin
Hydrogen
Cocoa substitute
Soap
Salad
oil
A vocation for innovation
Desmet Ballestra’s R&D Team is composed
of professionals specialized in Oils & Fats,
oleochemical and chemical processes,
using the most comprehensive set of
technological resources and equipment:
ü High level scientists
ü Years of practical experience in the related industries
ü Fully equipped analytical and research laboratories
ü Flexible pilot units, including skid-mounted units available
for testing at customer’s facility
ü Collaboration agreements with several Universities
(Europe, Asia, USA…)
Improvement
of existing processes
New
applications
Custom
R&D
Pilot
plants
Backup
services
Oilseed and Oil Processing : Drivers for new Developments
15
5 5
40
65EFFICIENCY
- Improved nutritional quality
(meal and oil)
- Protein concentrates
- Oil fractions with better
physical properties
QUALITY
- Larger plant capacities
- Higher oil yield
- Lower operating cost
- Alternative solvents for
oil extraction
- Enzymatic40
oil processing
- Less (no) waste streams
SUSTAINABILITY
Desmet Ballestra R&D Center
R&D Center in Zaventem ( Staff :12 FTE)
•
Improvement of existing processes
•
Development of new (efficient, sustainable) technologies
•
Customized R&D in partnership with clients
R&D Center Zaventem : overview activities
5
40
R&D
55
- Limiting number of ‘active’ R&D projects
- First focus of the R&D center
- Supporting business of tomorrow
- Collaboration with (research) partners
R&D
Client/project
Other
Client/project related work
- Directly related to industrial projects (pre- or after sales)
- Process configuration – process guarantees – demo trials
- Assistance to on-site audits/trials/trouble-shootings
- In-house training programs for clients (theoretical/practical)
40
R&D Center Zaventem
§ ANALYTICAL LAB
- Fully equipped analytical laboratory
- Possibility to determine (standard) O&F quality parameters
- Regular participation to ring tests for method validation
R&D Center Zaventem
§ PILOT HALL 1
- Simulation of industrial oil refining & modification processes
- For R&D projects and demonstration trials
Batch deodorizer
Oil stripper
R&D Center Zaventem
§ PILOT HALL 1
- Simulation of industrial oil refining & modification processes
- For R&D projects and demonstration trials
Crystallizer for oil
fractionation
Membrane press filter
R&D Center Zaventem
§ PILOT HALL 2 (for experiments with solvents)
- Simulation of industrial oilseed/biomass extraction processes
- For R&D projects and demonstration trials
Batch extractor
High pressure reactor
Some R&D projects
§ Use of enzymes for oil refining : mild processing
§ Fish oil refining : removal of contaminants (dioxins,PCB,…)
§ Refining of ‘special’ oils : cocoa butter, rice bran oil , olive
oil, camelina oil,….
§ Extraction of sweetener from stevia leaves
§ Production of rape/soya protein concentrates
§ ……
Unique customer portfolio
Main technological partners
Main research partners
All your Desmet Ballestra contacts available at
www.desmetballestra.com