• Multi-stages Short Path Distillation Process is capable to obtain 60%-70% Omega-3 EPA/DHA ethyl ester
  • 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 for Thermally Sensitive Materials Separation
  • Falling Film Pattern which is compatible with Rotary and Thin Film Evaporators.

What Is Short-Path Molecular Distillation Equipment?

For Fish Oil Omega-3 Concentration

Molecular distillation, also known as short-path distillation, 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.

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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.

Why Use Molecular Distillation for Fish Oil Concentration?

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.

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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.

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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.

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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.

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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.

How to Use Molecular Distillation Equipment for Fish Oil Omega-3 Concentration

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:

Depending on the system, the evaporator and condenser can be internal or external. The design ensures close proximity between the two to enhance the distillation process.

Operational Process

Feeding: The fish oil is introduced into the molecular distillation system. Heating: The oil is heated under a vacuum to cause evaporation. Lighter components, such as Omega-3 fatty acids, evaporate while heavier impurities remain. Distillation: The evaporated Omega-3 vapors travel towards the condenser. Due to the short distance and high vacuum, the separation is efficient, and thermal decomposition is minimized.
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Driving and Sealing:

The driving mechanism is designed according to the material properties, scraper type, and rotation speed. Double-ended and mechanical seals are typically used, with magnetic fluid seals considered for ensuring high vacuum conditions.The condenser is placed close to the evaporator, generally within 20 cm, or even as close as 5 cm for higher requirements.

Distillation:

The evaporated Omega-3 vapors travel towards the condenser. Due to the short distance and high vacuum, the separation is efficient, and thermal decomposition is minimized. Condensation and Collection: The vapors condense on the cooling surface of the condenser and are collected as a concentrated fish oil product rich in Omega-3.
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Factors Influencing Molecular Distillation Equipment Performance.

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

 

short path distillation equipment assembly
  • Pilot scale 2 stages short path molecular distillation unit
  • 2 stages columns with 0.5m² heating area
  • Large-scale short-path molecular distillation unit
  • 4 stages columns with 5m² 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 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

short path distillation systems greatwall process and control

6 Stages Molecular Distillation Assembly Unit

Herbal/Plant Oil Extracts Purification and Separation

2 Stages Short Path Distillation Assembly Unit

removal of plasticizer with advanced process technology

2 Stages Molecular Distillation Equipment Assembly Unit

Vitamin E Concentration and Purification

Single Stage 4㎡ Evaporation Short Path Molecular Distillation Equipment

Lactic Acid Dissolvent Decolorization

6M ²+4m² Molecular Distillation Equipment Assembly Units

Isooctanoate Deacidification Decolorization Purification up to 97%.

Three Stages Short Path Molecular Distillation 

short path distillation equipment assembly
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 Crude Fish Oil Omega 3 Fatty Acid 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 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.

Testimonial

Johan Wemundstad
Johan WemundstadChief Engineer
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we have been working with GPC for over 6 years, and their reply was always quick and mostly can complete our projects with what we wanted.
Dylan Westland
Dylan WestlandProject Manager
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It was a pleasure working with the Greatwall company team and the installers were just in time to finish. They redesigned the complete system to fit the space, optimized the system, and add some functions. They are quick to response to the inquiry.
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On Site Installation
Process Flow Discussion and Training of Operation on Equipment
On Site Commissioning and Start Up
Continuous Operation and Guidance Until Obtain Qualified Product.
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