P-Jel Edible Oil Filtration System EFS series

General

The common problems faced in production of fried food products are the gradual quality deterioration of edible frying oil because during continuous and prolonged deep frying process, Free Fatty Acid value and Oxidation index increases inevitably, and which in turn affects the quality of the final fried products’ appearance, taste and its shelf life.

All these results in shorter life span of oil usage because of premature ageing, higher disposal rate of used oil, unnecessary logistics, additional wastage of man hour and of course, higher production cost.

These has been a persistent challenge to many engineering & food technician experts, Quality Controller, Cost management, Production Controller, etc. in the fried food industries to solve these problems as the present systems and methods available could only achieved limited effectiveness and success.

Introduction

To solve these problems, P-Jel Asia Pte Ltd, a company based in Singapore, works in close consultation with various engineering organizations and research institutes, and further making references to the working principles of advance filtration system and studies raised by experts in this field, had resulted in the manufacturing of a unique and high efficiency P-Jel Edible Oil Filtration System (EFS) series.

P-Jel Edible Oil Filtration System EFS series is a self-containing power packed unit available in portable, mobile or grounded version, and designed with a 1 stage to 5 stages of filtration process to cater for different rate and volume of oil for filtration needs, all efficiently fitted into one compact integral high grade stainless steel housing unit. P-Jel’s EFS equipment would also be tailored to integrate with customers’ existing production line.

Edible Oil Filtration System Main Components

P-Jel Edible Oil Filtration Equipment series main components are ;

High performance precision Pump directly coupled to a heavy duty Electric Motor,
Pre-Filtration Screen and/or Tank (to remove large solid carbonized crumbs),
Safety Strainer, Single and/or Double Mesh Filter Screen (for filtered oil passage),
Enclosed Vat Oil Reservoir Tank with cover (to prevent exposure to air oxidation),
Cooling Fan (to ventilate motor & pump compartment),
Electrical Control Panel, Vacuum Gauges (to monitor Vat’s pressure and flow),
Auto Shut-Down safety feature available for larger capacity model EFS-30, EFS-80 & EFS-200,
Discharge Hose/Lance c/w Nozzle, Control Switch and insulated handle (for filtered oil transfer),
Lockable Castor for Portable and Mobile version, Stabilizer Mounting for Grounded version.
Filter Compound & Filter Sheet – filtration components used together with the above.

The main Housing, Pre-Filtration Tank, Filtration Tray, Screen, Discharge Lance and Control Panel are fabricated of high grade Stainless Steel materials in compliance with Food manufacturing and service industries. Every stainless steel components had been grinded down to removed any sharp edges and polished to mirror finishing to give a hygiene, clean and work of art classy image. Maintenance and operation is simple and fuss free.

Common Problems Encountered When Deep Frying Food:

All Fresh edible oil quality will be affected by deterioration the moment it is exposed to environment and deep frying works begin because, during deep frying process ester hydrolysis (various chemical reaction) inevitable takes place under various frying environment and conditions.

During deep frying, the products concerned (eg. nugget, doughnut, meat, fish, chips, crackers, etc.) will contaminate the edible oil when seasoning coating, flour, water, fats, oil, food crumbs, moisture, etc. is disseminated, accumulated and circulated in the hot frying oil. These liquid and solid impurities contaminants together with prolonged high temperature heating of frying oil and with added oxidation from exposure to atmosphere expedite ageing of frying oil.

Under such circumstances, ester hydrolysis (chemical reaction with liquid and solid impurities contamination) is initiated, Free Fatty Acid indexes level increases and various Oxidation takes place. As a result of sub-micron carbonized food particles & polymers gradual built up (contamination) and in addition to exposure to air. When these problem is left untreated, frying oil degradation process is accelerated, the frying oil will turns dark, thicken, smells funny, foamy and smoky from impure liquid and carbonized particles contaminations.

Also, gradual built up of saturated fats, oil, carbonized particles and other contaminants would form along side walls and heaters of frying equipment, heat exchanger, etc. These would result in final products’ appearance, taste, smell and shelf life being affected. Fryers’ efficiency and performance would also be affected. All these are translated into higher operation cost as it means additional and more regular maintenance, unnecessary downtime, shorter life span usage of frying oil, regular disposal, high wastage, etc.

Filtration System Working Principle:

P-Jel Edible Oil Filtration Equipment treats the contaminated frying oil by way of its unique system.

Used and contaminated deep frying oil is first transfer from fryer into Filtration equipment’s upper holding tank where it is suck downward by a vacuum pump for filtration processes.
the contaminated frying oil enters its first phase filtration by passing through the a Pre-Filtration Tray or Pre-Filtration Tank (depending on the model used) to remove all large size carbonized solids.
The filtered oil is subsequently filter through our second phase EOFC Filter Compound. This food grade Filter Compound which is fully tested, analyzed and in full compliance with Singapore Food Regulation, is specially formulated mainly of silicon oxide together with other minor oxides. Its surfaces reacted actively in entrapping and absorbing sticky liquid and smaller solid impurities from contaminated frying oil.
Our final phase filtration of EOFS Micron Filter Sheet with its perfected porosity removes remaining sub-micron particles of up to 0.5 micron size and above.
The whole filtration process is done within the vacuum chamber to prevent oxidation of oil.
Our high performance precision pump, Filter Compound and Micron Filter Sheet are specially manufactured and formulated respectively, for handling and filtering frying oil at 120 Deg. C to 200 Deg. C condition.
Contaminated oil is suck through the three phases of filtration mentioned above by means of a high performance vacuum pump directly coupled to a heavy-duty motor seated below the main housing. Clean and Filtered oil is then collected in an enclosed vat reservoir within the lower housing.
The filtered oil is then transferred back to storage tank (if frying oil is needed for later usage) or fryer (if frying oil is needed for immediate use).

Filtration Working Theories:

Studies and theories raised by experts is that ester hydrolysis centralized and reacted actively to the liquid and suspended particles (both large and micron size) impurities contaminants disseminated into edible oil from deep frying products. By removing and filtering out these suspended contaminants, ester hydrolysis will have nothing to center on and react to.

P-JEL Edible Oil Filtration System is manufactured based on this theory to treat these problems at an early stage in order to achieve below advantages;

Advantages :

Free Fatty Acid and Oxidation levels are retarded preventing early stage breakdown of frying oil.
Edible oil usage duration extended by folds. Oil wastage reduced tremendously.
Improve frying environment. Improvement in final product taste & appearance. Product shelf life extended.
Reducing logistic handling of regular disposal of oil and rejected products.
Better management and control on cost, production and quality.
Tremendous savings and increase profit margins.
Simple and easy operation and maintenance. Safe, efficient and reliable.
No need experience operator. One man operation needs only 3 ~ 15 minutes (depending on size of Filtration System) for replacing Filtration Compound and Filter Sheet between 4 ~ 24 hours (depending on frying products and production shift change).

Tell us how we can assist you by calling Edwin
(Mobile) +65-90622216, Office +65 67570483, Fax +65 67570485,
email: enquiry@pjelasia.com.sg
or write to us at 20 Woodlands Link, # 06 - 26, Woodlands East Industrial Estate, Singapore 738733.

You can also view our products and services in Singapore Industrial Sourcing Guide 2007/8.