Fractional Crystallization System for Fish Oil Winterization

Specialized For Deep-Sea Fish Oil

Our state-of-the-art Winterization Fractionation and Crystallization Filtration System is specifically designed to meet the unique requirements of deep-sea fish oil refinement. The system includes customized crystallization reactors that utilize low-speed agitation and controlled cooling to specific temperatures. This process enables the formation of larger crystals from the solid fats within the oil, effectively facilitating the separation of components with higher melting points, such as stearin and saturated fatty acid esters.

Made To Measure Solution

A Continuous or Intermittent Crystallization Process System that aligns with your specific temperature control parameters.

Recognizing the significant variances in the melting points of different types of fish oils, and the divergent requirements for the final product, our system offers the flexibility to adapt to different fish oil types or applications. In instances where there is a high content of saturated fatty acids and specific requirements for the final product’s melting point, a secondary winterization process may be employed to ensure optimal yield.

Features & Benefits

Not only does the winterization process lower the melting point of fish oil, but it also modifies the fatty acid composition. Specifically, it elevates the content of Omega-3 polyunsaturated fatty acids (EPA/DHA), thereby augmenting the application value and economic nutritional worth of the refined fish oil.

Greatwall Process and Control offers customizable process engineering services to adapt the equipment to your specific requirements. Our team works closely with you to tailor the system to your needs.

Designed to be energy-efficient, our system supports the sustainability goals of your operations without compromising performance.

Safety is our priority. Our system comes with interlock control and fault monitoring features. In case of equipment failure, the system will automatically halt operations to prevent fault escalation.

Our system is designed to minimize labor involvement with a high level of automation. With customizable PLC programming, you can achieve precise control over the winterization, separation, and filtration processes. Benefit from real-time monitoring, fault detection, and process optimization capabilities.

Dynamic process display, various process parameters, and control points are available for real-time automatic monitoring. The equipment allows for both automatic and manual control, offering redundant systems for continued production in case of automated system failure.

The system can automatically display, store, and manage on-site data, including records of output, power consumption, flow rate, temperature, pressure, frequency, and equipment alarming records. It assists in production management, displaying real-time production data, thus improving the reliability of the system significantly.


Got a Question?

Greatwall Process and Control is thrilled to present the comprehensive Winterization Fractionation Equipment System. Engineered to serve Fish Oil Refinery and Oil Refinery Plants, our system offers top-quality features and customizable engineering services for high-yield fractionation processes.

Winterization is a specialized method of crystalline separation, strategically designed to segregate various components within oils and fats based on their freezing points. Specifically, it facilitates the precipitation of higher-melting-point constituents such as glycerides through controlled cooling mechanisms.

Regarded as a specialized form of dry fractionation, winterization is typically implemented subsequent to other refinement procedures including degumming, deacidification, decolorization, and deodorization. Utilizing meticulous control over cooling rates, the fully liquefied oil undergoes low-speed agitation while its temperature is systematically lowered to a range of 0-10°C over an approximate duration of 24-72 hours. This intricate process leads to the formation of sizeable stearin crystals, which can be effectively separated via press filtration units.

The practical applications of winterization are multifaceted. For instance, cottonseed oil undergoes winterization to produce salad oil, while fish oil requires winterization post-refinement to extract stearin. Paint oils are winterized to enhance film resilience at lower temperatures, edible oils are treated to sustain transparency and fluidity under refrigeration, and cod liver oil is winterized to preserve clarity in cold weather conditions.

The efficacy of the winterization process can be validated through a freezing test, wherein the winterized oil must remain free from cloudiness for a minimum duration of 5.5 hours at 0°C.

Dry fractionation is a method of filtering the heated liquid oil after slow cooling and crystallization for a certain period of time without adding other ingredients, depending on the melting point of different fatty acid glycerides.
Dry fractionation is suitable for the separation of fatty acid triglycerides with similar solubility in organic solvents. The components to be separated are highly crystallized and can be separated by filtration or centrifugation. Dry fractionation includes winterization, dewaxing, hydraulic pressure and grading.
This technology has no solvent and catalyst pollution, and is now widely used in the processing of many kinds of fats and oils.

However, there are also problems such as not being able to produce continuously with small volume, the membrane press filter used for filtration is easily contaminated and has a short service life.

Basically, the fish oil winterization and crystallization process is in accordance with the following steps: loading preheating, cooling and stirring, cooling and crystallization, filtration and de-crystallization procedures.

The batch/continuous winterization (fractionation) production line, which processes 3-300 tons of fish oil per day, can be designed and equipped to meet the requirements for the production of high-quality EPA-rich and DHA-rich fish oil of users. According to the crystallization characteristics of fish oil winterization fractionation, the crystallization tank adopts a unique mixing form, using ZCX variable cross-section axial flow paddles, high efficiency and low power distribution.

The continuous production line can be designed scalable according to the processing capacity, the equipment is smaller and the product quality is better. The disadvantage is that the machine generally runs 24 hours a day, at least a few days can not be stopped, of course, stopping is fine, but need to adjust the parameters from the new, such as qualified oil and then out of the oil.

As different varieties of fish oil freezing point difference is very great, the final product of the freezing point requirements are not consistent, determines the different varieties of fish oil or different uses, so that crystallization process in the winterization  should be flexible!

Fish oil winterization and separation process will be designed with key point and key location automated production, which can realize the automated operation of oil inlet and outlet, oil metering, temperature control, pressure control, flow control, liquid level control, frequency conversion control, crystallization, and crystal preservation process.

In order to reduce the oxidation rate of fish oil, we have designed a nitrogen sealing automatic device in the process, all the crystallization tanks, oil tanks and oil pipes can be filled with nitrogen sealing, self-control of air intake and exhaust, so that the fish oil is not easy to oxidize and rancidity.

If you complete with Thermal Melt Type Filtration Equipment, Liquid oil and crystallized wax are separated by filter cloth, in which liquid oil penetrates the filter cloth and enters the filter plate to flow into the oil tank and then transported to the oil tank by the pump.
Wax or grease can not penetrate the filter cloth because of crystallization into a solid state, and can only stay in the frame of the wax filter plate.
After filtering for a certain period of time, the amount of liquid oil filtered out will become smaller gradually, at this time, stop feeding oil, close all the oil and wax release valves, and then supply heat through the circulating coil in the plate frame.
Then the heat source will be heated to the wax or hard grease inside the wax filtering plate and frame through the circulating coil so that the hard ester will be melted into liquid, and then the wax valve will be opened, and the liquid wax or hard grease will be gathered together, and then transported to the grease tank by the pump to be reused in the industry. In this way, the filtering process is carried out in a cyclic manner.

If you complete with A Membrane Filter Press, Upon filling the filter chambers with well-crystallized fish oil, the material input is halted. Initially, low-pressure compressed air (with 0.2 MPa) passes through the membrane filter plate to pre-compress the wax cake, thereby equalizing its pore channels and enhancing its ventilation properties. Subsequently, the compressed air pressure is increased to 0.6 MPa. This higher pressure, executed through a high-pressure airbag, is effective in thoroughly expelling the oil from the wax cake, resulting in a low oil content and well-formed stearin cake, which will be falling on the belt or tank and transfered for storage.

The purpose of filtration is achieved by this cycle of operation. 

Normally it takes 2 people to operate a winterization process as one person is not safe, but additional manpower is needed to dismantle and repair the equipment if necessary.

Generally, automatic control retains the site’s manual operation. For example, motor start and stop, valve switch, etc.

Main Control Points:

  1. Feed Control: Regulates feeding oil flow and output based on the feedback from the flowmeter, enabling frequency conversion control of the feed flow.
  2. Temperature&Pressure Management: Utilizes software and hardware for automated control of main cooling processes, ensuring precise temperature and pressure control.
  3. Level Control: Provides automatic level control for main water tanks and oil tanks according to process requirements.
  4. Sensor-Based Monitoring: Employs temperature and pressure sensors for real-time monitoring or chain control of oil temperature, water temperature, nitrogen, and compressed air systems.
  5. Instrument Configuration: Features advanced, automatic instruments primarily from France’s Schneider brand. Cable and wire management is facilitated by a bridge for easy operation and maintenance.

Description of Main Control and Monitoring

process flow of winterizaton crystallization for marine fish oil

How To Operate Winterization Process

The Streamlined, Automated Process Offers Unparalleled Efficiency and Adaptability, Conforming to Diverse Oil Qualities and Operational Requisites.

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01/ Initial Preparation and Pre-Heating Phase

Prior to the commencement of the fish oil fractionation and purification sequence, verify the status of the crude oil storage tank and initiate the feed pump mechanism. Utilize 2-bar saturated steam to elevate the crude oil temperature to a calibrated range of 40-50°C. Following precise quantification via a mass flow meter. Accurate thermal regulation is achieved through meticulous manipulation of the steam control valve aperture.


02/Crude Oil Admission and Crystallization Sequence

Channel the crude oil into the Crystallization Hypothesis Unit. Upon reaching maximum capacity, activate the pre-configured crystallization control sequence, tailored to the specific oil quality. The crystallization program adheres to a pre-set progression, encompassing temperature reduction, crystallization, incubation, and cooling to the filtration temperature threshold. Integrated self-circulation cooling water pumps negate excessive cooling phenomena. The automated control system orchestrates a gradual, orderly decrement in temperature, thus enabling stearin precipitation with minimal residual liquid oil, optimized for plate filtration.


03/Crystallization Process Adaptability

The comprehensive crystallization sequence can be adapted to varying oil characteristics through pre-set adjustments in cooling rate, blending velocity, and incubation durations. During crystallization, each stratified oil layer is systematically compressed and directed towards tangential pathways, ensuring complete, homogenous circulation throughout the vessel. This achieves a vortex-like state of total mobility, eliminating dead zones.

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04/Secondary Crystallization and Filtration Phases

Each crystallization tank has a specific capacity and is filled in a sequential manner. The crystallization process initiates upon reaching full capacity. Multi-Stage Process: The operation employs a dual-phase crystallization and filtration protocol, featuring four crystallization tanks at each stage. Filtration: Initial filtration parameters are set at 12°C, though optimal conditions are determined by practical production metrics. Upon oil entry into the fourth tank, oil from the initially filled first tank is prepared for filtration.


05/Filtration and Storage

Open the basal oil drainage valve and activate the variable-frequency screw pump. Channel the crystallized oil into the membrane filter press for the filtration process. Oil and Stearin Storage: Transfer the filtrate into designated storage tanks. Melt the precipitated stearin via heating coils and relocate it to its respective storage unit.


06/Filter Press Regulation

Should the oil inlet pressure for the filter press cross a specified threshold, the system will halt oil introduction, commence automated filter pressing, and subsequently initialize the subsequent filtration cycle.

Our Services

From Process Engineering to Complete Production Information-Based Design & Supply

24/7 Support

Our sales team will respond to your inquiries within 4 working hours, and after-sales support is assured within 48 hours.

Online&Site Tutorials

Process operations and technical documents are available for handover and ensure that each operator receives them prior to system unit operation.

Powerful Design Capacities

Starting from the initial technical specifications and process flow to meet your expected target output quality, to the final approved performance is guaranteed.

Strict Quality Control

Sophisticated equipment manufacturing, strict production quality control, inspection, and testing prior to delivery.

Prolong Warranty Period

Provide a warranty period of at least two years for the membrane unit, including the membrane tube, sealing, and membrane shell.

On Site Commissioning

Engineers with 10+ years of experience will be dispatched upon request to support the start-up and commissioning work on-site.

Contact Us

Greatwall Process and Control is proud to introduce the comprehensive Winterization Fractionation Equipment System. Engineered to serve Fish Oil Refinery and Oil Refinery Plants, our system offers top-quality features and customizable engineering services for high-yield fractionation processes.

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