margarine Pilot Plant
THE POLARON MARGARINE PILOT PLANT
FOR MARGARINE AND SHORTENING
In a competitive and fast-moving market, the ability to test, refine, and launch new margarine and fat-based products quickly is essential. The Polaron Margarine Pilot Plant is designed to support efficient, small-scale production trials, helping you accelerate R&D, optimise recipes, and bring new products to market faster. Whether you’re experimenting with alternative oils, adjusting emulsifier systems, or fine-tuning product texture, the pilot plant gives you the flexibility to explore new formulations without the high costs and risks of full-scale production.
Scalable R&D for fat-based products
The Polaron Margarine Pilot Plant is a complete, small-scale processing solution for R&D and innovation in fat-based products. Designed to help you develop, test, and fine-tune margarine and shortening recipes with confidence, it offers the flexibility and control needed for rapid experimentation with minimal raw material use, making it ideal for cost-effective product innovation, optimisation, and market testing.
Built on Polaron technology
At the core of the pilot plant is the Polaron pilot SSHE – a compact tubular scraped surface heat exchanger available with up to four processing cylinders on a stainless steel frame. Designed for direct cooling with CO₂ (R744) or NH₃ (R717), it operates at working pressures of up to 120 bar, mirroring the capabilities of full-scale production lines to ensure reliable, scalable results.
The pilot plant also includes a high-pressure pump and a pilot pin rotor machine, both rated for 120 bar. Pin rotor cylinders are modular and available in different volumes, allowing tailored texture development for a wide range of fat-based formulations.
Materials
All product contacting components are made from AISI 316 stainless steel or better materials to ensure optimal hygiene and corrosion resistance. The process cylinder features a carbon steel body with a hard chromium-plated surface for excellent heat transfer and durability, while the tungsten carbide seal faces provide exceptional wear protection and long service life.
Easy scale up
The Polaron Pilot Plant is designed to replicate full-scale production conditions, ensuring a smooth and reliable transition from development to industrial manufacturing. The system can be configured with 1-4 cooling systems, allowing precise control of capacity and process parameters while mirroring the design and performance of full production lines. This scalable setup makes it easy to test new recipes, optimize formulations, and validate process conditions with results that directly translate to large-scale operation. Engineers can confidently move from pilot trials to production with minimal adjustment, saving both time and resources.
Scraper system
The Polaron scraper mechanism provides continuous renewal of the heat transfer surface, maintaining high efficiency. The scraper blades are easily replaceable and are available in a range of materials including stainless steel and PEEK allowing optimal performance for different product characteristics, operating temperatures, and wear requirements.
Hygienic design
All product-contact parts are made from food-grade stainless steel with smooth, polished surfaces that minimize product buildup and bacterial growth. The design follows health and safety requirements of Food and Contact Material Regulation (EC) 1935/2004 and FDA guidelines, ensuring compliance with the highest hygienic standards. The closed system eliminates external contamination and supports full CIP cleaning
Process flexibility
With fully adjustable scraper speed, cooling capacity, and product flow rate Polaron Pilot Plant easily adapts to different recipes and viscosities. Whether used for continuous crystallization, pasteurization, or controlled cooling, it delivers consistent results across a wide range of product types. Modular design and process cylinder configurations between 1-4 process cylinders allow for simple scaling or integration into existing lines. The modular design also allows for a fully customizable design with the addition of units like resting tube, homogenizer and emulsion preparation.
BENEFITS OF THE POLARON MARGARINE PILOT PLANT
FLEXIBLE, SMALL-SCALE PRODUCTION
Test and optimise recipes with reduced use of ingredients, energy, and time. The pilot plant is perfect for R&D teams focused on agility and efficiency.
SCALABLE RESULTS
With high-pressure capabilities and components that mirror industrial lines, you can move confidently from pilot trials to full-scale production.
MODULAR SETUP
Customise the pilot plant with additional units like a resting tube, pilot homogeniser, or emulsion preparation system, all mounted on mobile stainless steel frames for ease of use and cleaning.
PRECISE PROCESS CONTROL
Quickly adjust parameters like pressure, temperature, and kneading intensity to evaluate performance across different formulations and conditions.
Flexible pilot-scale setup for full process control
The Polaron pilot plant can be configured with a range of modular components to simulate real production conditions on a small scale. Available equipment includes nitrogen equipment for the pilot pump, a pilot homogenising arrangement, a pre-fabricated emulsion preparation unit, and mobile pilot tanks mounted on sanitary wheels. This flexible setup allows you to test line configurations and recipes at any given time, troubleshoot formulations, and optimise processing parameters efficiently – without interrupting full-scale production.
Trusted expertise in fat crystallisation and processing
With a legacy rooted in decades of innovation and engineering excellence, Gerstenberg Services is a recognised leader in fat crystallisation technology. From margarine and shortening to low-fat spreads and specialty fats, our deep industry knowledge helps producers bring high-quality products to market with speed, confidence, and consistency.
The Polaron Margarine Pilot Plant reflects our commitment to practical, scalable solutions that support product development and production efficiency. Every component is built with the same focus on hygiene, durability, and performance as our full-scale systems; this ensures that you can trust your test results to translate reliably to real-world conditions.
Whether you’re refining an existing recipe or pioneering something entirely new, the Polaron Margarine Pilot Plant gives you the flexibility and control to innovate with confidence – backed by the proven reliability of Gerstenberg Services.
From purchase to production
At Gerstenberg Services, we are more than a system provider: we are your processing partner. When you choose a Gerstenberg Services solution, you gain more than cutting-edge equipment. You gain a committed team that supports you through every stage of the production journey.
From initial consultation and system selection to installation, commissioning, and ongoing service, we are by your side to ensure your equipment delivers optimal performance from day one. Our experts work closely with your team to customise solutions, provide comprehensive training, and offer responsive technical support whenever you need it.
With Gerstenberg Services, it’s not just about delivering a product: it’s about building a lasting partnership that helps your business run smoothly, faster, and more profitably. The Polaron Margarine Pilot Plant reflects our commitment to practical, scalable solutions that support product development and production efficiency. Every component is built with the same focus on hygiene, durability, and performance as our full-scale systems; this ensures that you can trust your test results to translate reliably to real-world conditions.
Whether you’re refining an existing recipe or pioneering something entirely new, the Polaron Margarine Pilot Plant gives you the flexibility and control to innovate with confidence – backed by the proven reliability of Gerstenberg Services.
Are you interested in learning more about the Margarine Pilot Plant, or do you have questions about our other products? See all of our crystallisation equipment.
Get in touch with our experts to learn how Gerstenberg Services can help you improve your process, reduce downtime, and boost profitability.
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Polaron is a registered trademark of Gerstenberg Services and covers the series of advanced high pressure crystallisation equipment.