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LIPICO-PGE Calcium Soap Process:

Calcium Soap from PFAD as Rumen Bypass Fat

What is Rumen Bypass Fat

In the dairy industry, it has become a common practice to feed fats to dairy cows to achieve
higher milk yield. This can be achieved by feeding high energy diets to dairy cows.

Calcium soap is a rumen bypass fat that is made especially for high milkyielding dairy ruminants
(animals with 4 stomachs) such as cows, goats and sheeps.

Ruminants have a very specific digestive system that would not tolerate the presence of oil
(triglycerides or fatty acids) in the 1st stomach or rumen. And hence this energy feed must be
able to stay inert to be digested in the later part of the system.

Calcium soap is a rumen-protected fat designed to:
• Provide energy for increased daily milk production
• Improved fertility
• Enhanced body condition and general health of ruminants
• Increase the fat content in milk.

How Calcium Soap Works
Calcium soaps do not interfere with rumen metabolism by coating the fibrous material within
the rumen, or inhibit the action of rumen bacteria at optimal rumen pH.

Calcium soap bypasses the rumen (ideal pH>6) but is broken down in the abomasum (pH
2.5) to release the fat and calcium for digestion. The combination of rumen protection, high
digestibility in the lower gut and efficient energy use explain the superior Net Energy of
Lactation (NEL) value associated with calcium soap product. Calcium soap is proven
to supply high energy for milk production.

In the acidic environment of the abomasum (4th stomach), calcium soap dissociates from
the fatty acids, and this allows the fatty acids to be digested and converted into energy.

Calcium Soap from PFAD
Fatty acids from palm oil are the ideal choice due to the consistency of its fatty acid profile.
There is also considerable research demonstrating that calcium soap from palm fatty acid
distillate (PFAD) improves reproductive performance as well. Palm oil is rich in linoleic acid,
the fatty acid that appears to have the greatest impact on the reproductive hormonal axis.

LIPICO-PGE calcium soap process is designed to produce calcium soaps from PFAD that are
free-flowing granular powder. The calcium soap product is tack-free, non-cohesive, have
low dust content, stable from oxidative rancidity, can be easily transported and mixed in
feed rations (by simple blending with other ingredients).

Typical Specifications:

Process Description

Filling & Mixing Section
During filling step, palm fatty acid distillate (PFAD) is pumped into the plough reactor. After
that, suitable amount of calcium oxide (CaO) will be measured and added to the plough
reactor which is specially designed for the production of calcium soap. Mixer in the reactor
is started to homogenize the reactants.

Reaction Section
Upon adding of water into PFAD and CaO mixture, Ca(OH)2 will be formed. The reaction between PFAD and Ca(OH)2 will start and temperature of the mixture will rise due to exothermic reaction. When the reaction is completed, calcium soap will is subjected to vacuum to reduce its moisture content. As the water evaporated, calcium soap is converted into granulate-form and it is also being cooled down to about 50 - 55 °C.

Packaging Section
The calcium soap is discharged from the reactor into the collecting funnel. It is then fractioned over a vibrating sieve to obtain the desired particle size, typically ranging between 0.3 mm to 3.0 mm.

Calcium soap with the desired particle size will be sent to bagging machine for packaging.

The undesirable fine fractions will be returned to the reactor while the coarse fractions will be grinded into the desired size by hammer mill.


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