Emulsifiers are surface-active agents that stabilise the mixing of immiscible components such as oil and water. By reducing interfacial tension, they create smooth, uniform and stable formulations. They are essential to modern food processing, influencing stability, texture and product quality across bakery, confectionery, dairy, margarine, ready-to-eat and plant-based foods.
With rising demand for natural, sustainable emulsifiers derived from vegetable oil sources, manufacturers are increasingly investing in in-house or dedicated emulsifier production facilities. These systems offer improved quality control, cost optimisation and greater supply reliability.
Kumar designs and delivers turnkey, hygienic and energy-efficient emulsifier production plants for a wide range of food-grade emulsifiers. Every system is custom-engineered for consistent performance, operational reliability and compliance with global food safety standards.
Emulsifier Types and Processes
Mono- and Diglycerides (E471)
Function: Widely used in bakery, dairy, margarine and confectionery for improved aeration, softness, emulsion stability and shelf life.
Production: Manufactured by glycerolysis of edible fats or oils with glycerine at elevated temperatures under vacuum and alkaline catalysis, followed by purification through short-path distillation to achieve the required monoglyceride content.
Acetic Acid Esters of Mono- and Diglycerides (ACETEM – E472a)
Function: Enhances whipping properties, foam stability and smooth texture in whipped toppings, non-dairy creams and ice creams.
Production: Produced by acetylation of monoglycerides with acetic anhydride under controlled conditions, followed by neutralisation and distillation to reach the desired acetyl value.
Lactic Acid Esters of Mono- and Diglycerides (LACTEM – E472b)
Function: Acts as an effective dough strengthener and crumb softener; improves volume and texture in baked goods.
Production: Created by esterifying monoglycerides with lactic acid under controlled conditions, followed by neutralisation, washing and drying.
Citric Acid Esters of Mono- and Diglycerides (CITREM – E472c)
Function: Prevents fat separation in sausages, beverages and margarine; enhances creaminess in low-fat spreads.
Production: Produced via esterification of monoglycerides with citric acid, followed by neutralisation and deodorisation to achieve high purity.
Diacetyl Tartaric Acid Esters of Mono- and Diglycerides (DATEM – E472e)
Function: A superior dough conditioner that strengthens the gluten network, increases bread volume and improves mechanical tolerance.
Production: Formed by esterifying monoglycerides with diacetyl tartaric anhydride, followed by neutralisation, purification and drying.
Polyglycerol Esters of Fatty Acids (PGE – E475)
Function: Supports aeration and fat dispersion in cakes, sponge goods and non-dairy creams; stabilises emulsions in dressings.
Production: Produced by polymerising glycerol and subsequently esterifying it with selected fatty acids.
Polyglycerol Polyricinoleate (PGPR – E476)
Function: Highly efficient viscosity-reducing agent in chocolate, spreads and compound coatings; improves flow and fat dispersion.
Production: Produced by polymerising glycerol followed by esterification with polycondensed ricinoleic acid.
Sorbitan Esters (SPAN – E491–E495)
Function: Provides excellent emulsifying and anti-crystallisation properties in chocolates, fats and creams.
Production: Prepared by esterifying sorbitol or dehydrated sorbitan with fatty acids at elevated temperatures under vacuum.
Lecithin (E322)
Function: A natural emulsifier and wetting agent used in chocolate, bakery, instant mixes and margarine; reduces viscosity and prevents phase separation.
Production: Extracted during the degumming of soybean or sunflower oil, then purified, deoiled, dried and standardised to the required purity and flow properties.
Key Technologies
- Reactors & esterification systems: Precision-engineered for efficient glycerolysis and esterification with uniform temperature and mixing control.
- Short-path distillation systems: Ensure high-purity emulsifiers through gentle and efficient mono-/diglyceride separation.
- Washing, filtration & vacuum drying systems: Designed for effective purification and consistent quality.
- Optimised heating, vacuum & mixing systems: Deliver precise reaction control with energy-efficient operation.
- Plant automation: Advanced control systems for accurate monitoring, improved consistency and reduced manpower requirements.
Key features
• Tailor-made solutions for specific capacities and formulation requirements.
• Fully automatic or semi-automatic operation for operational flexibility.
• Hygienic design with SS-316L/SS-304 contact parts to meet global food safety standards.
• CIP (Clean-in-Place) provision for simplified maintenance and hygiene.
• Modular, skid-mounted design for fast installation, compact layout and future scalability.
• Reliability and quality assurance backed by robust engineering and global manufacturing standards.
• R&D and innovation support from our OM Innovation Centre for pilot testing, process optimisation and product development.
Our services
We help minimise downtime and keep your operations running smoothly through a combination of high-quality components, advanced technology and expert on-demand support. Our service standards ensure your plant performs at its best, day in and day out.
Audits
Detailed performance reports to assist with process changes related to output, energy consumption, spares, inventory and plant upgrades.
Project EPC
Full or partial turnkey management and execution of the project from cost projections and modelling to installation and commissioning.
Spares
Spare parts as required to maximize uptime and ensure the longevity of your investment.