The reaction is accomplished only through intimate and thorough contact between water and fat molecules. High temperature makes it possible to dissolve an appreciable quantity of water in the fat phase and to obtain intimate contact. At room temperature, water and fat are essentially insoluble. At elevated temperature, the solubility of water increases to 12-25%, depending upon the type of fat. At the higher temperatures, high-pressures also are necessary to keep the water from flashing into stream.

The reaction is reversible. In order to make it proceed to the right, the proportion of water to fat can be increased or the glycerin is used as the reaction-forcing method. The required combination of high temperature, high pressure, and continuous glycerin removal is accomplished in a countercurrent hydrolyzer column.

Fat stocks (tallow), blended in the proper formula, are mixed with dry zinc oxide catalyst. The mixture is maintained at about 212 F (100 C) to ensure dryness and to keep the catalyst in solution. Hot water for the hydrolysis reaction is put under high pressure by piston-type feed pumps with adjustable drives so that the rates and proportions of fat to water can be accurately controlled. The fat and water are heated to the hydrolyzing temperature by direct steam injection or by heat exchangers. The fats are pumped into the column near the bottom, and the water enters near the top. Thus, a countercurrent flow of water downward through rising fatty material is obtained.

The hydrolysis occurs in a two-phase reaction system. The fats and fatty acids flow continuously with droplets of water falling through them. Glycerin from hydrolysis is dissolved in the excess water falling through the column. The rate-limiting factor is the transfer of glycerin into the water droplets. Zinc oxide catalyzes the reaction which increases the glycerin transfer across the oil-water interface. Fresh water entering the column at the top reduces the glycerin to the lowest possible point, while a glycerin-water seat maintained at the bottom of the column (where the glycerin content is highest) prevents fat from washing out.

The fatty material passes upward through the column with about 99% completeness in splitting. The fatty acids, saturated with water, are discharged through an orifice into a flash tank. The dissolved water vaporizes, cooling the fatty acids and blanketing them with steam. The fatty acid contains CMO and remaining unsplit fat.

The column, pumps, and piping in contact with the hot fatty acid are made from corrosion-resistant stainless steel. The column is a hallow vessel, containing no baffles, trays, or packing material of any kind. The quality of the hydrolyzing operation is determined by the degree of split obtained on the fat. The fatty acid stream should contain very little free glycerin, if any. The fatty acid rich CMO is collected and packaged for further processing.

Manufacturing Methods – CMO Powder

General: CMO fatty acid ester wax is unsuitable for encapsulation in its raw state. It resembles common candle wax and is resistant to milling, blending and encapsulation. The objectives of milling and blending are thorough and intimate final mixing of the fatty acid ester wax and other ingredients to create a free flowing powder for encapsulation.

A variety of methods are used to produce final CMO powders. These methods include heating and cooling of CMO waxes to achieve final powders. Other methods for complete mixing use multiple plodding or milling and screening, in which the CMO and minor ingredients are pushed together through finer and finer mesh screens. Usually, no one method can produce a final powder without overheating or converting a portion of the CMO back into the waxy phase. Often, powder is produced in stages, using a combination of methods depending upon final formula and additional ingredients required.

Cold Milling: CMO is chilled or frozen prior to processing. Then it is processed in a mill equipped with a cooling jacket. Dry ice is added to prevent heating during the process. This produces a large granular product ready for mixing with other ingredients and further processing.

Cold High Speed Shearing: CMO is chilled or frozen prior to processing. CMO and all other ingredients are added to a vertical high-speed blender. The blender is used at its highest setting for the minimum time required creating a roughly mixed powder. The main purpose is to use this blender to pulverize the CMO. The other ingredients act as a blending agent to absorb the CMO and allow it to flow within the blender. The product is now ready for further processing in a fine mill or low speed ribbon blender.

Hot Slow Speed Blending: CMO is heated until it is a liquid prior to processing. CMO and all other ingredients are added to a ribbon blender. The blender is set for the minimum time required creating roughly mixed large diameter granules. The product is now ready for further processing in a fine mill.

Hot High Speed Blending: CMO is heated until it is a liquid prior to processing. CMO and silica are added to a vertical high-speed blender. The blender is set for the time required creating a thoroughly mixed fine powder. The product is now ready for encapsulation or the addition of other ingredients and mixing in a slow speed ribbon blender.

Blending: Granulated or powdered CMO is mixed with further ingredients in a ribbon blender or drum mixer. The blender is set for the time required creating a thoroughly mixed batch. The resulting granulated product is ready for milling. The resulting powder product is ready for encapsulation.

Milling: Granulated or powdered CMO is milled with fine screens. The resulting powder product is ready for encapsulation.

Manufacturing Methods – CMO Capsules & Bottles

General: All manufacturing is conducted in facilities that meet all regulatory standards and are inspected and licensed by the State Food and Drug Branch of Health Services.

Premises: All manufacturing is conducted in a plant, which is a facility licensed and approved for the manufacture of dietary, nutritional and food products.