Global demand for phytosterols continues to grow, as manufacturers become aware of their versatility and the benefits they can bring. For example, they are added to margarine as cholesterol-reducing agents. Cognis is one of the world's leading producers of phytosterols, and has now developed a process for extracting them from the by-products of methyl ester production. Usable methyl esters also result from the process, whose creators were recognized by their employers with this year's Gold Cognis Innovation Award.
Cognis's sterol production was previously part of the same edible oils refining process by which Vitamin E is produced, at its US plant. However, this methodology offered limited scope for increasing sterol production, so an international cross-functional team was set up to examine alternative methods.
The solution they arrived at was to use by-products of methyl ester production as a raw material. The project team, including staff from France, Germany and the USA, succeeded in developing a technique for converting the sterol esters that make up 20 to 30 percent of the by-products of methyl ester production into free sterols, and refining them. As a by-product of this multi-stage process, methyl esters are also produced, which can be used as bio diesel or a raw material for fatty alcohol production.
The stages of the new process include the chemical conversion of the sterols, purification and granulation. Working closely with customers from the food and pharmaceutical sectors, the team was able to ensure the end product is one that fully meets actual market requirements. Comments team member Bernhard Gutsche, head of Process Technology at Cognis Deutschland: "From the first day the production process went live, we have been achieving a sterol purity of up to 99 percent. Another key benefit is that the process does not involve GM oils at any stage, so the high-purity sterols we produce are perfectly suited for use in the food industry."