PROJECT DESCRIPTION
BACKGROUND
Industrial margarine manufacturing has traditionally used chemical processing which generates a significant amount of environmentally detrimental residues. In the case of LASEM,S.A, industrial margarine has been produced by chemically refining oils (Soya, Sunflower and Palm oil), followed by hydrogenation and plastification (adding chemical emulsifiers, antioxidants, preservatives etc.) As a result, Sodium Soaps are generated and have to be removed through washing and hydrochloric acid treatment. This process produces a large quantity of wastewater with a high pollutant load (8,000mg02/l, before purifying), as well as releasing hydrogen into the atmosphere. The growing market interest for more ecological products, above all in the food sector, has stimulated LASEM’S interest in producing Ecological Margarine that produce no detrimental effects on the environment as as part of a long-term sustainable strategy for growth.
OBJECTIVES
The aim of the project was to produce Ecological Margarines based on ecologically produced raw materials and employing totally clean technology. To achieve this, the project would guarantee that the initial raw materials had been produced by environmentally-friendly methods. They would also ensure that the manufacturing process did not include any chemical stages or generate wastes or emissions of any kind. The project proposed to design and put into operation a demonstration plant using crude palm oil produced by ecological cultivation in Indonesia. This would be transformed using a non-chemical process in several stages. Firstly, the fats would be refined physically by being subjected to high temperatures under vacuum conditions. They would then be mixed and emulsified before passing through the stages of crystallization, crystal maturing/stabilization and plastification. Finally, the product would be packaged. In the entire process no chemicals would be used nor solid or liquid waste produced. In this way, the project could guarantee an ecologically cultivated and manufactured product which was respectful to the consumer and the environment.
RESULTS
The beneficiary succeeded in designing and putting into operation a completely clean technological process for producing ecological margarine, despite a 6 months delay. In itself, the project was very innovative and its strategic planning could be extended to other products and processes within the sector and even to other areas of industry in the EU. The process produced no waste products of any kind, and the elimination of contaminating wastewater saved on in its consequent treatment as well as removing its negative environmental impact. The non-generation of sludge from the wastewater plant should also be taken into account, implying further savings in its collection and transportation to a garbage dump. Although the plant’s operation was generally executed according to the specification, a major change was introduced in the raw material used.The project replaced palm oil with a mix of coconut fat and sunflower oil. This was due to problems in finding reliable suppliers who could guarantee its ecological cultivation. Exhaustive studies indicated that the combination of coconut and sunflower oil was justified as it gave the right combination of solid fat for consistency and oil to assist plasticity. Moreover, as the Cocus nucifera (the tree from which coconut fat is extracted), could be found in its wild form in the Philippines, it could therefore be guaranteed pesticide and herbicide free. A similar situation occurred with sunflower oil, which also offered the value-added of improving the nutritive qualities of the product with a higher quantity of unsaturated fats. Generally the physical refining stage was well experimented at an industrial level; the only problem detected being the darker shade of the product due to the removal of the fat decoloration stage. However, this was solved by an adjustment in the level of natural carotene coloring added. As predicted, the production stage proved initially more complex and time-consuming, involving internal cleaning of the production equipment which often could not be assured given that the equipment was hermetically sealed. Special Plastification and packaging equipment aimed at this type of margarine were therefore introduced. Overall, it is clear that the market is increasingly interested in more ecological products and is prepared to pay a higher market price. This means that even though the cost of the raw materials is certainly higher, the lower plant operation costs due to process simplification and the reduction in energy and purification treatment costs, makes the new products increasingly economically and environmentally viable. . In summary, according to a report on the project featured in the LIFE Focus publication, "Industrial pollution, European solutions: clean technologies" (2004), despite the higher costs of the raw materials, the process consumes less energy and avoids the need for high expenditure on water purification and sludge treatment. It benefits from sound opportunities on a market which is increasingly open to ecological products. Highly innovative, this LIFE project also applies strategic planning, which may be of interest to other agri-food producers and other industrial sectors.
