In the rapidly evolving landscape of health and nutrition, the demand for high-quality fish oil, rich in Omega-3 fatty acids, has never been higher.

Industries are seeking more efficient, sustainable, and quality-conserving methods for fish oil refinement.

The physical deodorization and deacidification process, equipped with advanced process equipment systems, stands at the forefront of this technological revolution.

This blog post explores how these advancements are setting new standards for industrial applications, offering insights for businesses looking to enhance their production capabilities.

Understanding the Process

Deodorization is traditionally the final step in the edible oil refining process.

Invented in the late 19th century, the primary purpose was to improve the taste and smell of refined oils.

Today, while still referred to as “deodorization,” the objectives of the process have expanded beyond merely removing off-flavors.

The deodorization process now serves three main purposes:

1. Removal of Volatile Components: This includes the physical refining of free fatty acids, valuable minor components (such as tocopherols and sterols), and contaminants (like pesticides and light polycyclic aromatic hydrocarbons).
2. True Deodorization: The elimination of various off-flavors to achieve a genuinely deodorized product.
3. Thermal Destruction of Pigments: Often referred to as thermal bleaching, this process involves the breakdown of color pigments in the oil.

Deodorization plays a crucial role in the oil refining process, significantly impacting the final product’s quality.

However, the deodorization process can also lead to certain undesirable side reactions, such as the formation of trans fatty acids and polymerized triglycerides.

The process conditions—temperature, time, pressure, and the ratio of steam to oil—are critically important for achieving the desired standard of oil quality and preserving its nutritional value.

The deodorization process involves heating the oil under vacuum to vaporize the volatile compounds responsible for off-flavors and odors, and free fatty acids, which are then removed through steam distillation.

Therefore, the design and process conditions of the deodorization tower can be continuously optimized to ensure that the generation of trans fatty acids is minimized, the removal of volatile pollutants is maximized, and valuable secondary components such as tocopherols and sterols can be controlled.

The Origin of Fish Oil Odor

The origin of fish oil odor is a topic of significant interest in both the production and consumption of fish oil products.

A clear understanding of where these odors come from is crucial for producers looking to refine their products and for consumers concerned about quality and freshness.

Here’s a professional and succinct explanation of the origins of fish oil odor:

1. Biological Sources: Fish oil odors primarily originate from the compounds that fish produce naturally. These include various fatty acids, proteins, and other organic compounds that fish accumulate through their diet and metabolic processes. When fish oil is extracted, these compounds can contribute to the characteristic “fishy” smell.
2. Oxidation of Unsaturated Fats: Fish oil is rich in polyunsaturated fatty acids, such as Omega-3s (EPA and DHA), which are prone to oxidation. Oxidation leads to the formation of volatile compounds, including aldehydes and ketones, which have strong odors. The extent of this oxidation depends on factors like exposure to air, light, and temperature.
3. Microbial Activity: The presence of microorganisms in fish or in the environment where fish oil is processed can lead to the production of odorous compounds. Bacteria and fungi can metabolize the components of fish oil, producing gases and other by-products that contribute to the odor.
4. Degradation Products: In addition to oxidation, other degradation processes can occur in fish oil, leading to the formation of compounds with strong odors. These processes can be accelerated by improper handling, storage conditions, and the presence of catalysts that promote degradation.
5. Environmental Contaminants: The water bodies from which fish are sourced can contain pollutants that contribute to the odor of fish oil. These may include chemicals from industrial runoff, agricultural practices, and natural sources that fish absorb through their skin or diet.

When the free fatty acid is reduced to 0.01-0.03%, the odor is eliminated, so the depth of deodorization is often measured by the reduction of free fatty acid content.

How Steam Deodorization or Extraction of Odor Occurs?

The theory of deodorization or steam extraction of odor process is a critical concept in the refinement of oils and fats, aiming to remove odorous substances efficiently.

This process is based on the principles of steam distillation and the physical properties of the compounds involved.

here’s a professional breakdown of this theory:

1. Vapor Pressure Differences: Odorous substances present in oils have a higher vapor pressure than triglycerides at the same temperature. For example, at 250℃, the vapor pressure of long-chain fatty acids ranges from 26.66 to 2.67 KPa, whereas the vapor pressure of corresponding triglycerides is significantly lower, between 1.33×10^-3 and 1.33×10^-4 kPa. This difference in vapor pressure is the key to separating odorous components from the oil.
2. Higher Vapor Pressure of Other Odorous Components: Besides fatty acids, other odorous components in the oil possess even higher vapor pressures than the fatty acids themselves. The deodorization process is essentially a liquid-gas mass transfer operation. When the liquid (oil) comes into contact with the gas (steam) at the gas-liquid interface, the steam becomes saturated with volatile odorous components. These components then escape the oil based on their partial pressure ratios, thereby achieving deodorization.
3. Concentration-Dependent Vapor Pressure: The vapor pressure of fatty acids and other odorous components is equal to their pure substance vapor pressure multiplied by their concentration in the oil. This principle underlines the effectiveness of steam deodorization in removing these compounds.
4. Efficiency Factors of the Deodorization Tower: The efficiency of the deodorization tower, where this process takes place, is influenced by three main parameters: the operation temperature, pressure, and the ratio of steam to oil. Under specific vacuum conditions, an increase in operating temperature enlarges the vapor pressure difference between odorous components and the oil, resulting in a lower final concentration of these odorous components in the deodorized oil.

The Combined Packing Type Tower for Deodorization Process

The efficacy of the doodorization process significantly depends on the sophistication of the equipment used.

A key piece of equipment in this process is the Combined Packing Type Tower, which ingeniously integrates the features of both packing and tray towers to leverage the benefits of both designs.

This core equipment enhances the deodorization process with its distinctive characteristics:

1. Combined Packing and Tray Design: This tower incorporates both packing sections and tray layers, offering superior deodorization efficiency. The synergy between these two components allows for a more thorough removal of odorous compounds.
2. Structured Packing: The conditioning section utilizes corrugated plate packing, providing a larger contact area and lower gas resistance, which is advantageous for acid stripping and deodorization. This design facilitates more effective interaction between the oil and stripping steam.
3. Oil Circulator at the Tower Bottom: Equipped with an oil circulator at its base, the tower promotes forced circulation, preventing oil from taking shortcuts and ensuring a more uniform treatment. This feature is particularly effective in removing volatile components like FFA, thereby significantly enhancing the thermal bleaching effect and ensuring more stable product quality.
4. High-Quality Seals and High-Temperature Sight Glasses: The tower is fitted with premium sealing gaskets and high-temperature-resistant sight glasses, ensuring excellent sealing performance and safety throughout the operation.
5. Special Foam Trapping Device: At the top of the tower, a special foam trapping device is installed, improving the efficiency of foam capture and ensuring a cleaner operation.

The complete systems are designed to optimize the conditions under which deodorization and deacidification occur, including precise temperature control, vacuum levels, and minimal exposure time. Click Here for precise solutions.

These parameters are crucial for minimizing the loss of essential Omega-3 fatty acids (EPA and DHA), which are sensitive to heat and oxidation.

Key Features of Advanced DOD Equipment Systems:

1. Integrated Automation: Modern systems come equipped with programmable logic controllers (PLC) and computerized monitoring, enabling precise control over process parameters. This automation ensures consistent product quality and operational efficiency.
2. Energy Efficiency: Advanced equipment often features energy recovery systems, reducing the overall energy demand of the deodorization and deacidification process. This not only lowers operating costs but also aligns with sustainability goals.
3. Enhanced Safety and Reliability: Built-in safety features and robust construction minimize the risk of operational disruptions and ensure the longevity of the equipment, protecting your investment.
4. Customizability and Scalability: The latest equipment is designed to be adaptable to various production capacities, from small-scale boutique operations to large industrial applications, ensuring scalability as your business grows.

Process Overview:

Hot oil at high temperatures enters the packing section, where it comes into thin-film counter-current contact with steam rising from below.

This interaction facilitates the rapid removal of free fatty acids, residual solvents, and other low-volatile components from the oil, thanks to the packing’s large specific surface area and the mass transfer occurring in a thin-film state.

The oil, stripped of volatile components like FFA, then moves into the retention section (tray tower structure), where a Monel pump eliminates shortcutting.

This separation step further enhances thermal bleaching effects compared to conventional tray towers, leading to more stable production outcomes.

Distinct Advantages:

1. Strong Deacidification Capability: Capable of reducing the acid value of oil ready for deodorization from 8mg KOH/g to 0.2mg KOH/g in a remarkably short time.
2. Advantageous for High Acid-Value Oils: The equipment’s design offers clear benefits for treating oils with high acid values.
3. Compatibility with Physical Refining: When combined with proper pretreatment of the oil and extraction processes, the system facilitates physical refining.

Factors Influencing Process Performance

Optimizing the performance of fish oil deodorization equipment and minimizing the loss of Omega-3 nutritional ingredients during the Deodorization and Distillation (DOD) system operation requires careful control of various process conditions.

The efficiency of the process and the quality of the final product are influenced by multiple factors and including:

1. Temperature: High temperatures are necessary for effective deodorization but can also lead to the thermal degradation of sensitive Omega-3 fatty acids (EPA and DHA). Optimal temperature control minimizes these losses while ensuring the removal of unwanted odors and flavors.
2. Vacuum Level: The use of vacuum in the DOD process helps lower the boiling points of volatile compounds, allowing for their removal at lower temperatures.
3. Residence Time: The duration the fish oil spends in the deodorization column affects both the efficiency of impurity removal and the extent of Omega-3 loss. Shorter residence times at optimal temperatures can help preserve Omega-3 content.
4. Steam Rate: The rate of clean steam injection plays a role in stripping away undesirable compounds. However, excessive steam can increase the loss of valuable Omega-3s. Balancing steam rate is key to maximizing deodorization efficiency while minimizing nutrient loss.
5. Feed Quality: The initial quality of the fish oil, including its free fatty acid content, moisture, and impurities level, impacts the deodorization efficiency and the extent of nutrient preservation.

Factors to Control for Reducing Omega-3 Loss

1. Optimize Temperature Settings: Implementing a precise temperature control strategy, possibly through lower temperature deodorization techniques.
2. Maintain Optimal Vacuum Conditions: Ensuring a high vacuum level to facilitate the removal of volatiles at lower temperatures helps in preserving the integrity of Omega-3 fatty acids.
3. Adjust Residence Time: Optimizing the residence time to ensure effective deodorization while preventing unnecessary exposure to heat can help in retaining Omega-3 levels.
4. Control Steam Introduction: Fine-tuning the steam rate to achieve effective removal of volatiles without stripping away beneficial Omega-3s is crucial. Using sparging steam minimally or employing alternative stripping gases like nitrogen can also be considered.
5. Pre-Treat Feedstock: Treating the fish oil before deodorization to remove impurities and reduce free fatty acid content can improve the efficiency of the DOD process and reduce the need for harsh conditions that might lead to Omega-3 loss.
6. Inert Gas Blanketing: Introducing inert gases such as nitrogen into the deodorization column can help displace oxygen, reducing the oxidation of Omega-3 fatty acids during the process.
7. Continuous Monitoring and Adjustment: Implementing real-time monitoring of the process parameters and adjusting them as needed based on the quality of the input and desired output can significantly impact the preservation of Omega-3 fatty acids.

Deodorization Loss Explained:

In the context of advanced processing techniques and proper operational conditions, the minimal loss rate during the deodorization process typically ranges from 0.01% to 0.4%.

Additionally, this loss includes 1.05 to 1.2 times the content of Free Fatty Acids (FFA) present in the raw material oil.

The Distillation Loss includes the loss of easily distillable low-molecular-weight aldehydes, ketones, and free fatty acids.

It also encompasses a small portion of fatty acids generated through the hydrolysis of oils.

When the FFA content is reduced to between 0.015% and 0.03%, the rate of removal of free fatty acids reaches a balance with the rate at which free fatty acids are produced through the hydrolysis of the oil.

In practice, the distillation loss in neutral oil can be attributed to the distillation of diglycerides and fatty acids formed through the hydrolysis of triglycerides.

There might be also a small amount of spatter loss, caused by the mechanical action of stripping steam caused by oil spatter loss. There are also a small number of sterols and other unsaponifiable substances that are difficult to dissect.

Benefits for Industries

Adopting advanced physical deodorization and deacidification systems offers a multitude of benefits for industries focusing on fish oil production:

• Higher Product Quality: By minimizing the loss of nutritional value and ensuring the removal of impurities, businesses can meet the growing consumer demand for high-quality fish oil supplements.
• Operational Efficiency: Automation and precise control reduce the need for constant manual intervention, streamlining operations and reducing labor costs.
• Sustainability: Energy-efficient designs and the ability to produce cleaner products contribute to environmentally friendly production practices.
• Competitive Advantage: Leveraging advanced technology can set businesses apart, offering a superior product that aligns with consumer preferences for purity and efficacy.

The transition to advanced physical deodorization and deacidification equipment is not just an operational upgrade—it’s a strategic move towards sustainability, efficiency, and quality.

For businesses in the fish oil production sector, embracing these technologies could be the pivotal step toward achieving unparalleled success in a competitive landscape.
Businesses interested in advanced physical deodorization and deacidification systems for fish oil refinement likely have a range of questions.

We are capable of clarifying common concerns and providing valuable insights to project implementations.

Here are some of the most likely FAQs:

1. How does advanced deodorization and deacidification technology impact the quality of fish oil?

Answer: Advanced systems ensure optimal temperature and vacuum conditions to minimize the loss of essential Omega-3 fatty acids while effectively removing unwanted odors, flavors, and free fatty acids. This results in a high-quality fish oil product with preserved nutritional value.

2. What are the energy efficiency benefits of using advanced systems?

Answer: These systems often include energy recovery mechanisms, reducing the overall energy consumption of the deodorization and deacidification process. This not only lowers operating costs but also supports sustainability goals.

3. Can the equipment be integrated into existing production lines?

Answer: Yes, our systems are designed to be modular and scalable, allowing for seamless integration into existing production setups. Customization options ensure that the system meets specific production needs and capacities.

4. What level of automation do these systems offer?

Answer: Advanced systems feature integrated automation and computerized monitoring, enabling precise control over process parameters and consistent product quality with minimal manual intervention.

5. How do advanced systems ensure the safety and reliability of the deodorization process?

Answer: These systems are equipped with built-in safety features and are constructed using robust materials, minimizing the risk of operational disruptions and ensuring the longevity of the equipment.

6. Are there customization options available for businesses with specific needs?

Answer: Yes, our deodorization process equipment is typically customization options to meet the unique needs of different businesses, whether it’s adapting to various production capacities or specific product quality targets.

7. What is the typical return on investment (ROI) for implementing an advanced deodorization system?

Answer: While the initial investment may be higher than for conventional systems, the ROI is typically favorable due to increased operational efficiency, reduced energy costs, higher product quality, and the ability to meet market demands for premium fish oil products.

8. How does the implementation of advanced technology align with sustainability practices?

Answer: By reducing energy consumption and improving the efficiency of the fish oil refinement process, advanced systems contribute to more sustainable production practices. This includes minimizing waste and optimizing the use of raw materials.

9. What support and maintenance services are available for these systems?

Answer: Our after-sales service offer comprehensive support and maintenance services, including training, technical support, spare parts supply, and preventative maintenance plans to ensure the system operates efficiently over its lifespan.

10. How can businesses get started with the transition to an advanced deodorization and deacidification system?

Answer: Interested businesses should start by consulting with us, as a professional process equipment supplier to discuss your specific needs, operational goals, and any customization requirements. Manufacturers can then provide tailored solutions and support throughout the implementation process.

Reference Resources:

https://www.sciencedirect.com/topics/agricultural-and-biological-sciences/deodorization

https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8767382/#:~:text=Chemical%20refining%20consists%20of%20removing,refining%20%5B29%E2%80%9332%5D.