1. Healthy Table Spread from Algae
Team Alpha
Travis Dallas
Eric Graves
Joaquin Martinez
Chris McNinch
Ramune Otterson Meskyte
Charu Saini
Crypthecodinium Cohnii

2. Design Project Deliverables
Design Basis
Block Flow Diagram
Process Flow Diagram
Material and Energy Balances
Calculations
Annotated Equipment List
Economic Evaluation Factored from Equipment Cost
Utilities
9. Conceptual Control Scheme
Major Equipment Layout
Distribution and End
Constrains Review
Applicable Standards
Project Communication File
Information Sources and References

3. Sterilization
Thermal Sterilization will be conducted at 121°C for 1 hour
Shell and tube heat exchangers will be used for continuous sterilization with steam
Medium components will be mixed and sterilized

4. Fermentor Mass Balance
Inlet Material Flow
Basis: Batch Fermentor with 92,400 Liters of fermentation broth
Inocculum of 7,000 Liters of seed batch with c cohnii concentration of 20 g dwcells/L
93 hours required per batch
Aerated to 20% Dissolved Oxygen Saturation
Ton (US)
Liters
Glucose Used per Batch
12.27
5058
Yeast Used per Batch
1.67
690
Sea Salt Used per Batch
4.45
30% Silicon Anti-foam
1.86
1540
Glucanex
0.10
Water
92.82
85112
Initial Algae Biomass
0.02

5. Fermentor Energy Balance
Fermentation is exothermic and cooling water is required to keep the broth at 27°C.
Fermentor is constructed out of stainless steel with an area of sq meters.
Metabolic Heat Evolution (kJ)
49,219,622
Cooling Water Required (L)
1,308,024

6. From Algae Oil to Table Spread
Though the table spread market is shrinking, the health food market is increasing at an incredible rate
AlphaAlgae Healthy Table Spread will have zero trans-fats, zero animal ingredients (vegan), and no dairy components (kosher), allowing for it to attract a very large group of consumers
It will be assumed that AlphaAlgae will take 1 % of the table spread market the first year, and will increase every year afterwards. 6

7. Table Spread Production
First, the oil phase and the water phase must be prepared.
The oil phase consists of refined, zero trans fat oil mixture, the DHA-rich algae oil, and oil-soluble flavors, golden color, and lecithin.
The water phase consists of purified water and sea salt, used for both flavor and as a preservative.
These two phases are mixed together in an emulsion tank with a temperature around 100 °F.
A two-tank system is called a “flip flop” system. When one tank is emulsifying, the other tank is undergoing preparations.
The emulsification then undergoes pasteurization to both kill microbes and to ensure a consistent temperature throughout the spread
This is followed by cooling and crystallization, creating the final spread product
The spread is then stored, ready for transit. 7

8. Example of a Table Spread Production Line:
Found one line online for euros, converts to us dollars 8

9. Example Process Flow Diagram of Table Spread Production Line
Easy to see the “flip flop” emulsification system 9

10. What is in Each Tub Of Table Spread?
11.3 grams of algae oil (4.6 grams DHA)
329.3 grams zero-trans fat oil mixture (interesterfied hardstock, palm, coconut, liquid oil)
grams water
6.058 grams natural sea salt
.852 grams natural soy lecithin
μg beta-carotene (vitamin A and color)
2 ppm diacetyl (butter flavor)
2.13 grams mono and diglycerides
0.426 grams sorbic acid
μg ergocalciferol (vitamin D)
I IU Vit. A from beta-carotene: .6 micrograms / pound need IU / pound
IU Vit. D from egrocalciferol: .025 micrograms / pound no more than 1500 IU / pound 10

11. Production Rates of AlphaAlgae Table Spread:
10.4 million tubs of butter / year
tons of table spread / year
tons of table spread / hour
lbs / batch
tubs / batch
batch / day
Assume 330 days a year with 18 hours a day lbs / hour table spread produced tubs / day 11

12. Table Spread Marketing Analysis
Table spreads enjoy a market size of around 5.2 billion dollars / year
A spread with 1 % of the market would sell around 52 million dollars / year
Sales straight from the plant are around 35 % of the selling price at the market
For the first year, our total table spread sales will then be around 18.2 million dollars
Health food market is increasing very rapidly
This increase will allow for the market share of AlphaAlgae Healthy Spread to increase quickly 12

13. Market Financial Analysis (Based on Whole Foods Market Analysis)
Growth Rate
Net Income (YTD vs last YTD)
3.7%
Sales (5-year Annual Avg)
15.75%
Profit Margins
Net Profit Margin (last year)
3.1%
5 Year Net Profit Margin (5 year Avg)
2.4%
Financial Conditions
Debt/Equity Ration
0.36
Investment Returns
Return on Equity (5 year Avg)
10.8%
Return on Assets (5 year Avg)
6.0%
Return on Capital (5year Avg)
7.6%

14. Soybean Oil (SBO) 781.39 tons SBO Hardfat (Cargill)
tons crude SBO (Cargill) at $867.40/ton

15. Refining Crude SBO Degumming(removal of phospholipids)
Mix with water and H3PO4
Forms a gum, and then centrifuge out
Removal of free fatty acids
Use NaOH and NaCO3 to form soluble in water salts, removed by centrifuge
Rinse with hot water to remove soapstock, centrifuge again
Soapstock – add H2SO4 make feedstock for chickens
Bleaching – Filtering with both a Fuller’s Earth filter and activated carbon filter
Deodorization
Steam distillation under high vacuum and °F
Cooled under vacuum

16. Interesterification Mixing hardfat with refined SBO
Using 99% pure Sodium methoxide at 0.4% wt under vacuum at 100°C
Stirring 500rpm for 20 minutes
Termination
Add DI and citric acid
Wash with DI to remove soap
Dried at 110°C for 30 minutes