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Healthy Table Spread from Algae

Healthy Table Spread from Algae. Team Alpha. Travis Dallas Eric Graves Joaquin Martinez Chris McNinch Ramune Otterson Meskyte Charu Saini. Crypthecodinium Cohnii. Design Project Deliverables. Design Basis Block Flow Diagram Process Flow Diagram Material and Energy Balances

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Healthy Table Spread from Algae

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  1. Healthy Table Spread from Algae Team Alpha Travis Dallas Eric Graves Joaquin Martinez Chris McNinch Ramune Otterson Meskyte Charu Saini Crypthecodinium Cohnii

  2. Design Project Deliverables Design Basis Block Flow Diagram Process Flow Diagram Material and Energy Balances Calculations Annotated Equipment List Economic Evaluation Factored from Equipment Cost Utilities 9. Conceptual Control Scheme Major Equipment Layout Distribution and End Constrains Review Applicable Standards Project Communication File Information Sources and References

  3. Thermal Sterilization will be conducted at 121°C for 1 hour Shell and tube heat exchangers will be used for continuous sterilization with steam Medium components will be mixed and sterilized Sterilization

  4. Fermentor Mass Balance Inlet Material Flow • Basis: Batch Fermentor with 92,400 Liters of fermentation broth • Inocculum of 7,000 Liters of seed batch with c cohnii concentration of 20 g dwcells/L • 93 hours required per batch • Aerated to 20% Dissolved Oxygen Saturation

  5. Fermentor Energy Balance • Fermentation is exothermic and cooling water is required to keep the broth at 27°C. • Fermentor is constructed out of stainless steel with an area of 149.1 sq meters.

  6. FromAlgae Oil to Table Spread Though the table spread market is shrinking, the health food market is increasing at an incredible rate AlphaAlgae Healthy Table Spread will have zero trans-fats, zero animal ingredients (vegan), and no dairy components (kosher), allowing for it to attract a very large group of consumers It will be assumed that AlphaAlgae will take 1 % of the table spread market the first year, and will increase every year afterwards.

  7. Table Spread Production First, the oil phase and the water phase must be prepared. The oil phase consists of refined, zero trans fat oil mixture, the DHA-rich algae oil, and oil-soluble flavors, golden color, and lecithin. The water phase consists of purified water and sea salt, used for both flavor and as a preservative. These two phases are mixed together in an emulsion tank with a temperature around 100 °F. A two-tank system is called a “flip flop” system. When one tank is emulsifying, the other tank is undergoing preparations. The emulsification then undergoes pasteurization to both kill microbes and to ensure a consistent temperature throughout the spread This is followed by cooling and crystallization, creating the final spread product The spread is then stored, ready for transit.

  8. Example of a Table Spread Production Line:

  9. Example Process Flow Diagram of Table Spread Production Line

  10. What is in Each Tub Of Table Spread? 11.3 grams of algae oil (4.6 grams DHA) 329.3 grams zero-trans fat oil mixture (interesterfied hardstock, palm, coconut, liquid oil) 75.7252 grams water 6.058 grams natural sea salt .852 grams natural soy lecithin 8452.52 μg beta-carotene (vitamin A and color) 2 ppm diacetyl (butter flavor) 2.13 grams mono and diglycerides 0.426 grams sorbic acid 35.2188 μg ergocalciferol (vitamin D)

  11. Production Rates of AlphaAlgae Table Spread: 10.4 million tubs of butter / year 4883.68 tons of table spread / year 0.822168 tons of table spread / hour lbs / batch tubs / batch batch / day

  12. Table Spread Marketing Analysis Table spreads enjoy a market size of around 5.2 billion dollars / year A spread with 1 % of the market would sell around 52 million dollars / year Sales straight from the plant are around 35 % of the selling price at the market For the first year, our total table spread sales will then be around 18.2 million dollars Health food market is increasing very rapidly This increase will allow for the market share of AlphaAlgae Healthy Spread to increase quickly

  13. Market Financial Analysis(Based on Whole Foods Market Analysis)

  14. Soybean Oil (SBO) 781.39 tons SBO Hardfat (Cargill) 2993.72 tons crude SBO (Cargill) at $867.40/ton

  15. Refining Crude SBO Degumming(removal of phospholipids) Mix with water and H3PO4 Forms a gum, and then centrifuge out Removal of free fatty acids Use NaOH and NaCO3 to form soluble in water salts, removed by centrifuge Rinse with hot water to remove soapstock, centrifuge again Soapstock– add H2SO4 make feedstock for chickens Bleaching – Filtering with both a Fuller’s Earth filter and activated carbon filter Deodorization Steam distillation under high vacuum and 250-260°F Cooled under vacuum

  16. Interesterification Mixing hardfat with refined SBO Using 99% pure Sodium methoxide at 0.4% wt under vacuum at 100°C Stirring 500rpm for 20 minutes Termination Add DI and citric acid Wash with DI to remove soap Dried at 110°C for 30 minutes

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