- Concentrate EPA+DHA from 30% to 90%+ purity — at low temperature, without thermal degradation, solvents, or oxidation.
- The multi-stage Short Path Distillation Units(SPDU) are capable of enriching up to 60%-74% Omega-3 EPA/DHA PUFA.
- Made to Measure Solution for Liquid-Liquid Separation Technology
- Integrated Solvent Free Process for Separation, Purification, Concentration, Decolorizing, Deodorization.
- Turn-Key Project Solution from Pilot Plant to Industrial Production scale for Thermally Sensitive Materials Separation
- Falling Film Pattern which is compatible with Rotary and Thin Film Evaporators.
Approved, recognized process working performance of 20+ years in marine Omega-3 concentration
Multi-stages SPDU lines applicable for 5–90 TPD plants
Process flow design +end to end engineering+ equipment fabrication+ commissioning+turnkey solution
- In a multi-stage setup, oil flows continuously through a sequential (series) of distillers for fractionation of desired fatty acids.
- Each stage operates under carefully controlled temperature and vacuum gradients to separate different fractions progressively.
- Different concentration products are drawn from different stages of the multi-stage system simultaneously (e.g., lower DHA concentrations from earlier stages, higher concentrations like 36/24 or 33/22 from middle stages (e.g., stages 4,5,6), and DHA-rich fractions from later stages (e.g., 7,8)). This enables the co-production of multiple product fractions, which is far more economical than focusing on a single target concentration.
From crude fish oil de-plastsizers to high-purity EPA/DHA concentrates – complete wiped-film multi stages short path distillation systems with process engineering, installation, and training.
Which Company Has Utilized SPDU
SPDU in Omega-3 Production Lines
- POPs Decontamination: Industrial short-path distillation is highly effective at removing persistent organic pollutants (POPs), such as dioxins and PCBs, from fish oils with minimal loss of Omega-3 content
- Fractionation of Ethyl Esters: SPDU is used for the multi-stage optimization of ω-3 ethyl esters, often operating within temperature windows of 120–140 °C to reach high concentration targets.
- Nutraceutical-Grade Purification: The technology is essential for refining oils (such as anchory or sardines) to meet nutraceutical-grade standards.
- Hybrid Concentration Routes: Many modern facilities pair SPDU with Urea Complexation (UC), using UC for a coarse lift of EPA/DHA levels and SPDU for the final high-purity “polish.
- EPA/DHA Enrichment: Advanced setups can integrate SPDU into flowsheets to elevate EPA/DHA concentrations in the heavy phase of the distillation process.
- In moden fish oil Omega-3 plants, SPDUs are capable to remove the Dioxins and Furans PCBs Mineral Oils and Saturated Hydrocarbons (MOSH) Mineral Oils and Aromatic Hydrocarbons (MOAH) Phthalates Plasticizers and Biphenols Toxaphene Pesticide Residues Polycyclic Aromatic Hydrocarbons (PAH) Peroxides Aldehydes and Carbonyls Free Fatty Acids.
- It is mandatory practice to remove these components before the next step of enrichment and concentrating
Benefits from Two Decades of Process Innovations
Focusing on marine lipids, refined fish oils, and Omega-3 products. utilizes specialized separation and refining techniques to process crude fish oils into high-purity molecular structures. Their technical ability allows them to tailor concentrations rather than just offering rigid, off-the-shelf bulk volumes.
Manages a large-scale refining plant with an annual output of 18,000 tons, including a fish oil storage warehouse and six oil tanks with 23,000-ton capacity
Recognized as a major global source for reliable Omega-3 marine fatty acids and fish oils
Operates an annual production capacity of 8,000 tons, specializing in pure OMEGA-3 fatty acids, polyunsaturated fatty acids (PUFAs), and refined fish oil products
Specializes in high-concentration OMEGA-3 refined fish oil with a state-of-the-art production facility and an annual capacity of 3,000 tons
Integrates a fish oil processing platform (500 tons/year) with EU-GMP pharmaceutical manufacturing for APIs and soft capsules
Why We Use for EPA/DHA Enrichment
Achieving 74% EPA + DHA Purity through Modular Fractionation and Energy-Efficient Engineering
Precision, Scalability, and Purity — Engineered for Omega-3 Excellence
🔬Individual lines handle different cut ranges (light, medium, heavy fractions)
🌡️ Each line operates under unique temperature/vacuum settings
⚙️ Modular system allows maintenance on one line without downtime
⚡ Heat recovery and vacuum balance reduce total energy consumption
Our engineering team designs, fabricates, and commissions complete turnkey solutions — from fish oil pretreatment to final high-purity ethyl ester production.
For Fish Oil Omega-3 Concentration
Molecular distillation, also known as short-path distillation unit(SPDU), is a specialized liquid-liquid separation technology that operates under the principles distinct from traditional distillation which relies on boiling point differences. Instead, it utilizes the variances in the average free path of molecular motion to achieve separation.
When a liquid mixture flows along a heated plate and is warmed, lighter and heavier molecules escape the liquid surface and enter the gas phase. Due to the different free paths, these molecules travel varying distances. If a condenser is appropriately placed, lighter molecules will reach it and condense, while heavier molecules will not, thus achieving separation.
Benefits
- High Purity: Ensures high-purity concentration of Omega-3 fatty acids.
- Low Thermal Stress: Minimizes thermal degradation of sensitive Omega-3 compounds.
- Efficient Separation: Achieves a high degree of separation that surpasses traditional distillation methods.
Omega-3 ethyl esters and other components have different molecular sizes, weights, and intermolecular forces, causing them to exhibit different volatilities. Molecular distillation, operating under high vacuum, reduces the boiling points and enables the more volatile components (possibly the lighter or smaller molecules like some impurities or specific ethyl esters) to evaporate first.
Enhanced Removal of Impurities:
Molecular distillation technology is highly effective in removing unwanted substances, such as Free Fatty Acids (FFAs) and Phthalate Acid Esters (PAEs) during the oil refinement and concentration process. Through precisely controlled distillation conditions, these undesirable components can be removed at lower temperatures, reducing thermal damage to sensitive components like Omega-3 fatty acids.
Improved Oil Quality:
Molecular distillation facilitates the production of highly pure and concentrated fish oil. By selectively removing impurities and unwanted constituents, the resulting oil is of superior quality, with a higher concentration of beneficial Omega-3 fatty acids. The precise control over distillation conditions ensures minimal thermal degradation, preserving the integrity and efficacy of the oil.
Low-Temperature Processing:
The process operates under high vacuum, significantly reducing the boiling points of constituents. This allows for distillation at much lower temperatures, which is crucial for preserving the delicate structure and nutritional profile of Omega-3 fatty acids.
Short Residence Time:
The design of molecular distillation equipment, particularly short-path distillers, ensures a minimal residence time for the oil in the heated zone. This further reduces the risk of thermal degradation, making it an ideal method for concentrating high-quality fish oil.
What is the primary objective of this project?
The goal is to design and implement a new production line to obtain high-quality Omega-3 concentrates (EPA+DHA) up to 60-75% or higher, utilizing specific marine crude fish oil as the primary feedstock.
What is the proposed production capacity?
The system is engineered for a continuous feeding capacity of an average of 10-40 Tons Per Day (TPD) of Triglyceride(TG) form or Ethyl Ester (EE) feedstock (ranging from 24–36 TPD)
What is the starting point for the raw material?
The starting point is typical crude deepsea fish oil or 18/12 EE (ethylated fish oil)
The feedstock must have <1% water content and minimal FFA
What core technology will be used for concentration?
The project utilizes multi-stage Short Path Molecular Distillation (SPDU), typically involving 8 to 10 stages for a continuous, efficient process
Why is SPDU preferred over rectification for food-grade products?
SPDU operates at lower temperatures, which is critical for protecting heat-sensitive unsaturated fats. Rectification columns operate at 20-30°C higher, posing a significant risk of producing trans-fatty acids, which are strictly restricted in food markets
This FAQ represents the essential technical, operational, and commercial discussions regarding the proposed 10-30 TPD Omega-3 concentration plant expansion.
For any further inquiries just feel free to send us your message,
Your project info and contacts will be not disclosed to any third party without your consent.
Achieving consistent enrichment levels of up to 74% EPA and DHA while yielding bioactive ingredients of 68% and beyond requires systematic project planning, experienced process practical expertise, and in favor of a rigorous “Basic Engineering Package” (BEP)
What specific product ratios can be produced?
The system is flexible and can co-produce multiple fractions simultaneously, including 50/10EE, 36/24 EE, 50/20 EE, 33/22 EE, 30/20 EE, 10/40EE and 05/60 EE, etc.
The feed fatty acides profile largely determines the ouput fatty acide ratios.
Is it possible to produce high-DHA products like 20/50 EE from Peruvian oil?
It is highly impractical to produce high-DHA products like 20/50 EE from Peruvian anchovy because it is naturally EPA-dominant. To achieve high DHA levels, feedstocks like Russian herring, tuna, or squid oil are required.
What is the expected yield for standard products?
Based on actual working process technologies, the obtainable yield of saleable product reaches at least 68% or higher.
For example, approximately 3 tons of 18/12 feedstock yields 1 ton of 36/24 EE concentrate
Why is decolorization performed after transesterification?
It is necessary to remove trace amounts of glycerol and monoglycerides resulting from the ester exchange. This process also facilitates the control of trichloropropanol and glycidyl esters
How is oxidation prevented during the process?
Every process is protected for antioxidation using vacuum pumping followed by nitrogen blanketing. The target standard is a Peroxide Value (PV) below 1 meq/kg prior to dispatch.
A molecular distillation system typically consists of a molecular distiller, vacuum pump system, degasser, pressure-temperature-flow control instruments, and storage tanks. The primary devices are the molecular distiller and the vacuum pump system, with the molecular distiller being either of the wiped film type or the centrifugal type.
Evaporators and Condensers:
Operational Process
Driving and Sealing:
Distillation:
The performance of molecular distillation equipment, especially for sensitive applications such as the concentration of Omega-3 in fish oil, is influenced by a myriad of factors. Below are the key factors that have a significant impact on the efficacy and efficiency of molecular distillation processes:
01
Vacuum Levels:
The degree of vacuum within the distillation system directly influences the boiling points of substances, allowing for distillation at lower temperatures. This is crucial for thermally sensitive compounds like Omega-3 fatty acids.
Under high vacuum, the total pressure inside the distillation equipment is significantly lowered, thus affecting how individual components contribute to the vapor phase. This selective volatility helps in separating components based on their ability to exert pressure in the vapor phase, thus separating Omega-3 ethyl esters from other components.
02
Feed Rate:
The rate at which the feedstock is introduced into the distillation system must be optimized. Too high a feed rate can lead to inadequate separation, while too low a rate can result in inefficiencies.
03
Evaporator Temperature:
The temperature of the evaporator needs to be precisely controlled to ensure that the desired compounds vaporize without decomposing. Optimal temperatures vary based on the specific composition of the feedstock.
The temperature gradients are crucial. The kinetic energy of the particles (in this case, the fish oil components) will vary, causing them to move and separate based on their molecular energy levels, facilitated by the high vacuum which reduces collision frequency and allows for easier separation.
04
Condenser Temperature:
The temperature difference between the evaporator and the condenser creates the driving force for distillation. The condenser must be cool enough to effectively condense the vaporized compounds.
05
Wiping System:
In wiped-film and short-path molecular distillation systems, the design and speed of the wiper blades are crucial for creating a uniform thin film of the feedstock, which promotes efficient heat and mass transfer.
06
Distance Between Evaporator and Condenser:
Shorter distances reduce the likelihood of compound degradation due to minimized exposure to heat and lower travel time for the vaporized compounds.
The kinetic theory explains the behavior of particles, particularly gases, in terms of their movements, energy, and interactions. It posits that particles in a warmer part of a system will typically move toward a cooler part until energy equilibrium is reached.
07
System Material:
The materials used in constructing the distillation system should be resistant to corrosion and should not react with the feedstock, especially since high-purity products are often the goal in pharmaceutical and nutraceutical applications.
08
Operational Stability:
Stable operating conditions are essential for consistent performance. Fluctuations in temperature, vacuum, or feed rate can lead to variations in product quality.
09
Design of Distillation Path:
The configuration of the distillation path affects the residence time and the separation efficiency. A well-designed path minimizes pressure drops and ensures adequate contact between the vapor and the condensing surfaces.
10
System Maintenance:
Regular maintenance is vital for ensuring the longevity and performance of molecular distillation equipment. This includes checks for leaks, ensuring vacuum pumps are functioning optimally, and keeping all components clean and free from build-up.
Product Portfolio
Greatwall Process and Control offers a range of high-quality and customizable solutions for the separation and purification of a wide range of biochemical compounds. Our equipment utilizes a short-path distillation process that allows for efficient and precise separation of compounds with low boiling points, while minimizing thermal degradation and cross-contamination.
We offer a variety of configurations and sizes to meet the specific needs of our customers, with options for various materials of construction, feed rates, and control systems. Our portfolio includes both manual, semi-automatic and fully automated systems, as well as options for various process operations.
We pride ourselves on providing reliable, efficient, and cost-effective solutions for industrial molecular distillation applications across a range of industries, including oil, pharmaceuticals, food additives and cosmetic, nutriential, fine chemical and biochemical.
Moreover, we conduct in-house distillation application tests as a service to verify the equipment selection and specifications.
- Lab. scale single stage short path molecular distillation unit
- 0.1 ㎡ heating area
- Industrial scale 8 stage short-path molecular distillation unit
- 6 ㎡ heating areas
- Pilot scale 2 stages short path molecular distillation unit
- 2 stages columns with 0.5m² heating area
- Large-scale short-path molecular distillation unit
- 8 stages columns with 4m² heating areas
Separating with physical technology that cannot be solved by the ordinary separation method
Safe and Environmental Friendly Production Process
- Working under high vacuum conditions of minus 0.1Pa (absolute pressure), the liquid mixture flows along the heating plate and is separated far under the boiling point.
- The greater the molecular weight difference, the greater the molecular free path difference, and the more pure the distillate.
- The higher the vacuum, the greater the free path.
- Short distance between heating and condensing surface with minimum resistance.
- The average free paths of light components are long, thus light molecular matter can reach the built-in condenser and get captured.
- The heavy molecular component has a shorter free path than the distance from the heating and condensing surface, so it can not reach the built-in condenser surface.
- Only in a very short time, the thermal decomposition or polymerization can be minimized to eliminate the damage to the product compounds.
Application Range
Fine Chemistry
Erucyl amide,alcohol, oleamide, glycerides, herbicides, halogenated alkanes, pesticides, silicone oils, waxes, fatty acids, etc.
Oil
Base oil, bright oil, biodisel oil, lubricating oil, vaseline, fir oil, residual tar, waste lubrication oil, etc.
Pharmaceutical
Acyl chloride, amino acid ester, vitamin E, glucose derivative, terpene ester, natural or synthetic vitamin, β-carotene, gingerol, capsicum pigment, etc.
Food and Additive
Monoglycerides, palm oil, tocopherol, fish oil, rice bran oil, fatty acids and their derivatives, dienoic acid, Vegetable oil, diglycerides, lactic acid, linseed oil, conjugated linoleic acid,etc.
Cosmetic & Pesticide
Wool fatty acid, lanol, alkyl glycosides, including algae, roots of plants, extract of capsicum, high fat ester, turmeric essential oil,etc.
Plastic & Environmental Protection
Epoxy resin, epoxidated oil, isocyanate, plasticizer, stabilizer, polyether and polyether polyol,oil emulsion, waste water, etc.
Successful Projects Cases And Equipment References
8 Stages Molecular Distillation Equipment Assembly Unit
It is mandatory to utilize SPDUs to remove these components before the next step of enrichment and concentrating
Eight Stage 6㎡ Evaporation Short Path Molecular Distillation Equipment
Pharmaceutical API and Intermediates Purification and Separation
8 Stages Short Path Distillation Equipment
Colorless and Odorless Oil Get from Deacidification, deodorization, dehydration, decolorization and dewaxing.
Pesticide Raw Material Extraction with Short Path Molecular Distillation Equipment
Assembly Of Concentration Equipment
Specially designed fish oil Omega-3 Fatty Acid Processing Plant, the multi stages short path distillation equipment is a pre-assembled system for concentration and refinement processing of marine fish oil ester for purifying and enriching Omega-3 fractions. The entire system is completed with the lowest possible vacuum level and precise controlling of heating oil temperature for circulation for a short period of processing time. All contacted parts are fabricated with sanitary stainless steel. the complete system meets the GMP requirements.
Behind the Scenes: Crafting Multi-Stage Short Path Distillation Equipment
In this film, we open the doors to our factory floor and invite you to witness the craftsmanship behind our multi-stage short path distillation systems.
These units are not off-the-shelf machines; they are precision-engineered production lines designed to meet the most demanding requirements of fish oil purification and Omega-3 EPA/DHA enrichment, as well as high-value nutraceutical and specialty chemical applications.
Discover how we transform raw steel into sophisticated, multi-stage short path distillation equipment—the very tools that enable industrial production of high-purity Omega-3 oils, nutraceuticals, and specialty chemicals worldwide.
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