Healthy Table Spread from Algae

Team Alpha

Travis DallasEric GravesJoaquin MartinezChris McNinchRamune Otterson MeskyteCharu Saini

Crypthecodinium Cohnii

Design Project Deliverables1. Design Basis2. Block Flow Diagram3. Process Flow Diagram4. Material and Energy

Balances5. Calculations6. Annotated Equipment

List7. Economic Evaluation

Factored from Equipment Cost

8. Utilities

9. Conceptual Control Scheme

10. Major Equipment Layout11. Distribution and End12. Constrains Review13. Applicable Standards14. Project Communication

File15. Information Sources and

References

Sterilization

• 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

Fermentor Mass Balance• 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

Inlet Material Flow

Ton (US) Liters

Glucose Used per Batch 12.27 5058

Yeast Used per Batch 1.67 690

Sea Salt Used per Batch 4.45

30% Silicon Anti-foam 1.86 1540

Glucanex 0.10

Water 92.82 85112

Initial Algae Biomass 0.02

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.

Metabolic Heat Evolution (kJ) 49,219,622

Cooling Water Required (L) 1,308,024

From Algae 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.

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.

Example of a Table Spread Production Line:

Example Process Flow Diagram of Table Spread Production Line

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)

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

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

Market Financial Analysis(Based on Whole Foods Market Analysis)

Growth Rate

Net Income (YTD vs last YTD) 3.7%

Sales (5-year Annual Avg) 15.75%

Profit Margins

Net Profit Margin (last year) 3.1%

5 Year Net Profit Margin (5 year Avg) 2.4%

Financial Conditions

Debt/Equity Ration 0.36

Investment Returns

Return on Equity (5 year Avg) 10.8%

Return on Assets (5 year Avg) 6.0%

Return on Capital (5year Avg) 7.6%

Soybean Oil (SBO)•781.39 tons SBO Hardfat (Cargill)•2993.72 tons crude SBO (Cargill) at

$867.40/ton

Refining Crude SBO1. Degumming(removal of phospholipids)

• Mix with water and H3PO4

• Forms a gum, and then centrifuge out

2. 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

3. Bleaching – Filtering with both a Fuller’s Earth filter and activated carbon filter

4. Deodorization• Steam distillation under high vacuum and 250-260°F• Cooled under vacuum

InteresterificationMixing hardfat with refined SBOUsing 99% pure Sodium methoxide at 0.4% wt under vacuum at 100°CStirring 500rpm for 20 minutesTermination

• Add DI and citric acid• Wash with DI to remove soap• Dried at 110°C for 30 minutes