At the stage of the fatty acid concentration process, the refined fish oil undergoes short path distillation, a process that operates under high vacuum and minimal heat to prevent oxidation and degradation of the Omega-3 fatty acids.

This technique is highly effective in separating and removing low molecular weight contaminants (e.g., PCBs, dioxins, plastisizers, and heavy metals) while concentrating the EPA and DHA content.

Short Path Molecular distillation is a key process for concentrating Omega-3 fatty acids from fish oil.

This technique allows for the selective separation of EPA and DHA from other fats and impurities based on their molecular weights and volatilities.

Why to Concentrate Fish Oil Omega-3 Ingredients?

Market Demand and Health Awareness

• Increased Health Consciousness: There’s a growing awareness among consumers about the health benefits of Omega-3 fatty acids, including improved heart health, reduced inflammation, and better cognitive function. This awareness drives demand for high-concentration Omega-3 products.
• Nutraceuticals and Dietary Supplements Market Growth: The expanding market for dietary supplements and nutraceuticals directly influences the demand for concentrated fish oil products. High-purity Omega-3 oils are a key ingredient in these products.
• Pharmaceutical Applications: Omega-3 fatty acids have applications in various pharmaceutical formulations, especially for conditions like hypertriglyceridemia. The pharmaceutical industry’s stringent purity requirements often necessitate the concentration and purification of fish oil.

Technological Advancements

• Advances in Extraction and Concentration Technologies: Developments in processing technologies, such as supercritical fluid extraction and short path distillation, have made it more efficient and cost-effective to concentrate Omega-3s from fish oil.
• Improved Product Stability and Shelf Life: Concentration processes can also improve the stability and shelf life of Omega-3 oils, making them more attractive for various applications.

Regulatory and Quality Standards

• Regulatory Compliance: Regulatory agencies worldwide have established guidelines and standards for Omega-3 supplements, including purity and concentration levels. Meeting these standards often requires the use of advanced concentration techniques.
• Certification and Label Claims: To make specific label claims, such as “high in Omega-3,” products must meet certain concentration thresholds. This drives the need for concentration processes in manufacturing.

Sustainability and Resource Utilization

• Sustainable Resource Use: With increasing concern over fish stocks and marine resource sustainability, there’s a push to extract maximum value from marine fish oil, including the concentration of valuable Omega-3 acids.
• Byproduct Valorization: Concentrating Omega-3 from fish oil can also be part of a broader strategy to valorize byproducts from fish processing, turning waste into high-value products.

Economic Considerations

• Premium Product Segmentation: High-concentration Omega-3 products often command premium prices in the market. Companies may focus on these products to differentiate products and company competitiveness and capture higher profit margins.
• Cost Efficiency: Advances in concentration technology may lower production costs, making it economically viable to produce high-purity Omega-3 oil even in competitive markets.

What Shall be the Fish Oil Quality before the Concentration Process

The quality of fish oil before the concentration process is crucial for ensuring the purity, stability, and effectiveness of the final Omega-3 concentrates.

High-quality raw material contributes to the efficiency of the concentration process and the overall quality of the end product.

Here are several key quality parameters that should be considered:

1. Color

The color of fish oil can be an indicator of its purity and the extent of its processing.

Ideally, fish oil should be relatively light in color before concentration, indicating minimal oxidation and the removal of impurities.

A lighter color is typically achieved through the refining processes of degumming, neutralization, bleaching, and deodorization.

Although color specifications might vary, a Gardner color of 5 or less is often considered desirable for concentrated fish oil products.

2. Ester Form

• Triglyceride (TG) Form: Fish oil in its natural form consists mainly of triglycerides. High-quality fish oil intended for concentration should retain its triglyceride form if the end goal is to produce TG-based Omega-3 concentrates, which are closer to the natural dietary sources of Omega-3s.
• Ethyl Ester (EE) Form: For most concentration processes, particularly those involving molecular distillation or enzymatic transesterification, the oil might be converted into ethyl esters. This form is easier to purify and concentrate but can be converted back into triglycerides if needed.

3. Acid Value

The acid value is a measure of the free fatty acid content in the oil, reflecting the degree of hydrolysis and oxidation.

Lower acid values are preferable, as high acid values indicate degradation and possible quality issues. Before concentration, a low acid value, typically below 1 mg KOH/g, is desired to ensure stability and minimize the risk of oxidation during processing.

4. Peroxide Value

The peroxide value measures the primary oxidation products (peroxides) in the oil and is a key indicator of oxidative stability. Lower peroxide values are indicative of fresher, less oxidized oil.

Before concentration, the peroxide value should be as low as possible, generally below 5 meq/kg, to ensure that the oil is stable and has not undergone significant oxidation.

5. Environmental Contaminants

Fish oil should be tested and confirmed to be free from or contain minimal levels of environmental contaminants, including heavy metals (like mercury, lead, cadmium, and arsenic), dioxins, PCBs, and other harmful compounds.

These contaminants can affect the safety and quality of the final product.

6. Purity and Impurities

The oil should be largely free from impurities, including moisture, sediment, and unsaponifiable matter, as these can interfere with the concentration process and affect the quality of the final product.

For effective removal of persistent organic pollutants (POPs) using short-path distillation equipment, the setup should be optimized for precise control over temperature and vacuum conditions.

High-performance equipment will allow for fine-tuning these parameters to target the specific boiling points of POPs without degrading the quality of the Omega-3 fatty acids.

Additionally, incorporating advanced monitoring and control systems can help in achieving consistent results.

The SPD system design should also ensure minimal residence time of the oil in the heated zone to prevent thermal degradation, supporting the efficient separation of desired compounds from contaminants.

What’s the Information Request for A Precise Solution?

When requesting a quote for multi-stage short-path distillation units for fish oil Omega-3 concentration and separation, it’s essential to provide detailed information to ensure the equipment is tailored to your specific needs.

As an experienced process equipment supplier, we typically require our customers to fill out a FAQ or questionnaire covering various aspects of their process requirements, project specifics, and preferences. Here are some of the typical questions you might need to answer:

Basic Information

1. Company Name and Contact Information: Who are we speaking with, and how can we get in touch?
2. Project Timeline: When do you need the equipment installed and operational?

Process Specifications

3. Feedstock Characteristics:
   • What is the composition of the fish oil? Is it Triglycerides(TG) form or Ethyl Ester(EE) form or rTG form?
   • What are the expected concentrations of Omega-3 in the feedstock?
   • Volume of fish oil to be processed daily?
4. Desired Product Specifications:
   • What are the target concentrations of Omega-3 in the final product?
   • Are there specific impurities or components that need to be removed or reduced?
   • Desired daily production capacity (e.g., liters or kilograms per day).
5. Operating Conditions:
   • What are the available utilities (e.g., steam, cooling water, chilling water, compressed air, nitrogen)?
   • What are the preferred operating temperatures and pressures, if known?

Equipment and Integration

6. Existing Infrastructure:
   • Do you have existing equipment that the new system needs to integrate with?
   • Is there a specific space or layout requirement for the new equipment?
7. Configuration Preferences:
   • Are there specific requirements for material of construction due to process compatibility or regulations? The common standard configuration is with sanitary stainless steel 304 or 316 for medium contacted parts construction.
   • Do you have a preference specifically for the number of stages in the short path distillation unit?
8. Control and Automation:
   • What level of automation is required (e.g., manual operation, semi-automatic, fully automatic)?
   • Are there specific control systems or software you currently use or prefer?

Safety and Compliance

9. Regulatory Requirements:
   • Are there specific industry or government regulations that the equipment must comply with (e.g., FDA, EMA, GMP)?
10. Safety Features:
    • Are there specific safety features or systems you require (e.g., explosion-proof design, inert atmosphere operation)?

Budget and Financing

11. Budget Range: What is your budget range for this project? we are capable to configure and select the equipment process production line according to your project range and budget level.
12. Financing Needs: Are you seeking financing options for this purchase?

Additional Information

13. Project Goals and Challenges:
    • What are the primary goals for this project (e.g., increase capacity, improve purity, optimal process conditions, process adjustability)?
    • Are there specific challenges or concerns you have regarding this project?
14. Service and Maintenance:
    • What are your expectations regarding service, maintenance, and support post-installation?

What Measures to Guarantee Your Process Performance

As an experienced supplier of process equipment for fish oil Omega-3 concentration and purification, the selection of the appropriate equipment structure and design is paramount for the success of your projects.

The key steps aims at understanding your process requirements, evaluating your specific process conditions, and providing expert guidance based on years of industry experience.

1. Detailed Requirement Gathering

• Understand the Customer’s Goals: We shall start by comprehensively understanding what our customer aims to achieve with the Omega-3 concentration and purification process. This includes desired product specifications, capacity requirements, and compliance needs.
• Analyze Feedstock Characteristics: Obtain detailed information about the fish oil to be processed, including its composition, variability, and any potential challenges it might present during distillation.

2. Process Evaluation and Feasibility Analysis

• Conduct a Feasibility Study: Based on the provided information, we shall evaluate the feasibility of various distillation designs and configurations. This might involve laboratory or pilot-scale testing to understand how different designs affect product quality and yield.
• Simulation and Modeling: We shall use process simulation software to model different distillation scenarios, helping to predict outcomes and optimize the process before any physical equipment is manufactured.

3. Customized Design Proposal

• Tailored Equipment Solutions: We propose equipment designs that are specifically tailored to the customer’s needs. This includes suggesting the number of stages, type of internal components, material of construction, and any auxiliary systems required for optimal operation.
• Energy Efficiency and Sustainability: We shall recommend designs that not only meet the processing requirements but are also energy-efficient and sustainable, considering the entire lifecycle of the equipment.

4. Technical and Commercial Consultation

• Provide Detailed Consultations: We offer in-depth technical consultations to discuss the proposed designs, explaining the rationale behind each recommendation and how it meets the customer’s goals.
• Review Regulations and Compliance: Ensure that the proposed design complies with all relevant industry and safety standards, as well as any specific regulatory requirements the customer must meet.

5. Prototype Testing and Validation

• Pilot Testing: If feasible, we will conduct pilot testing with the proposed equipment design to validate performance under real-world conditions. This helps in identifying any potential issues and making necessary adjustments before finalizing the design.
• Feedback Loop: We will establish a feedback loop with the user throughout the testing phase to ensure that the equipment meets or exceeds their expectations.

6. Education and Training

• Operational Training: We shall provide comprehensive training to the operators on the correct use and maintenance of the equipment, ensuring they are fully prepared to operate the system efficiently and safely.
• Technical Support: We shall offer ongoing technical support to address any operational issues and ensure the equipment continues to perform optimally over its lifespan.

7. Post-Installation Evaluation

• Performance Monitoring: After installation, we shall monitor the equipment’s performance to ensure it meets the expected output, purity, and efficiency metrics.
• Continuous Improvement: We shall be open to making adjustments or providing additional support based on the post-installation performance of the equipment.

How Many Stages of Short Path Distillation Column Shall We Choose?

The number of stages required in a short path distillation (SPD) column for separating Omega-3 fractions to achieve desired product ratios of EPA/DHA depends on several factors.

The selection criteria and determination of the exact number of stages involve a balance of theoretical and practical considerations, influenced by the complexity of the mixture, desired purity, yield targets, and process efficiency.

Here’s a breakdown of the key considerations and criteria for selecting the number of stages:

1. Feed Composition and Desired Product Specifications

• The complexity of the feedstock and the specific concentration targets for EPA and DHA in the product are primary determinants. Higher purity requirements generally necessitate more distillation stages to achieve finer separation of the desired components from the feed mixture.

2. Separation Difficulty

• The relative volatility of the components to be separated affects the number of stages needed. Omega-3 fatty acids, particularly EPA and DHA, might be closely boiling or have similar volatilities, making their separation more challenging and possibly requiring additional stages.

3. Process Efficiency and Recovery Goals

• The desired efficiency of the process and recovery rates of EPA and DHA also influence the stage count. Higher recovery rates and process efficiencies can be achieved with more stages, at the expense of increased capital and operational costs.

4. Theoretical Plates vs. Actual Stages

• Theoretical plates are a concept used in distillation design to represent an idealized stage of vapor-liquid equilibrium. The actual number of stages required may be higher due to inefficiencies in real systems. The design often includes additional stages beyond the minimum theoretical requirement to account for non-idealities and ensure the target separation is achieved.

5. Operational Considerations

• Operating conditions such as temperature, pressure, and the presence of azeotropes can impact the effectiveness of each distillation stage. Lower operating temperatures, as preferred for heat-sensitive products like Omega-3 oils, may require more stages to achieve the same separation efficiency due to reduced relative volatilities.

6. Production Capacity

• For a targeted production capacity, such as 5000 kg of crude oil per day, the design must ensure that the selected number of stages can handle the throughput efficiently without compromising product quality. This involves scaling up from pilot or laboratory data while considering the impact on separation efficiency and product loss.

Determining the Number of Stages

The determination of the exact number of stages required for separating Omega-3 fractions to achieve specific EPA/DHA ratios typically involves simulation and pilot-scale testing.

Process simulation software can model the distillation process, incorporating feed composition, desired product specifications, and operational parameters to estimate the number of theoretical stages needed. Pilot-scale testing validates these simulations and helps refine the design for full-scale production.

For instance, a system designed to produce high-purity EPA and DHA fractions may start with a baseline of 3 stages based on initial assessments but, through simulation and testing, could reveal that 6 or 8 stages are necessary to meet all product and efficiency criteria effectively.

Reference Resources:

https://www.acrossinternational.com/news/post/the-ultimate-guide-of-short-path-distillation

https://www.sciencedirect.com/science/article/abs/pii/S0045653510004236

https://www.goldleaflabs.com/blogs/articles/short-path-distillation-step-by-step-guide-and-sop/

https://aocs.onlinelibrary.wiley.com/doi/10.1007/s11746-010-1571-4

https://www.sulzer.com/-/media/files/products/separation-technology/distillation-and-absorption/technicalarticles/be_smart_about_column_design.pdf?sc_lang=en