AAK takes patented fractionation technology to commercial scale at NURA

AAK is preparing the first commercial deployment of its patented dry-fractionation technology at NURA Speciality Oils & Fats, its Malaysian joint venture with KLK, as it looks to expand production of specialty fats while reducing investment, operating costs and emissions.

• NURA will be the first commercial deployment of AAK's patented dry-fractionation technology
• The process will produce specialty palm-mid fractions used in cocoa-butter equivalents
• Ramp-up at the Pasir Gudang facility is expected in 2028, with full production planned for 2029

The technology will be installed at the NURA facility currently under construction in Pasir Gudang, Malaysia, where it will be used to manufacture specialty palm-mid fractions (PMFs). These fractions are an important ingredient in high-quality cocoa-butter equivalents (CBEs) used by chocolate and confectionery manufacturers.

For AAK, the project takes a technology developed through its research activities into an industrial setting for the first time. The company said the dry-fractionation process will complement its existing fractionation capabilities rather than replace them.

Fractionation separates oils and fats into components with different physical properties, allowing manufacturers to produce fats tailored to specific applications. In chocolate and confectionery, PMFs are particularly valuable because their properties make them suitable for producing CBEs, which can replicate key characteristics of cocoa butter.

AAK said its new technology creates opportunities to lower the initial capital investment required for fractionation as well as subsequent operating costs. It also has the potential to reduce CO2e emissions while maintaining the quality standards required for specialty fats.

"Taking this technology from a research project to commercial production is an important milestone for AAK. It demonstrates how long-term innovation combined with close collaboration across functions, can create new opportunities for more efficient and sustainable production. NURA is the first deployment, and we see strong potential for the technology going forward," said Jeppe Lindegaard Hjorth, Head of Process Development.

The first deployment comes as AAK expands its upstream capabilities in specialty palm fractions through NURA. The joint venture with Kuala Lumpur Kepong Berhad (KLK) is intended to provide AAK with greater access to the fractions it uses in the production of cocoa-butter equivalents.

That additional capacity will support the company's Chocolate & Confectionery Fats business, while AAK also sees scope for the technology to increase the flexibility of its wider fractionation operations.

"For AAK, this technology will further strengthen our position as a market leader in the CBE space and allow us to leverage AAK's fractionation capabilities for growth in other business areas as well," said Alexander Perlaky, Strategy & Projects Director, Europe.

Dry fractionation is a physical separation process that relies on controlled crystallization and separation of different fat fractions. For specialty-fat producers, the economics of the process are influenced not only by product yield and quality but also by equipment requirements, energy consumption and overall plant efficiency.

The commercial deployment at NURA will therefore provide AAK with an opportunity to demonstrate the process at production scale and establish how the benefits identified during development translate into day-to-day manufacturing.

The Pasir Gudang project also adds another stage of the supply chain to AAK's production footprint. By strengthening upstream access to specialty palm fractions, the company expects NURA to provide additional support for the long-term growth of its CBE portfolio.

CBEs are vegetable-fat systems designed to provide properties similar to cocoa butter and are used in a range of chocolate and confectionery applications. Their performance depends heavily on the characteristics of the underlying fat fractions, making control of the fractionation process particularly important.

Construction of the NURA facility is ongoing. AAK expects ramp-up to begin in 2028, with the site scheduled to reach full production in 2029.

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