🧊 DRY FRACTIONATION PLANT – SUMMARY
🔹 What is Dry Fractionation?
Dry fractionation is a physical, cooling-based process that separates crystallized fats (stearins) from liquid oils (oleins) in edible oil by controlled cooling and filtration, without using any chemicals.
🔹 Oils Commonly Processed
🌴 Palm Oil
🥥 Palm Kernel Oil
🧈 Butter Oil / Ghee
🌾 Rice Bran Oil (partially)
🐄 Animal Fats / Tallow
🧪 Hydrogenated or blended oils
🔹 End Products
| Fraction | Description | Uses |
|---|---|---|
| Olein | Liquid part (low melting) | Cooking oil, salad oil |
| Stearin | Solid fat (high melting point) | Margarine, bakery fats, soaps |
| Mid Fraction (optional) | Used in confectionery blends | Cocoa butter substitutes |
🔹 Key Process Stages
✅ 1. Preconditioning / Heating
Oil is heated to ~70–80°C to ensure it’s fully melted and homogeneous.
✅ 2. Controlled Cooling (Crystallization)
Oil is cooled slowly and precisely (down to 18–24°C for palm oil).
Crystallizes solid fat molecules (stearins) under controlled agitation.
Carried out in crystallizer tanks or cooling chambers.
✅ 3. Maturation
Oil is held for several hours to complete the crystallization process.
Ensures proper crystal size and texture.
✅ 4. Filtration
Solid stearins are separated from liquid oleins using:
Membrane filters
Vacuum drum filters
Hydraulic presses
Stearin forms a cake; olein is collected as filtered oil.
🔹 Equipment Used
Crystallizer (Agitated Cooling Tank)
Chiller / Brine System
Pump & Transfer System
Membrane Filter Press
Heat Exchangers (for temperature control)
Storage Tanks for Olein & Stearin
🔹 Plant Capacity Examples
| Capacity | Olein Output | Stearin Output | Space Needed |
|---|---|---|---|
| 5 TPD | ~3.5 tons | ~1.5 tons | ~1000–1200 sq.ft |
| 20 TPD | ~14–15 tons | ~5–6 tons | ~3000 sq.ft |
| 50–100 TPD | Large-scale | Industrial use | 6000+ sq.ft |
🔹 Utilities Required
Chiller/Compressor System
Vacuum Pump (if drum filters used)
Hot Water/Steam Line (for pre-heating)
Power Supply
Compressed Air (for filter press)
✅ Key Advantages of Dry Fractionation
🌱 Chemical-free process (no solvents or acids)
♻️ Eco-friendly and energy-efficient
🔄 Reversible process (reheat and recombine if needed)
🧼 High-purity stearin – ideal for margarine, soaps
🛢️ Value-added product diversification
🔹 Common Applications of Output
RBD Olein: Premium frying and cooking oil
RBD Stearin: Margarine, shortening, bakery fat, soap manufacturing
Mid fractions (CBEs): Used in chocolate & confectionery industries