Effective oil management

09182_CFS_Oilmanagementbrochure.indd 1

05-11-2009 12:57:05

Contents
Consistent product quality and reduced
cost from good oil management

What is oil?

Why does oil deteriorate?

Protecting oil from attack preventive care

Daily oil management

10

The role of equipment in oil management

13

CFS fryers and filters

13

Finding the optimum oil turnover rate

14

Oil Management checklist

15

09182_CFS_Oilmanagementbrochure.indd 2

05-11-2009 12:57:08

Consistent product quality and reduced

costs from good oil management
Oil is a complex and expensive commodity; managing it efficiently
saves processing costs and ensures consistently high food quality
for the consumer.
In a highly competitive market, there is considerable pressure on
convenience food producers to provide excellent products at the
lowest possible price. As a result, many manufacturers are becoming
increasingly interested in efficient oil management - which brings two
valuable benefits: keeping oil use to a minimum and maintaining
optimum product quality and appearance.
Mismanagement of oil can cause several
undesirable changes in its characteristics:
Colour which darkens with
black spots appearing.
Viscosity which increases
during frying.
Smoke point which reduces as the oil
is broken down causing the oil to develop
smoke even under normal operating
conditions.
Sensory the taste and odour of the frying
oil becomes poor.
Oil pickup which increases with products
fried in degraded oil.
Foaming the oil starts to foam.

With over 30 years experience of fryers and

frying techniques, CFS has prepared this
guide to introduce you to the key aspects of
managing oil:
Oil composition and the causes
of deterioration.
The effects of oil deterioration and how to
prevent them.
Daily oil care.
The role of oil management
fryers, filters and storage tanks.

CFS Fryers are designed to help you

get the most from your oil
3

09182_CFS_Oilmanagementbrochure.indd 3

05-11-2009 12:57:09

What is oil?
Fats and oils are composed of four components: a glycerol backbone
and three molecules of fatty acids, called triglycerides.
The composition of these fatty acids - their chain length and the nature
of their carbon bonds (saturated, unsaturated, polyunsaturated, etc.) determines oil characteristics.
HIGJ8IJG:D;6IG><AN8:G>9:

INE:HD;;6IIN68>9H

VXXdgY^c\idi]ZcjbWZgd[YdjWaZWdcYh

;ViinVX^Y
HVijgViZYcdWdcY

;ViinVX^Y

;ViinVX^Y

BdcdjchVijgViZY&WdcY
EdanjchVijgViZY>&WdcY

Fats and oils are made of four molecules: one glycerol and three triglycerides
Source: http://www.eufic.org/jarticle/en/food-nutrition-guide/fats/expid/basics-fats/

When it comes to choosing a frying oil, food

producers and consumers have conflicting
requirements. Producers want frying oil

for oils that are healthy and easy to digest,

generally poly-unsaturated and nonhydrogenated fats/oils, Because of their

that is able to withstand frying conditions

for longer periods of time. Generally
saturated and hydrogenated fats/oils meet
these criteria and thus are stable at frying
conditions. In contrast, consumers look

nature, however, these are not so stable

at frying conditions. In practice, producers
adopt the best possible compromise based
on costs, market demands, oil management
practices and frying oil stability.

ESSENTIALS OF OIL MANAGEMENT

To ensuring your frying oil is always at its best quality, its important to adopt
a few vital principles when choosing your frying operation:
Efficient sediment removal -

Keeping the oil out of UV light.

preferably in a closed system.

Minimizing contact with water
and oxygen.
Protecting the oil from overheating,
and limiting the temperature difference
between heat exchangers and the oil.

Continuous oil level control and use

of minimum oil quantities.
Choosing equipment designed for good
oil management.

09182_CFS_Oilmanagementbrochure.indd 4

05-11-2009 12:57:09

Why does oil deteriorate?

Frying inevitably degrades the cooking oil, leading to chemical changes
that can eventually adversely affect the appearance, flavour and odour
of the fried foods. These changes can also alter oil pick-up and thus the
final product weight, or release smoke and other irritants into the cooking
environment.
THE MAIN CAUSES OF FRYING OIL
DEGRADATION DURING FRYING ARE:
Sediment (food particles)
Water combined with heat (hydrolysis)
Oxygen combined with heat (oxidation)
Heat (the higher the temperature
the faster the degradation reactions
take place)
Light (a minor factor in frying situations)

A^\]i

Slowing down frying oil degradation requires

a combination of preventive actions in your
process, starting with choosing the right
frying equipment, oil management system
(filters, tanks etc.), fryer settings and the best
frying oil for your typical application.

Dmn\Zc

LViZg
=ZVi
HZY^bZci
The main causes of frying oil degradation during frying

09182_CFS_Oilmanagementbrochure.indd 5

05-11-2009 12:57:09

Protecting frying oil from degradation preventive care

Sediment
Particles falling from fried foods carbonize and darken the oil, imparting
bitter flavours and spoiling appearance. Although hard to eliminate entirely,
sediment contamination can be limited by minimizing the amount of freebreading on products entering the fryer. This can be achieved with an
efficient blow-off device or flip, which removes any excess breading.
In addition to this, CFS Fryers incorporate
several sophisticated mechanisms to prevent
sediment spoiling your frying oil and fried
foods:
Continuous sediment removal and filtering
through a closed, internal sediment-removal
system and slotted screen filter.

Take-over outside the fryer - lost coating

does not enter the fryer.
Adjustable oil flow to ensure good oil
circulation in the fryer, optimum temperature
control and sediment removal.

CFS Fryers are equipped with a closed internal filter for continuous sediment removal.

For more effective sediment removal,

CFS offers:
Optional external filters, CleanOil
and RotoFilter.
An optional conical oil storage and settling
tank which allows sediment to be drained
before the oil is pumped back into the fryer.

09182_CFS_Oilmanagementbrochure.indd 6

05-11-2009 12:57:09

The CFS filters

CFS CLEANOIL
The CleanOil is a high capacity continuously
operating centrifuge suited for a wide
range of applications like suspended (flour
type) breading applications, crumb coated
products or non coated products (meat
balls or hamburgers).
The CleanOil separates sediment from the
oil by high-speed centrifuge.
For separating sediment from frying oil,
the frying oil is fed into the scroll body via
the feed pipe. The frying oil with sediment
is fed into the centrifuge bowl. Under the
influence of the high centrifugal force, the
sediment is forced to the outside of
the bowl and conveyed by a screw to the
discharge end of the bowl section.
Adjustable filtration level to control the oil
content of the sediment.
Filtration of oil with optimum separation
results. Fine particles up to 1 micron will be
separated from the oil.
The CleanOil maintains the colour and
characteristics of the oil throughout the
various production shifts and can extend
the lifetime of the oil by 5 times or more.

CFS CleanOil

CFS ROTOFILTER
The RotoFilter is a continuously operating
filter suited to different frying applications.
The filter system consists of a drum with a
two-step stainless steel filter screen and a
sediment removal system.
The economic design and small footprint
combined with excellent filtering
capabilities make the RotoFilter a very cost
effective solution suited for a variety of
fryers.
The RotoFilter is delivered with both a 50and a 77-micron filter screen for optimal
adaption to the application.
The RotoFilter combines good filtration with
low cost-of-ownership.

CFS RotoFilter
7

09182_CFS_Oilmanagementbrochure.indd 7

05-11-2009 12:57:12

FILTRATION HELPS YOU MAINTAIN THE

HIGHEST PRODUCT QUALITY AND RESULTS
IN A SIGNIFICANT REDUCTION OF FRYING
OIL COSTS.
The different types of external filters have
proven to be very effective in optimizing
our customers frying operation in different
applications.
In specific applications, the use of our
filters can give a five-fold improvement in
oil lifetime compared with the situation
without the filter. This not only results
in a huge reduction of frying oil costs but,
more importantly, it drastically improved
the product quality. Thanks to the effective
filtration and lower oil degradation rate,
optimum oil quality can be maintained for
longer, resulting in: better product quality,
more constant product quality (colour,
flavour etc.), less off flavour, less smoke
in production, and fewer quality related
complaints from end users.

WATER COMBINED WITH HEAT

(HYDROLYSIS)
When water gets into the frying oil it
evaporates, consuming extra heat (energy)
and splitting (hydrolysis) the triglycerides
from their glycerol backbone, leaving free
fatty acids in the oil.
Water is always present in foods, but you can
limit the degradation of oil by water through:
A balanced recipe, where the added water
is absorbed by the product.
Blowing off excess water from the product
at the fryer infeed.
Drying the fryer carefully after cleaning,
and ensuring all valves and pipes are dry
before filling it with fresh oil.
CFS builds in condensation capture trays
around fryer hoods and exhaust stacks,
preventing condensation from running back
into the frying oil.

In other specific cases, the implementation of an external filter could enable the
customer to run constantly with the same
frying oil without the need for discharging it
at a specific moment. In this situation, the
filter enables the frying oil to be maintained
at optimal quality due to effective removal of
sediment combined with the natural supply
of fresh oil caused by to the oil pickup of the
fried product.
For more information please contact
our specialists

Water locks on CFS Fryers collectcondensation

09182_CFS_Oilmanagementbrochure.indd 8

05-11-2009 12:57:13

OXYGEN COMBINED WITH HEAT

(OXIDATION)
Exposure to oxygen causes fats and oils
to oxidize, creating peroxides and other
secondary oxidation products that give the
oil an off flavour. Heat, especially the high
temperature during frying, increases the
rate of oxidation. In addition, the breakdown
products formed during frying further
accelerate degradation of the frying oil.
Oxidation can be minimized by:
Ensuring the oil in the fryer has as little
contact with the air as possible.
Storing fresh oil in closed containers/tanks
at the storage temperature recommended
by the oil supplier.
Designed to keep oxygen away from the oil,
CFS Fryers and filters are equipped with:
Adjustable in- and out-feed openings
minimizing air coming into the fryer on the
in- and out-feed side.
Fryer and filter hoods (ensuring these are
always lowered protects the oil from air).
Mechanisms within CFS Fryers further
reduce oxidation by:
Eliminating turbulence in the oil circulation
to the filters and tanks - preventing oil and
air mixing.
Ensuring minimum exhaust volume (excess
exhaust increases oxygen exposure and
energy use).
HEAT
Normal operational frying temperatures
range between 170 and 195 C, but for
the heat exchangers in the fryer to transfer
heat to the oil their temperature must be
much higher. When oil is exposed to these
high temperatures for long periods, a whole
range of breakdown products are produced

and other degradation processes are

accelerated. Overheated oils can also emit
smoke and other irritating substances into
the production environment.
A variety of methods can be used to limit the
effects of contact with the heat exchangers:
Thorough insulation of the fryer and
auxiliary equipment: this will reduce heat
loss to the environment, preventing the heat
exchangers from having to operate at very
high temperatures just to keep the oil at its
operational frying temperature.
Heat up slowly: increasing the temperature
of the heat exchangers and turning off the
circulation pump will certainly heat the
oil more rapidly, but it will also degrade it
much faster.
Place the temperature control unit as close
to the fryer as possible to create a stable
temperature level, avoiding excessive
changes in heat.
Use continuous oil level control: if oil is
added a little at a time, the heat exchangers
can maintain the overall temperature
with only a small increase in their own
temperature.
Use a balanced heating coil surface: this
allows for a maximum amount of energy to
be transferred while ensuring a minimum
temperature difference between the heat
exchangers and the oil itself.
LIGHT
Ultra violet (UV) light degrades oil by
catalyzing oxidation reactions, leading to offflavours and reduced shelf life.
UV degradation is not a major issue when
frying, but it can be avoided during storage by
ensuring oil storage tanks and the fryers are
closed to light.
9

09182_CFS_Oilmanagementbrochure.indd 9

05-11-2009 12:57:13

Daily oil management

The aim of industrial frying processes is to produce food products of a
consistent quality, with no variation in taste, colour or appearance. Batch
frying, where the oil is changed after a fixed time, will not give these results
because the frying oil performance varies considerably over its lifetime.

<ho_d]E_bGkWb_jo9khl[

;ddYFjVa^in

OdcZ
%"67gZV`"^c
6"7;gZh]
7"8Dei^bjb
8"99Z\gVY^c\
9":GjcVlVn

'89:;<
=ZVi^c\I^bZ
;^\jgZ&#7ajbZci]Vah;gn^c\D^aFjVa^in8jgkZ!l]^X]YZhXg^WZh
[^kZhiV\Zd[d^aYZ\gVYVi^dc/WgZV`"^c![gZh]!dei^bjb!YZ\gVY^c\
VcYgjcVlVn

How exposure to heat affects the quality of frying oil.

HOW EXPOSURE TO HEAT AFFECTS THE

QUALITY OF FRYING OIL.
The Frying Oil Quality Curve clearly shows
the relationship between quality and heating
time. After the initial Break-in period (region
0-A), final product acceptance increases
(regions A-C) because the frying oil is at its
optimum for frying. The fried product has
optimum colour, odour and crispness. As the
frying oil degrades (regions C-E), the frying
product quality will slowly decrease, the
product becomes too dark, off flavours

develop and the oil pick-up increases.

Beyond this time, the oil is degraded, the final
product quality will be unacceptable and the
oil must be renewed (past point E).
FRESH OIL ADDITION DURING FRYING
A key criterion in designing your fryer system
and selecting your oil is to ensure oil quality
always remains the in optimum region on
the Frying Oil Quality Curve (B-C). In an ideal

10

09182_CFS_Oilmanagementbrochure.indd 10

05-11-2009 12:57:13

situation this can be achieved by continuously

replacing the oil absorbed during frying by
fresh oil.
For example, a 500 kg/hr production rate
of coated products absorbs 10% of the oil
- 50 kg/hour. This 50 kg of oil is replaced
on an hourly basis. So, if the fryer contains
approximately 500 litres, the retention time
of the oil in the fryer will be eight hours.
Clearly, to gain optimum oil performance
in such an application, the food processor
should use an oil with a performance that
peaks at approximately eight hours. With this
combination of production process and oil
characteristics, the producer can be sure of
maintaining the oil at its best and guaranteeing
consistently high product quality.

UNDERSTANDING THE PROCESS DYNAMICS

DURING FRYING
The frying process can be seen as a dynamic
process with a lot of variables.
Variables during frying are:
Type of frying oil.
Type of product (coating, frozen, fresh etc.).
Frying time and temperature.
With or without filtration.
Oil circulation speed.
Oil pick-up level.
Fresh oil addition level.
Production capacity.
Fryer oil volume.
All these process variables affect the speed
of oil degradation.

The CFS Oil tank can be used for storing,

filtering and continuously filling the fryer to
maintain the desired oil level (when combined
with an automatic level control system).
11

09182_CFS_Oilmanagementbrochure.indd 11

05-11-2009 12:57:14

REDUCED PRODUCTION
Decreasing demand may lead to a processor
having to reduce production and this can have
a serious impact on the oil retention time in
the fryer. For example, reducing production
by half from 500 kg/hr to 250 kg/hr in a 500
litre fryer, will lead to a retention time of
sixteen hours, instead of the previous eight,
before the oil is completely refreshed. And
this could bring the oil beyond its acceptable
heating time on the Frying Oil Quality Curve.
The oil can then degrade to such an extent
that it must be completely thrown away
and renewed.
Briefly, when production is decreased, oil
retention time increases. Oil retention time is
directly related to the oil pick-up level and the
production capacity.

CHANGE OF PRODUCT
When the product changes, the minimum
amount of oil pick-up will also change and
this will affect oil performance. If oil pick-up
reduces, the oil retention time will be longer.
Once again, the oil performance can shift to
the right of the Frying Oil Quality Curve into
the region where oil degrades.
CHANGE OF FRYING TIME
Although a change in frying time does
not have as big an effect as a change in
production volumes or product, it can
still cause oil performance to move to the
degrading region (past E) on the Frying
Oil Quality Curve. However, changes in
frying times will affect capacity and oil
pick-up as well as the oil absorption rate.
In combination, these factors tend to
balance each other out, so the impact on oil
performance is probably not very great, but
producers should still check that quality is
not negatively affected.

AVWdgVidgniZhih[dgd^afjVa^in
IZhi

CVijgZd[iZhie]nh^XVa$X]Zb^XVa

;ddYd^ahZchdg E]nh^XVaiZhi[dgedaVgXdbedjcYhYZ\gVYVi^dcegdYjXih
Dm^[g^i 



8dadg^bZig^XiZhi"XdadjgX]Vc\Zh[gdbWajZidWgdlc"
XdggZaViZhl^i]dm^Y^oZY[ViinVX^YhVcYedaVgXdbedjcYh

8dadjg 



8dadg^bZig^XdgXdbeVg^hdcl^i]iZhi`^i"^cY^XVidgd[
egdeZggZ[^c^c\

K^hXdh^in

E]nh^XVaiZhil^i]k^hXdh^bZiZgd[Xje

Hbd`Zed^ci

7jgc^c\[aVbZ

I^igVi^dc

8]Zb^XVaiZhi[dg[gZZ[ViinVX^Yh;;6

12

09182_CFS_Oilmanagementbrochure.indd 12

05-11-2009 12:57:14

The role of equipment in oil management

Selecting a fryer requires great care.
A machine built to your precise process
specifications will give better results and cost
efficiency than a re-manufactured or overdimensioned fryer. If the fryer is too large, the
oil retention time in the fryer will be relatively
long and its quality will drop more quickly

than with a smaller fryer (performance will

move to the right of the Frying Oil Quality
Curve). The final result could be a situation
where oil has to be thrown away and
replaced, leading to additional costs that
would not have occurred with the right fryer.

CFS fryers and filters aid good

oil management
CFS fryers require a minimum quantity of oil
thanks to their compact heat exchangers and
integrated filter systems, resulting in fast oil
turnover and consistently high quality foods.
They can also be integrated with additional oil

management systems such as the RotoFilter,

CleanOil and oil storage tanks to ensure the
highest quality of your fried products.

Thanks to its integrated heat exchanger and filter system,

this CFS Thermal Oil Heated Fryer requires a minimum amount of oil.

13

09182_CFS_Oilmanagementbrochure.indd 13

05-11-2009 12:57:14

CFS continuous fryers require a minimum

quantity of oil thanks to their compact heat
exchangers and integrated filter systems,
resulting in fast oil turnover and consistently
high quality foods. In fact, all our machines,
including our CleanOil and RotoFilter are
designed to help you get the most from your
oil, by protecting it from sediment, water,
oxidation and light.

OIL RETENTION TIME (HRS)

Oil retention time is a key factor in ensuring

high product quality. Ideally, the oil in the
fryer should be entirely replaced every 12
hours at most. The replacement rate depends
on a number of factors:
How much product is being produced
the production volume (kg/hr).
The amount of oil absorbed by the product
the oil pickup (% of oil).
The quantity of oil in the fryer
the fryer contents (litres of oil).
A theoretical approach to calculate the oil
retention time (oil turnover rate) is given in
the formula below:

FRYER CONTENT (LITRES)

OIL PICKUP (%) X PRODUCTION VOLUME (KG/HR)

The ideal frying operation reaches a steady

state where the time it takes to degrade the
oil at frying temperatures is longer than the
oil retention time in the fryer. In this ideal
situation, the producer may never have to
throw away the frying oil since it is refreshed
by replacement of fresh oil that is absorbed
by the product at a faster rate than the oil is
degrading. The oil thus remains at a steady
state of good quality. Whether this point can

be reached does of course depend on the

application. In general, a high pick-up of oil
by the product will allow this steady state to
be reached earlier.
External filters (RotoFilter or CleanOil) are
in most frying operations an essential part
of the oil management system, the type of
filter depending on the type of sediment and
fryer volume, as well as on the frequency of
periodic cleaning of the fryer.

14

09182_CFS_Oilmanagementbrochure.indd 14

05-11-2009 12:57:14

Checklist
HEAT
Use continuous oil level control.
Prevent excessive heat losses to the
environment.
Avoid using high temperatures (>195 C)
if possible. Higher temperatures greatly
accelerate oil degradation.
Dont stop oil circulation during heating.
Oil circulation is critical for good
temperature distribution in the fryer.
For thermal oil heated fryers. Use the
lowest possible thermal oil temperature.
Keeping in mind that you keep your
required heating capacity.
SEDIMENT
Remove any excess coating (flour, batter,
crumbs, water etc.) from the product
entering the fryer. Use air knives (blower)
and adjust the coating system and make
your line operators understand the
importance of removing excess coating.
Put a transfer stage between the last
coating machine and the fryer in order to
collect any loose coating.
Use an integrated slotted screen filter in
the fryer. Finer filters can be supplied if
required.
Use a conical storage tank for storing
oil during fryer cleaning to enhance
sedimentation of the dirt in the frying oil
during temporary storage. Tap off sediment
before refilling the fryer.

WATER
Make sure the fryer is well drained after
cleaning and check that the piping is dry.
Blow excess water off the product before
it enters the fryer.
Prevent condensation from the hood and
ventilation running back into the fryer.
OXYGEN & LIGHT
Eliminate any unnecessary venting through
the exhaust stack.
Prevent drag through the fryer.
Keep the hood closed when the fryer
is not in use.
Make sure the oil supply tanks
are kept closed.
Prevent exposure of oil to light.

15

09182_CFS_Oilmanagementbrochure.indd 15

05-11-2009 12:57:14

ARGENTINA / AUSTRALIA /
AUSTRIA / BELGIUM / BRAZIL /
BULGARIA / CANADA / CHILE /
CHINA / COLUMBIA / COSTA RICA
/ CZECH REPUBLIC /
DENMARK / DOMINICAN
REPUBLIC / ECUADOR /
EGYPT / FINLAND / FRANCE /
GERMANY / GREECE /
HUNGARY / ICELAND / INDIA /
INDONESIA / IRAN / IRELAND /
ISRAEL / ITALY / JAPAN /
JORDAN / KOREA / MALAYSIA /
MEXICO / NETHERLANDS / NEW
ZEALAND / NORWAY / PERU /
PHILIPPINES / POLAND /
PORTUGAL / ROMANIA /
RUSSIA / SINGAPORE / SOUTH
AFRICA / SPAIN / SWEDEN /
SWITZERLAND / TAIWAN /
THAILAND / TURKEY / UNITED
ARAB EMIRATES / UKRAINE /
UNITED KINGDOM / UNITED
STATES / VENEZUELA

CFS B.V.
Beekakker 11
5761 EN Bakel
The Netherlands
Tel. +31 492 349 349
Fax +31 492 349 416
info@CFS.com
www.CFS.com

09182_CFS_Oilmanagementbrochure.indd 16

B03.03.05EN / 112009 CFS B.V.

As a result of constant improvement, drawings
and specifications of CFS machines and
software are subject to change. Some
features and/or equipment mentioned in this
publication are options.

To learn more please visit www.CFS.com

05-11-2009 12:57:15