What Is DMG?
Distilled Monoglyceride, short as DMG, also called Distilled Glycerol Monostearate, is produced by an esterification reaction containing C16-C18 long-chain fatty acids with glycerine, and further refined through multi-stage molecular distillation equipment.
It can also be made from refined hydrogenated palm oil esterified with top glycerol and concentrated by multi-stage molecular distillation equipment.
Molecularly Distilled Monostearic Fatty Acid Glycerides: i.e. molecularly distilled monoglycerides, abbreviated as monoglycerides (MG) are clean white powder or small cylindrical solids, with content above 90%.
Its molecular formula is C21H42O4. Structural formula: molecular weight 358.57.
DMG is a non-ionic surfactant and has both hydrophilic and lipophilic genes, it has various functions such as wetting, emulsifying, and foaming, etc.
In addition to emulsification, it also has the functions of sedimentation, deposition, antioxidant and fatty acid coagulation control.
The hydrophilic and lipophilic balance value (HLB value for short) of 90% monoglyceride is 3.9-5.3. It is a multi-purpose emulsifier and an internationally recognized safe food additive with unlimited dosage in FDA.
How To Produce DMG?
Hydrogenated fats and glycerol are used in transesterification reaction to produce mono- and di- fatty acid glycerides, in which the content of monoglycerides is 40% to 50%, and the content of monoglycerides can be increased to 90% to 96% by molecular distillation.
- Selection Of Raw Materials
The raw materials for the production of monoglycerides mainly include glycerol and fatty acids.
Glycerol is a colourless, odourless liquid that can be extracted from animal and plant fats and oils.
The sources of fatty acids include vegetable fats and oils, animal fats and oils and so on.
When selecting raw materials, factors such as their purity, price and availability need to be considered.
- Reaction Conditions
The synthesis process of monoglycerides is generally achieved by esterification, a reaction between glycerol and a fatty acid in the presence of a catalyst.
Common catalysts are sulphuric acid, hydrochloric acid and enzymes.
Conditions such as temperature, pressure and reaction time have a great influence on the rate of the esterification reaction and the quality of the output product.
Generally, the reaction temperature is between 120-180°C and the reaction time is about 2-6 hours.
- Process Flow
The process for the production of DMG usually includes steps such as esterification reaction, neutralization, dehydration, concentration and purification.
Esterification: Glycerol and fatty acids are mixed in a certain proportion and a catalyst is added to carry out the esterification reaction. The temperature and reaction time should be controlled to ensure that the reaction is carried out completely.
Neutralization reaction: a certain amount of acid is generated after the esterification reaction, which needs to be neutralized in order to meet the product criteria. The neutralization reaction is usually carried out using an alkaline substance such as food grade sodium hydroxide solution, which neutralizes the acidic substance into a neutral one. Sodium fatty acids, or saponins, are generated and then separated from the oil in the process.
Dehydration: After the neutralization reaction, a certain amount of water will present in the product. So the dehydration process is required in order to improve the purity and stability of monoglycerides. The dehydration process uses methods such as distillation or membrane separation to remove water from the product.
Quality Control of Products: In the production process of monoglycerides, product quality shall be strictly controlled. It mainly includes the testing of esterification rate, ester value, acid value, moisture content and other indexes.
Esterification rate is an important index to evaluate the degree of esterification reaction, ester value is an index to evaluate the purity of monoglyceride, and acid value is an index to evaluate the product quality.
The product obtained by chemical synthesis contains a mixture of monoglycerides, diglycerides, neutral oils and fatty acids, of which the monoglyceride content is about 40% to 60%. In order to obtain high purity monoglycerides, with a purity of more than 90 per cent, the mixture must be separated and purified efficiently.
Short Path Molecular Distillation (SPMD) is currently the only industrialized and effective separation process, which basically comprises two processes, removal of light components and evaporation of monoglycerides.
Alternatively, solvent crystallization, adsorption, ion exchange and supercritical fluid extraction can be used for further separation. But the production cost will be much higher than short path molecular distillation.
In this article, we will explore how cutting-edge Short Path Molecular Distillation Equipment can transform DMG production. Discover the unparalleled efficiency, purity, and sustainability benefits of this advanced technology.
At Greatwall Process And Control(Wuxi) Co., Ltd., we are passionate about providing actionable solutions that empower your DMG production process, enhancing your productivity and product quality.
Your process requirements demand precision and efficiency, especially when concentrating monoglycerides using short-path molecular distillation. Understanding the equipment structure and working conditions is critical for achieving high concentration and purification. Here’s a comprehensive breakdown:
Equipment Structure and Working Conditions:
- Vacuum System:
- Comprising mechanical vacuum pumps and a two-stage cold trap in series.
- First-stage evaporation surface pressure ≤ 150 Pa.
- Second-stage evaporation surface pressure ≤ 100 Pa.
- Third-stage evaporation surface pressure ≤ 0.5 Pa.
- Condensers are cooled using chilled water.
- Thermal Oil System:
- Heating on the final stage evaporation surface, with distillation temperatures ≥ 200°C.
- Thermal oil is used to heat the evaporation surface, and electric heating of the thermal oil facilitates precise temperature control.
- Material Transport System:
- Utilizes metered feeding with insulation required between stages for both input and output.
- The feeding pump is a plunger-type metering pump, and the input/output pumps between stages are helical gear pumps (cycloidal gear pumps) equipped with jackets.
- Steam System:
- Supplies heat for the second stage of molecular distillation.
- Steam pressure within the jacket ranges between 0.1-0.2 MPa.
- Second-stage steam pressure ranges between 0.6-0.7 MPa with temperatures of 160-175°C.
- Hot Water System:
- One system is maintained at 60°C for condensing fatty acids and low carbon chain esters in the second stage.
- Another system at 70°C is used for condensing monoglycerides, both equipped with temperature control devices.
- Automatic Control and Electrical System:
- Integrates control parts and actuators.
- Second and third-stage molecular distillation main bodies and auxiliary equipment are unified.
- Vacuum adjustments are made in response to material changes and feed rates, adapting temperature and flow to maintain fixed pressure under normal circumstances.
- Storage tanks are equipped with continuous level indicators and upper/lower limit signals to control actuators.
- The thermal oil system includes an oil shortage alarm, and the hot water system is equipped with a water shortage alarm.
By understanding and leveraging the intricacies of each system, your monoglyceride concentration process can reach new heights of efficiency and purity.
Unmatched Efficiency and Purity
SPMD is a specialized distillation technique that reduces the residence time and precise temperature control of the material during the distillation process, which helps minimize thermal degradation and ensures superior purity of the desired product of DMG.
- Short Path Distillation Mode
In traditional distillation processes, the material spends a considerable amount of time in the heated zone, leading to potential thermal degradation and decomposition of heat-sensitive compounds.
SPMD, on the other hand, combines short evaporator path, low pressure, and efficient heat transfer ensures that the residence time of the material in the high-temperature zone is minimized, typically with a distance of a few centimeters, which significantly reduces the residence time of the material in the heated zone.
As a result, the material quickly moves through the system, the exposure to high temperatures is minimized thus reducing the likelihood of thermal degradation.
- Low Pressure and Temperature
SPMD operates under high vacuum conditions maximum to minus 0.1 Pa, which lowers the boiling point of the components being distilled.
By distilling at lower temperatures and pressures, the risk of thermal damage to the sensitive compounds is reduced, as they are subjected to milder processing conditions.
SPMD systems are specially designed to achieve efficient heat transfer between the heating surface and condensing surface. This allows for rapid evaporation and condensation of the volatile components, further reducing the time the material spends in the heated zone.
- High Purity Product
As a result of the short residence time and gentle separation, SPMD can produce a high-purity product with efficient control conditions. With reduced thermal degradation, the final product maintains its integrity and purity, making it suitable for sensitive applications in pharmaceuticals, nutraceuticals, and other high-value products.
The distillation process conditions can be efficiently optimized to ensure high product purity by reducing the residence time, minimizing thermal degradation, and maintaining the quality of heat-sensitive DMG compounds.
- Optimal Boiling Point
DMG has a specific boiling point at which it vaporizes and can be separated from other components during the distillation process. Precise temperature control ensures that the distillation system consistently operate at the optimal temperature, where DMG vaporizes efficiently while minimizing the vaporization of other unwanted components.
By maintaining the temperature at the optimal point, the focus remains on efficient separation, leading to a reliable and repeatable concentration of DMG with fewer impurities.
Many industries have strict purity standards for DMG, especially in food and beverage, pharmaceutical and nutraceutical applications. Precise temperature control allows manufacturers to consistently produce DMG that meets or exceeds specific industry standards, making the product more valuable and reliable in the market.
Streamlined Operation and Automated Controls
User-friendly controls and automation are features in DMG production equipment, which simplify the entire manufacturing process, making it more efficient, consistent, and less reliant on highly specialized operator expertise.
- Intuitive Interface
The equipment is completed with an easy-to-navigate and intuitive user interface. Operators can quickly understand the system’s functionalities and access various settings with needed in-depth technical knowledge.
The pre-programmed settings are for standard DMG production processes. These settings can be optimized for efficiency and quality, allowing operators to initiate the production process with a few simple selections.
- Automated Process Sequences
Automation streamlines the entire production process by automating various steps, such as heating, feeding, pressure control, vacuum control, distillation and material transfering. Operators can initiate these sequences with minimal manual intervention, reducing the risk of errors and variations in the final product.
- Real-time Monitoring and Control
The automation system includes real-time monitoring of critical parameters, including heating temperature, vacuum degree, rotation speed and flow rates. The system can automatically adjust these parameters as needed to maintain optimal conditions for DMG production, ensuring consistent quality.
Operators are notified when any deviations from the desired conditions. Alarms help operators take prompt action to address issues and prevent production delays or product quality concerns.
- Safety Features
The design of automation program include built-in safety mechanisms to protect both the equipment and operators from potential hazards. It includes automated shut-off functions in case of abnormal conditions.
Automated processes minimize the reliance on manual intervention, reducing the risk of human errors that can occur during processes. This leads to more reliable and consistent production outcomes.
- Data Logging and Reporting
The program has data logging capabilities to capture key process data during production. These informations will be important for process analysis, quality control, and process optimization, ensuring continuous improvement of the production process.
Flexibility and Scalability
The modular and scalable nature of SPMD Equipment offers significant flexibility in adjusting capacity and throughput to meet varying demand levels.
- Modularity & Expandability
SPMD equipment is designed with modular components that can be added or removed to customize the system’s process configuration. These combined modules include evaporators, transfer pumps, chiller, feed vessels, heater, vacuum pumps, and storage tanks.
The modular design allows for easy expansion of the capacity by adding additional modules or increasing the size of existing . This enables the equipment to handle higher volumes and accommodate growing production needs.
The operator can adjust various parameters, such as feed rate, vacuum level, and temperature settings. By fine-tuning these parameters, the equipment’s performance can be optimized for different throughput levels.
- Interchangeable Components
Our SPMD equipment features interchangeable components that can be switched out to adapt to specific applications or production requirements.
For example, thin film evaporators can be completed with SPMD for degumming, dehydration, desolvation and preheating treatment, different types of condensers can be used for better heat exchanging based on the characteristics of the feed material.
In some cases, modular SPMD equipment can be operated in parallel, allowing multiple units to work simultaneously. This parallel processing capability increases throughput and production capacity to handle higher process flow levels.
- Energy Efficiency & Cost-Effectiveness
Scaling up or down the equipment to match demand levels helps optimize energy consumption. When production requirements are lower, operators can use a smaller configuration, resulting in energy savings.
The scalability of SPMD equipment means that manufacturers can invest in a system that meets their current demand levels and gradually expand it as their business grows. This approach can lead to better resource utilization and cost-effectiveness.
Scalable equipment ensures that manufacturers are prepared to meet future increases in demand without the need for significant capital investments in new equipment.
- Sustainable and Eco-Friendly Solutions
At Greatwall Process and Control (Wuxi) Co., Ltd., we are committed to promoting sustainable practices in the processing industry. Our short path molecular distillation equipment is engineered to minimize energy consumption and reduce waste generation.
- Dedicated Support and Expertise
We value our customers’ success and are dedicated to providing exceptional customer support. Our team of experienced engineers and technical experts is available to assist you throughout the installation, commissioning, and maintenance phases of your short path molecular distillation equipment. With our assistance, you can maximize the potential of your DMG production process.
Conclusion:
Try to select proper Distilled Monoglyceride (DMG) production process with our cutting-edge short path molecular distillation equipment.
We combine advanced technology, unmatched efficiency, and top-tier support to empower your manufacturing capabilities.
Contact us today to learn more about how we can take your DMG production to the next level.
Reference site:
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7010209/
https://www.sms-vt.com/industries/oils-fats/monoglyceride-distillation
https://pubmed.ncbi.nlm.nih.gov/19862491/
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6582132/
http://www.australianoilseeds.com/__data/assets/pdf_file/0012/7005/fabricius,_rainer_00396.PDF
