Transcript Process Engineering Lipophilic Systems

Lecithins
- Products - Applications - Markets Degussa Food Ingredients
April 2004
Lecithin
1
General and Legal Definitions
2
Composition of Lecithin
3
Production Processes
4
Applications
5
Markets
17/07/2015
Lecithin-Overview
Slide 2
General and legal definitions
What is Lecithin?
Lecithin (historical)
= Lipids from plant or animal origin
containing phosphorus
Lecithin (scientific)
= Phosphatidylcholine (1,2-diacyl-snglycero-3-phosphocholine)
Lecithin (commercial)
= Mixture of polar and nonpolar lipids
with minimum 60% A.I. (acetone
insolubles), E-No. 322
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Lecithin-Overview
Slide 3
General and legal definitions
E 322 - Lecithins (1)
 Lecithins are mixtures or fractions of phospholipids which are obtained from
animal or vegetable food stuffs by physical processes.
 They also include hydrolized substances which are obtained by the use of
harmless and suitable enzymes. The finished product is not allowed to show
any residual enzyme activity.
 Lecithin may be bleached in an aqueous medium by hydrogen peroxide, but
this may not affect the phospholipids of lecithin chemically.
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Lecithin-Overview
Slide 4
General and legal definitions
E 322 - Lecithins (2)
Content / Appearence
Lecithin
Hydrolized Lecithin
Acetone insoluble
substances
min. 60%
min. 56%
< 35mg
< 45mg
Acid Value
(potassium hydroxide/g)
Toluene insoluble
substances
< 0.3%
Volatile Substances
< 2%
(after 1h drying at 105°C)
Peroxide Value
10 or less
(mequ/kg)
Consistency
highly viscous, semiliquid or powder
Colour
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light brown to brown
Lecithin-Overview
Slide 5
Lecithin
1
General and Legal Definitions
2
Composition of Lecithin
3
Production Processes
4
Applications
5
Markets
17/07/2015
Lecithin-Overview
Slide 6
Composition of lecithin
Composition
Other Phospholipids
PA = Phospatidic Acid
C
PI = Phosphatidylinositol
PE = Phosphatidylethanolamin
E OP
P
T L
H
O A S O PA
N R P PI
H
E L O PE
L
I
I
P
I
D
O
PC =Phosphatidylcholin
L
NEUTRAL
LIPIDS
PC
I
P
N
S
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A
I
D S
S
UB L E
Lecithin-Overview
Slide 7
Composition of lecithin
Phospholipid structure
Triglyceride
CH2
CH
CH2
Basic phospholipid structure
CH2
CH
O
H2C-O-P-O-X
O
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Lecithin-Overview
Slide 8
Composition of lecithin
Phospholipid structure
HO
Basic phospholipid structure
CH2
OH
phosphatidylinositol (PI)
X=
OH
CH
HO HO
O
H2C-O-P-O-X
O
inositol
X=
phosphatidic acid (PA)
H
hydrogen
CH 3
X=
CH 2
CH 2
+
N
CH 3
phosphatidylcholine (PC)
3
CH
choline
X=
CH 2
CH 2
+
NH 3
phosphatidylethanolamine (PE)
ethanolamine
X=
CH 2
CH
COOH
phosphatidylserine (PS)
NH 2
serine
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Lecithin-Overview
Slide 9
Composition of lecithin
Glycerol “Backbone”
Fatty Acid Chains
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Lecithin-Overview
lipophilic
Polar Headgroup
hydrophilic
Phospholipids:
The active components of lecithin
Slide 10
Phospholipid sources
Phospholipids are essential components of all cell membranes
That means:
Phospholipids are part of all living organisms and can be obtained from these
(plants, animals, micro-organisms)
Commercial sources:
oil seeds (soybeans, sunflower, rapeseed)
egg yolk
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Lecithin-Overview
Slide 11
Lecithin
1
General and Legal Definition
2
Composition of Lecithin
3
Production Processes
4
Applications
5
Markets
17/07/2015
Lecithin-Overview
Slide 12
Production process
Oil Mill
Protein
Carbohydrates
Water
Fat
Lecithin
Soybean
cleaning
crushing
Extracted
meal
solvent extraction
42.0%
26.0%
12.5%
19.0%
0.5%
Miscella
filtration
solvent evaporation
Crude Soybean Oil
Crude
water
^^
Lecithin
evaporation
Purification
Standardization
Fractionation
Deoiling
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Lecithin
Sludge
+ water
separator
Soybean Oil
(Degummed)
Lecithin-Overview
Slide 13
Production process
Degussa Texturant Systems
Standard raw material
NGM raw material
Liquid raw material
modification
standardization
acetylation
hydrolysation
hydroxilation
ethanol
extraction
compounding
Topcithin
TopcithinNGM
50,
Topcithin200,300
NGM Premium
Emulfluid A
Emulfluid
Emulfluid
NGM
E
Emulfluid HL 33
Emulfluid
Emulfluid F25/
F30 IP
30
Chocotop
Chocotop320
320IP
Metarin
MetarinS40
F/FM
NGM
Chocotop
Chocotop
120
120
NGM
Acetone extraction
Emulpur IP
N
Lecimulthin
Lecimulthin100
100IP
Nutripur
MetarinPPIP
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Emultop
EmultopIP
Lecimulthin
Lecimulthin150
150IP
Emultop
EmultopHL
HL50
50IP
Lecithin-Overview
Metarin
MetarinCP
CPIP
Slide 14
Production process
Standardization
Principle:
 adjusting of product parameters
(e.g. microbiology, viscosity, E 322)
 purifying (filtration)
 selecting
 blending
Advantages:
 reproducible product quality
 improved transparency
 constant behaviour in final application
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Lecithin-Overview
Slide 15
Production process
Ethanol extraction
Principle:
 difference in solubility of the phospholipids in ethanol
PC
soluble
PI
PE
partly soluble
PA
 PC enriched and PC depleted fractions are produced
insoluble
insoluble
Advantages:
 less flavour effect by PC-enriched fraction as lower dosage can be used
compared to standard lecithin
 clear solubility in oil
 improved functionality in various applications when used at same dose as
standard lecithin
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Lecithin-Overview
Slide 16
Production process
Modification - Hydrolysation
Principle:
Enzymatic Hydrolysis
Advantages:
 increased water dispersibility
 less amount necessary to reduce surface tension
 better o/w emulsion formation properties
 complex formation with starch  anti staling agent (dough)
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Lecithin-Overview
Slide 17
Production process
Acetone extraction - deoiling
PI = Phosphatidylinositol
Other Phospholipids
PA = Phospatidic Acid
PA = Phospatidic Acid
A
PE =
Phosphatidylethanolamin
PI = Phosphatidylinositol
C P
E LO H P
T A
O
PA
S
O R P PI
PE
P
H
N L H
O
PE =
Phosphatidylethanolamin
I
N
S
PC
=Phosphatidylcholin
I
D
D
O
PC
=Phosphatidylcholin
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II
P
PI
PE
PC
PC
O
L
II
NEUTRAL
P
P I
D
D S
S
PA
LIPIDS
Other Phospholipids
S
L
U B L E
Lecithin-Overview
Slide 18
Production process
Acetone extraction - deoiling
Principle:
 non polar lipids (triglycerides) are acetone soluble
 thus a separation from polar lipids (phospho- and
glycolipids) is possible resulting in powdered
consistency
Advantages:
 increased water dispersibility
compared to liquid lecithin
 less influence on taste and colour
 easier dosing
 increased amount of active substances
i.e. less lecithin addition necessary
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Lecithin-Overview
Slide 19
Production process
Degussa Texturant Systems
Standard raw material
NGM raw material
Liquid raw material
modification
standardization
conventional
and NGM / IP
liquid lecithins
acetylation
hydrolysation
hydroxilation
conventional
conventional and
NGM / IP hydrolysed
lecithin
conventional
acetylated
lecithin
hydroxilated
lecithin
ethanol
extraction
compounding
conventional
and NGM / IP
lecithin fractions
conventional
and NGM / IP
lecithins
compounds
Acetone extraction
Emulpur N
Lecimulthin 100
Metarin P
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Emulpur IP
Lecimulthin 100 IP
Nutripur P IP
Metarin P IP
Emultop
Lecimulthin 150
Emultop HL 50
Emultop IP
Lecimulthin 150 IP
Emultop HL 50 IP
Lecithin-Overview
Metarin CP
Metarin CP IP
Slide 20
Production Plants
Germany
Netherlands
Italy
USA
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Lecithin-Overview
Hamburg
Zaandam
Vigonza
Decatur
Slide 21
Production Plants and Processes
Process / Plant
Germany
USA
Netherland
Italy
Selection
X
X
X
X
Standardization
X
X
X
X
Purification
X
X
X
X
Blending
X
X
X
X
X
Chemical Modification
X
Enzymatic Modification
Fractionation
X
Deoiling
X
Compounding
X
Quanitiy 2003 [tons]
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6,500 (+2,750)
10,000
Lecithin-Overview
14,000
1,700
Slide 22
Lecithin
1
General and Legal Definition
2
Composition of Lecithin
3
Production Processes
4
Applications
5
Markets
17/07/2015
Lecithin-Overview
Slide 23
Product Range and Branding Philosophy
17/07/2015
Topcithin (fluid)
Various applications
Metarin (fluid, powder)
Instantizing
Chocotop (fluid)
Chocolate
Emulthin (powder)
Flour Improver
Lecimulthin (powder)
Bakery
Lecithin-Overview
Slide 24
Product Range and Branding Philosophy
17/07/2015
Emulfluid (fluid)
Emulsions
Emulpur / Emultop (powder)
Emulsions
Emulbesto (fluid)
Feed
Nutripur (powder)
Feed
Epikuron (various)
Dietetic / Pharma
Ovothin (various)
Egg Lecithins
Lecithin-Overview
Slide 25
Application
Confectionary - chocolate
Main lecithin effect:
viscosity reduction and yield point
depression/adjustment in chocolate mass
influence on
viscosity
yield point
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Liquid (Topcithin 50)


Fractionation
PC enriched (Chocotop 320)


Compounding
+ E 476 (Chocotop 120)
(Chocotop 135)
+ E 442 (Chocotop 200)






Lecithin-Overview
Slide 26
Application
Instant products
Main lecithin effect:
coat formation around the instant powder
 increased wettability and solubility
Liquid (Metarin F/ FM)
 ready to spray on the product
Deoiling (Metarin P)  product becomes water dispersible
 lecithination / agglomeration in one step
 less influence on odour and taste
+ PC-enrichment (Metarin CP)
 less lecithin necessary for same effect
 better wetting properties at same dose
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Lecithin-Overview
Slide 27
Application
Oils and fats - margarine
Main lecithin effect:
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film formation around water droplets
 prevents coalescence during heating
 anti spattering effect
Liquid (Topcithin 300)
 good anti spattering effect
at high salt content (0.3 %)
Hydrolysed (Emulfluid E)
 anti spattering effect
at low salt content (0.15 %)
PC-enriched
(min. 23 % PC Emulfluid F 25)
(min. 32 % PC Emulfluid F 30)
 good anti spattering agent
 very good anti spattering agent
Lecithin-Overview
Slide 28
Application
Oils and fats - margarine (2)
Further lecithin effects:
 release agent
 Metarin FM
 Topcithin 300
 Emulfluid F 25
 Emulfluid F 30
 antioxidant
 flavour release
 co- emulsifier
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Lecithin-Overview
Slide 29
Application
Delicatessen / Meat products
Main lecithin effects:
stabilizer
emulsifier
facilitates dispersion/ distribution
 De-oiled (Emulpur N)
 less influence on taste/ odour
 Hydrolysed (Emultop)
 improved emulsifying properties
 heat stability
 acid stability of food emulsions
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Lecithin-Overview
Slide 30
Application
Animal feed
Main lecithin effects:
(technological)
emulsifier
improved wettability and dispersibility
decreased dust formation
improved pellet structure
antioxidant
 De-oiled (Nutripur P)
 Granulated
(Nutripur G)
 improved flowability
 + Flow aid
(Nutripur S)
 easier dosing and mixing
 better functionality
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Lecithin-Overview
Slide 31
Application
Dietary Supplements & Pharma
Main lecithin effects:
Cholesterole Control
Liver Treatment
Brain Function
Supplementation of LCPUFAs
Emulsifier in Enteral and Parenteral
Nutrition
 EPIKURON 100 Range
Standard de-oiled, Cholesterole control
 EPIKURON 130 / 135 F
Fractionated, de-oiled or fluid, liver treatment
 Leci-PS Range
Phosphatidylserin, powder or liquid, brainfunction
 EPIKURON 145/170/200
Emulsifier in parenteral preparations
 OVOTHIN Range
LCPUFA supplementation in Infant Nutrition
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Lecithin-Overview
Slide 32
Lecithin
1
General and Legal Definition
2
Composition of Lecithin
3
Production Processes
4
Applications
5
Markets
17/07/2015
Lecithin-Overview
Slide 33
Markets
Position of D-FD
World Lecithin Market
D-FD Lecithin Market
Total Market: ~ 180,000 tons
Our Market Share: 36,000 tons, ~ 20%
Others; 5%
Others; 9%
Oils & fat,
spreads; 7%
DS & Pharma; 5%
Instant &
Convenience; 6%
Animal Feed; 28%
Animal Feed; 21%
DS & Pharma; 8%
Industrial; 8%
Baking; 12%
Chocolate; 19%
Oils & fat,
spreads; 11%
Chocolate; 19%
Baking; 14%
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Industrial; 13%
Instant products;
15%
Lecithin-Overview
Slide 34
Markets
Position of D-FD
D-FD Market: Turnover
D-FD Market: Volumes
36,000 tons
58,000 k€ in 2003
Others; 5%
Oils & fat,
spreads; 7%
Others; 7%
Animal Feed; 21%
Animal feed; 10%
Oils & fat,
spreads; 6%
DS & Pharma; 8%
Chocolate; 15%
Baking; 12%
Chocolate; 19%
DS & Pharma;
31%
Instant products;
13%
Industrial; 13%
Industrial; 6%
Instant products;
15%
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Baking; 11%
Lecithin-Overview
Slide 35
Markets
Position of D-FD
D-FD Market: Turnover per Region
ROW; 3%
Asia; 13%
Germany; 15%
Other American;
2%
NAFTA; 13%
Other EC; 38%
Other European;
16%
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Lecithin-Overview
Slide 36