Our products consist of a water phase and a fat phase to which emulsifiers, flavors and coloring are added. Emulsifiers are surface-active substances that enable a good distribution of the water phase in the oil phase, since water does not dissolve in oil. The laboratory tests all raw materials to see if they meet our quality specifications before they are used in the production process.
1. Melting of Fats
The fats are melted before they can be pumped to the storage tanks. The drums are placed in a melting bath that is heated with steam to a temperature of approximately 60 degrees Celsius. It takes approximately 3 to 4 hours before the content of a drum is melted; depending on what type of fat is being melted.
2. Preparation of the Emulsion and Cooling
The fat and water phase are pumped to the emulsion tank per batch by a PLC controlled dosing system. In this tank the emulsion is stirred at around 45-50 degrees Celsius. A quality check is conducted after the emulsion is prepared to verify that the emulsion meets the specifications. Once this result is positive the process can be continued. A high-pressure pump then pumps the liquid emulsion to a ‘perfector’, a cooling cylinder that cools the emulsion. In this cylinder the emulsion is transformed to a solid product.
After the perfector solidifies the product, it is ready to be packed. If it is packed in wrappers, the structure of the product needs to be harder. This can be achieved by pushing the product through a resting tube where it remains for a few moments to crystallize further. Once this is done, it is hard enough for the packaging machine to cut it to size. After the products are packed in wrappers by the packaging machine, the ‘best before’ date and the batch number are printed on them and they are put in boxes that are sealed with a case sealer. During the packaging of the product the last quality control is conducted to make sure that the final product meets the required specifications. If the product is packed in cans or tubs it does not need to go through the resting tube, its shape will automatically adapt to the shape of the container. Packaging of margarine and butter in bulk boxes is simpler. The product is packed in buckets or in plastic bags that are put into a box. The shelf life of our products varies from six months to one year.