Purification Processes for the Dairy Industry 14th September- Madrid 1
2 Back to Basics
3 Industrial Biotech Business Unit
Worldwide Industrial Biotech at Novasep S.-M.-de-Beynost, FR Stravopol, RU Sales office Process Development Pilot, Engineering Shanghai, CN Boothwyn PA, USA Process Development Pilot Bangalore, IN Sales office Bangkok, TH Process Development Pilot, Engineering 4 Sales office
5 Industrial Biotech Business Unit
6 Industrial Biotech Business Unit
7 Industrial Biotech Business Unit
The Dairy Map Casein b Casein k Casein a a Lactalbumin b Lactoglobulin Immunoglobulins Enzymatic hydrolysis UF/MF Chromatography Electrophoresis UF/MF Chromatography Electrophoresis Bioactive peptides & phosphopeptides Caseinates Neutralisation Phosphocaseinates Lipid free whey MF Lipoproteins Lactoferrine Lactoperoxydase Casein Microfiltration / Ultrafiltration Phosphocalcic lipid removal Centrifugation Chromatography Skimed milk Coagulation acid or enzymatic Whey Electrodialysis Ion Exchange Ultrafiltration Permeate Ultrafiltration Demineralized whey Drying Concentration Milk proteins, MPC, MPI Lactose processing Drying Enzymatic Hydrolysis UF/MF Chromatography Electrophoresis 8 Whey proteins, WPC, WPI Hydrolysates for enteral & parenteral nutrition Bioactive peptides
9 The Dairy Map
Novasep and Mega Offering Whey demineralization objectives: Remove mineral ions naturally present in whey as 6-15% of total dissolved solids Preserve the microbiological quality Preserve the native protein content and functionalities Novasep and Mega offering: Best process solutions whatever: The production capacity The level of demineralization Optimum combination of our high performance technologies Optimized and most competitive processes for meeting any project needs 10
An Unparalleled Palette of Technologies Mastering all widely used purification technologies MF/UF: Kerasep ceramic ultra/microfiltration UF: Spiral wound ultrafiltration NF: Applexion NF150 spiral wound nanofiltration RO: Spiral wound reverse osmosis SSMB: Applexion SSMB continuous chromatographic separation IEX: Applexion ion-exchange demineralization DK: Applexion ion-exchange salt conversion ED: Mega Ralex electrodialysis HPLC: Novasep LP chromatography columns 11
Unlimited Milk Fractionation Possibilities Main fractions in 1 liter of milk: 12
A Complete Range of Process Solutions Product Process technology Period 1. Generation Whey powder Lactose Evaporation Spray drying Crystallization Early 1960s 2. Generation Demineralized whey powder Whey protein concentrate - WPC 35, WPC 60, WPC 80 Whey Protein Isolate - WPI Ion exchange Electrodialysis Membrane filtration Stirred Tank Chromatography 1970s - 1980s 3. Generation Lactoferrin Lactoperoxidase a- lactalbumin b- lactoglobulin Immunoglobulins Glycomacropeptides Fixed Bed/Expanded Bed Adsorption Chromatography 1990s 13
14 A Complete Range of Process Solutions
15 A Complete Range of Process Solutions
Main Applications using our Products and Processes Production of demineralized whey Novasep and MEGA Optimized Purification Solutions for Demineralized Whey Production of edible and pharma grade lactose Novasep Patented Purification Solutions for Improving Lactose Quality and Process Productivity 16
Cross-Flow Nanofiltration Most competitive technology for limited demineralization rate: 30-35% Whey pre-concentration up to 18-20% TS Water/chemical minimal usage, limited to membrane cleaning Highly efficient for acid salty whey, rich in monovalent mineral ions 17
18 Purification of Milk Products
MEGA Electrodialysis Flexible demineralization rate D50, D70, D90 Chemical minimal usage, limited to ED membranes cleaning Minimal requirement in peripheral equipment Optimum with pre-concentrated whey 15-22% TS 19
MEGA RALEX Membrane Benefits RALEX ED membranes are ion-exchange heterogeneous membranes They have tangible benefits compared with traditional and homogeneous membranes Efficient for all types of whey (acid, casein, sweet whey) Better transport of multivalent ions Demineralization rate tunable from 50% to 90% with the same equipment High recovery yield of the product No special chemicals required for CIP (industrial grade HNO 3 and NaOH are used) Electrodialysis process running at 15 C to ensure microbiological stability of whey 4 years membrane lifetime warranty and post-warranty services High process productivity Working cycle time of ED unit: up to 20 hours per day CIP cycle time: only 4 hours 20
Applexion Ion Exchange Applicable to all types of whey Extremely versatile and efficient mineral ions removal process Most efficient removal of divalent ions 21 Production of highly demineralized whey, compliance with specific D90 ionic profiles
Whey Demineralization Strategy 22 Based on average chemical, water and electrical power costs in Western European countries. To be adjusted to local conditions and specific project objectives to get the best process solution.
Cost-efficient Processes Ceramic membrane filtration Ion exchange & Adsorption Organic membrane filtration Electrodialysis 23
Benefits Design and implementation of processes for dairy applications using a wide range of purification technologies Design of customized processes depending on: The specificities of the desired ingredients The targeted capacity Optimized process solutions: Increase of productivity Increase of targeted product purity Maximize of ROI (Return On Investment) 24
UF Whey Permeate Softening Salts Conversion in UF Whey Permeate Convert divalent ions (Ca, PO4) into monovalent (Na,K,Cl) to avoid scaling/precipitation Minimized chemical consumption Minimized effluents generation Environmentally-friendly solution Soft edible lactose specifications: Lactose: 99.5% Total Protein: 0.3% Max ash: 0.15-0,2% 25
Premium Edible Lactose Quality High yield Lactose Production High Yield Lactose Production Lactose yield increased from 70% to 90-95% (lactose in crystals/lactose in permeate) Increased lactose purity in the crystallizers from 83-85% to 88-90% of the dry solids Increased lactose yield Reduced amount of mother liquor Premium edible lactose specifications: Lactose: 99.5% Total Protein: 0.3% Max ash: 0.15% 26
27 Purification Technologies also Available for Valuable Lactose Derivatives
Thank you. Any questions? Felipe Sánchez Manzano felipe.sanchez@mega.cz http://www.novasep.com/ http://www.mega.cz/ 28