Automated low-dead-volume hygienic melting system for solid edible fat blocks

Overview

The automated low-dead-volume hygienic melting system is designed to efficiently melt solid edible fat blocks while maintaining product quality and hygiene. This system employs a combination of staged indirect heating, friction-assisted melting, and a scraped surface heat exchanger to achieve uniform melting. By pre-conditioning the fat blocks near their melting point and using shear-assisted phase change, the solution ensures temperature stability and prevents localized overheating. The plug-flow design minimizes dead volume and facilitates effective lot segregation, while an inline mechanical separation module removes plastic packaging fragments without recirculation, enhancing product purity.

Technical specifications

Key features:

• Staged Indirect Heating: Gently brings fat blocks to near melting temperatures (~10 °C to ~80 °C) without overheating.
• Friction-Assisted Melting: Uses mechanical shear to aid phase change and maintain uniform temperature.
• Scraped Surface Heat Exchanger: Prevents fouling and hot spots, ensuring consistent product quality.
• Plug-Flow Design: Eliminates need for recirculation tanks, reducing dead volume to ≤250 L at 3 MT/h.
• Inline Plastic Separation: Mechanically removes incidental plastic fragments, ensuring product cleanliness.
• Scalability: System is scalable to 5 MT/h, with a compact and modular design.
• Materials: Constructed from food-grade SS316L, fully CIP/water-washable.

Technology readiness level

Currently at TRL 6, the system has been tested in a relevant environment with a pilot-scale system. Future steps include scaling to a 3 MT/h industrial configuration, validating performance under production conditions, and refining operational parameters for energy efficiency and product consistency.