PFD for Fat Making Process

Note: The above PFD would also apply to the manufacturing of a solid Fats as all the above metioned
steps should be followed in same sequence in addition to an extra step of dehydrogenation after
deodorizing & bleaching.
 Transportation of liquid fat

Tank cars are of various sizes, construction types, and specifications. The most common sizes used for
soybean oil with their normal capacities are:

Standard:

8000 gallons (30 m3)

60,000 lbs (27 MT)

Jumbo:

20,000 gallons (75 m3)

150,000 lbs (68 MT)

Super Jumbo:

23,000 gallons (87 m3)

175,000 lbs (79 MT)

NOPA Trading Rules specify weight tolerances that constitute good delivery in the

Various sizes

The U.S. Department of Transportation (DOT) classification number indicates that this tank is fusion-
welded steel construction with a test pressure of 100 psig (0.7 MPa) (4). While tank cars are generally
of similar construction, details and accessories vary. Steam coils may be provided and are needed for
soybean oil in cold weather, when the product may partially solidify and become difficult to pump.

The hatch (called a manway) on top is for loading and access for inspection and cleaning. A 4-inch or
6-inch (10 or 15 cm) iron pipe size bottom outlet is closed with an outlet valve and a cap with a test
plug. The outlet valve is usually operated from the top by a rod extending through the tank, although
some tanks have ball valves operated from the bottom.
Tankers
Fat degummed is shipped in international trade in seagoing tanker vessels. A single vessel may carry
30,000 tons (27,000 MT) of oils, fats, and other commodities as separate parcels in cargo tanks of
various sizes.

The pumping system should be designed to avoid risk of contamination and provide for proper cleaning
and maintenance. Some ships have separate pumps built into each cargo tank with individual lines.
Tanks should be of improved design with structural supports located outside the cargo tanks. Frames
and beams inside the tanks interfere with cargo handling and proper cleaning.

Double bottoms on ships that discharge oils and fats in cold climates eliminate risk of solidification of
the product resulting from direct contact of the tank bottom with cold water.

No brass, bronze, or copper should be used in tanks or piping, because these promote oxidation of the
fat. Provision for nitrogen blanketing of tanks is desirable, and some tankers have nitrogen generators
to provide a continuous supply.
Contamination
A major concern in handling and transporting vegetable oils is to avoid contamination. In particular,
substances regulated by pure food laws must be in conformance with established limits, but other
substances also need to be controlled. Trading rules include various regulations on cleaning,
inspection, and separation practices in transport equipment.

NOPA rules (1) stipulate that “Equipment that has at any time handled materials containing toxic
metalo-organic compounds (for example, leaded gasoline or pesticides) or within the past two years
handled other substances generally recognized as toxic will not be used for storage or transfer of
soybean oil.” NIOP (National Institute of Oilseed Products) rules include detailed lists of acceptable
prior cargo and unacceptable prior cargo (2). Backlog (7) discusses contamination and adulteration as
well as other concerns about the effects on quality of handling and shipping practices. The best
practice is that any tanks used be restricted to use for food products.

Sampling and Analyzing

Liquid fat is sold on specified grade and quality which are a part of the sales contract and are outlined
in detail in trading rules.

An Official Sample is taken at the time of loading by either continuous flow or Trier methods (9) (AOCS
C 1-47). It is divided into three one-quart (0.946 L) samples: one for analysis by the shipper, one
forwarded to the consignee, and one retained by the shipper as a referee sample. The emphasis in
sampling is on obtaining a truly representative sample. An experienced and qualified sampler is
required. Continuous flow sampling is generally the most satisfactory, but it is applicable only to
product that is completely liquid and does not contain any material that might plug the bleeder line.
Trier samples require close attention to detail. A properly designed bomb or core sampler must be
used, and the sample taken in a specific pattern depending on the size and shape of the tanks. The size
and number of samples must be adequate and composited to provide representation of the entire oil
shipment.

Cleaning of Tanks
Trading rules generally require that tanks for transport of soybean oils be suitable for edible products
and free of any prior contents. Any person responsible for cleaning and inspection procedures should
be fully aware of the detailed trading rules that apply and cleaning techniques.

Storage tanks at plants handling only fat may be in continuous use, with partial filling and
emptying determined by production and loading schedules. Such tanks should be fully emptied and
cleaned frequently. Excessive delays between cleanings can be counterproductive, because excessive
buildup of sludge can make cleaning much more difficult.

Cleaning equipment using high-pressure jets rotating horizontally and vertically is highly
effective even in large tanks. High temperature—85°C (185°F)—and an appropriate detergent are
desirable. Effective detergents are usually a combination of ingredients and must be suitable for use
in food plants. If an appreciable amount of sludge or sediment is present, it may have to be removed
manually before washing.

Safety
There are several specialized safety concerns in handling oils. Entering a tank to clean or squeegee is
especially hazardous. Precautions include the following:

▪ The tank car or truck should not be moved under any circumstances when a worker
is on or in it.
▪ Steam must be disconnected from coils. The tank must be thoroughly cooled and
free of any fumes. Fumes generated by the heating and oxidation of oil can be
hazardous.
▪ A suitable air supply must be provided.
▪ The worker in the tank should wear a harness with safety line attached, and
another worker outside the tank should be in attendance at all times to assist the
worker inside.
▪ Use of suitable protective clothing is essential. Falling or head injuries are possible
because of the restricted space, nonlevel and slippery surfaces, and impediments
such as coils and braces.
▪ Water safety precautions should be taken, including wearing life jackets, by
workers on barges or ships.
Storage of Liquid Fat

Storage of fats and oils is necessary to maintain sufficient quantities of oil to supply the refining
operation. The objectives of such a bulk-storage system are also to maintain the quality of the incoming
fats oil and to supply a uniform product to the Production operation. An ideal bulk-storage system is
depicted in Figure below. Key features include: (1) storage tanks and piping for Fats to be stored and
handled, (2) an inventory control system that allows an accurate measure of fats coming into the
refinery and to the refining operation, and (3) a spill prevention, containment, and control system.

• Fats and oils should be stored in specialized tanks constructed from materials like carbon steel,
stainless steel, or aluminium.

•These storage tanks vary in size, designed to accommodate standard rail tank carloads or full
operation batches.

• Maintaining quality during storage is crucial to prevent the need for reprocessing or producing
subquality products.

Key Components of FAT Storage Tanks:

1.Tank Construction: Typically made from carbon steel, stainless steel, or aluminium.

2. Size Variation: Ranges from small tanks holding 10 metric tons to large tanks capable of storing 500
metric tons.

3. Internal Features: Equipped with tank tops, internal heating or cooling coils, and agitators to ensure
proper heat transfer and prevent localized overheating.
Factors Affecting Fat Quality:

1. Contamination from Atmosphere: Introduction of foreign particles from the surrounding

environment.

2. Internal contamination from water and soaps

3. Overheating

4. Exposure to air and oxygen

• Finished products held in storage tanks can be contaminated by water leaking from steam or cooling
coils. Moisture in the oil can promote hydrolysis, particularly at elevated storage temperatures.

To prevent this problem properly maintained coils are necessary.

• Overheating of bulk-stored oil is undesirable because soaps and pro-oxidant metals are much more
active at elevated temperatures.

Oxidation has the most detrimental effect on the quality of liquid fat held in bulk storage. For this
Nitrogen Blanketing is a good solution. A simple nitrogen-blanketing system is shown in Figure 13.
The nitrogen blanket is maintained by a pressure system controlled by a regulator. As the tank is filled
with product, the pressure builds and the gas is vented to the atmosphere. Conversely, as the product
is pumped from the tank, the pressure drops and replacement nitrogen gas enters the tank.

Nitrogen blanketing can be applied to multitanks arrangements (Figure 14). The design is similar to
single-tank systems and has the advantage of being less wasteful of nitrogen; as one tank is emptied,
the gas can be displaced from another. When product is transferred from tank to tank, the inert gas is
merely exchanged.