Cheese and Whey Applications ESCUELA SUPERIOR INTEGRAL DE LECHERIA VILLA MARIA, ARGENTINA SEPTEMBER 13 14 2017
Topics of Presentation Whey Processing Overview Principles Types Cheese and Whey Applications GEA Offering Presenter: Jose Carlos De la Colina Phone: 1-715-410-2408 Email: jose.delacolina@gea.com 2
Cheese and Whey Applications 30 some years ago Whey was a Waste Stream Technology has transformed whey handling and the dairy industry. Introduced in the 70s Whey Processing Overview UF to fractionate whey protein concentrates RO to concentrate whole cheese whey to lower energy costs of roll drying and evaporation processes The milk and whey industries have driven membrane technology evolution and advancements; and, the milk and whey industries have continuously adopted and adapted to new membrane technologies and developed new applications over three decades. 3
Principles - Dead end vs. Crossflow Batch Filter Press Flow perpendicular to the filter media The solids form the filter media, often aided by precoat Variable filtrate flow Continuous Flow parallel to filter media Constant filtrate flow Fine separation based on size Cartridge Filter Drum Filter Gross filtration Not hygienic - Introduction March 31, 2016 4
Principles Crossflow Permeate Layer Feed Flow Channel The ability to produce very specific separations at low or ambient temperatures with no phase change can, in many applications, make membrane filtration a preferred costeffective separation solution. Microfiltration (MF) Ultrafiltration (UF) Nanofiltration (NF) Reverse Osmosis (RO) Suspended Particles >0.01 micron High Molecular Weight >1000 Daltons Low Molecular Weight >300 Daltons Dissolved Salts Water 18 Daltons 5
300-1000 20 65 Operating Pressure 150-450 10 30 30-150 2 10 15-300 psi 1 2 bar Water Minerals Lactose Whey Proteins Casein Fat Bacteria / spores Suspended solids Spectrum Milk Components 10-4 10-3 10-2 10-1 1 10 Microns MF Removal of Suspended Matter Removal of Bacteria & Spores Fractionation of Proteins UF Purification Proteins Concentration of Proteins NF Concentration of Liquid Dairy Desalting of Liquid Dairy RO Concentration of Liquid Dairy Water Recovery Applications in Dairy July 27, 2016 6
Types Modules GEA offers a wide range of systems and membrane types to allow each and every process to completely optimize their specific separation. The range includes a number of both Polymeric and Inorganic membranes: Polymeric Spiral Hollow Fiber Tubular Plate & Frame Inorganic Ceramic Stainless Steel Introduction - Webinar April 4 & 8 2016 7
Types Suppliers Polymeric Inorganic Hydranautics UF, RO KOCH Systems MF, UF, NF, RO GEA Ceramic membranes MF Microdyn Nadir DOW TAMI Industries UF NF, RO Ceramic membranes MF, UF TriSep Alfa Laval PALL Corporation NF, RO Spiral and Plate & Frame MF, UF, NF, RO Ceramic membranes MF, UF Synder Parker Atech Innovations MF, UF, NF MF, UF, NF, RO Ceramic membranes MF, UF GE Toray Graver Technologies MF, UF, NF, RO MF, UF, NF, RO Scepter R SS membranes MF - Introduction March 31, 2016 8
Types Polymeric - Spiral Wound Permeate Tube Feed Spacer Permeate Spacer Click to see Hydranautics: Spiral Wound Reverse Osmosis Elements Courtesy - Hydranautics - Introduction March 31, 2016 9
Types Polymeric - Spiral Wound Module Retentate/concentrate outlet Housing Permeate/filtrate End cap End cap with permeate/filtrate outlet Element Feed ATD - Anti Telescoping Device or ESA Energy Saving ATD - Introduction March 31, 2016 10
Types Polymeric - Spiral Wound Module Advantages Lowest cost per membrane area Most widely used Lower energy consumption Multiple membrane manufacturers Multiple membrane materials (PES, PVDF, PAN, PP) Continued development of new products Higher temperature Solvent stable Wider ph range Weaknesses Products with suspended or fibrous solids Viscous products Solvents or aggressive chemicals Limited ph and temperature tolerance - Introduction March 31, 2016 11
Types Inorganic - Ceramic Advantages Good clean ability High suspended solids High ph & temperature Narrow pore size distribution Long life Disadvantages High cost High power consumption Mostly in MF and some UF High replacement costs - Introduction March 31, 2016 12
Cheese and Whey Applications 13
Milk Standardization Cheese Milk by Addition of MPC UF Permeate Raw Milk Raw Milk Storage Clarifier / Separator Pasteurizer UF Plant UF Milk Storage Clarifier / Separator Standardize Fat Surplus Cream Cheese Milk Pasteurizer Cheese Vats Applications in Dairy July 27, 2016 14
Milk Standardization Cheese Milk by In-Line Addition of MPC Westfalia Standomat Type MCLA Cheese milk 8,951 kg/h 11,501 kg/h Fat: 3.60 Protein: 4.00 P/F ratio: 0.9 Raw milk 10,000 kg/h Fat: 4.25 Protein: 3.30 CIP return MPC60 1,035 kg/h Fat: 0.17 Protein: 9.33 OPTIQUAD-M 4050W - Spectroscopic Inline Analyzer 1,049 kg/h 29 kg/h Applications in Dairy July 27, 2016 15
Milk Standardization Cheese Milk by UF of Raw Milk UF Permeate 1.2 1.5 VCF in UF Excess Whey Protein in cheese milk causes texture and flavor defects Can we increase the Casein content without increasing the Whey Proteins Raw Milk Raw Milk Storage UF Plant UF Milk Storage Clarifier / Separator Standardize Fat Cheese Milk Pasteurizer Cheese Vats Applications in Dairy July 27, 2016 16
Protein Fractionation in Skim Milk by MF Microfiltration of Skim Milk Retentate Fraction containing Micellar Casein Concentrated to produce Micellar casein Concentrate (MCC) Products: MCC with NWP reduced by 65%, MCC with NWP reduced by 95% Used for Cheese Milk standardization reduce whey produced, lower Whey proteins in Cheese Milk Casein Production Dairy Ingredient, health foods Permeate fraction containing Native Whey Proteins - NWP (also called Serum Protein, Ideal Whey Protein, Virgin Whey Protein) Further concentrated to produce Native WPI (NWPI) Products 35%, 80% and >90% NWPI Superior to WPC/WPI from Sweet Whey due to absence of Glycomacropeptide, residual enzymes, color, bleaching agents, lactic acid and other components from cheese making process. Dairy Ingredient, health foods Applications in Dairy July 27, 2016 17
Water Minerals Lactose Whey Proteins Casein Fat Bacteria & spores Suspended solids Protein Fractionation in Skim Milk by MF Milk Protein Composition Proteins Casein micelles Whey proteins: -lactalbumin -lactoglobulin Immunoglobulins Bovin Serum Albumin % of TOP Isoelectric point Apparent Molecular weight [kd] Nominal Particle size [nm] 78-79 4.6 400 2,000 120 (50-500) 21-22 - - - 3-4 4.2-4.5 14 3-5 10-12 5.2-5.4 36 3-5 2-3 5.5-8.3 LgG: 150, IgA: 385 5-15 0.3-1 4.7-5.1 66 3-5 NPN 5-6 - < 1 < 1 MF UF NF RO Applications in Dairy July 27, 2016 18
Protein Fractionation in Skim Milk by MF MCC and NWPI Production Raw Milk Storage Pasteurizer Clarifier Separator Skim Milk Storage Ceramic MF Evaporator Raw Milk OR Native Whey Storage Spiral Wound MF RO RO Polisher MCC to Dryer MCC for Ingredient / Cheese milk Standardization UF / DF Polished Water RO Conc. UF Permeate for Lactose Conc. NWPI to Dryer Applications in Dairy July 27, 2016 19
Protein Fractionation in Skim Milk by MF Spiral Wound Vs Ceramic Comparison Comparison Spiral Wound Ceramics Running cost Low High Investment Low High Sensitivity suspended solids High Low Sensitivity viscosity Medium Low Permeate flux Low Medium life 1 2 years 10 Years Resistance chemicals and temperature Medium High Ceramic MF (50 C) 2) Spiral Wound MF (50 C) Spiral Wound MF (10 C) 1) At low temperatures loss of β Casein in permeate due to weak linkage with micellar casein 2) Operating Ceramic s at low temperature cost prohibitive due to low fluxes β Casein in Permeate 1) Low Low High Expected max. running time 8-10 hours 8-10 hours 20 hours Reachable CAS/TOP ratio (95%) High High High SP Permeability High Medium Medium Heat and hold stabilisation Yes No No Expected max. VCF VCF 4 VCF 4 VCF 4 Applications in Dairy July 27, 2016 20
Protein Fractionation of Skim Milk by MF GEA Microfiltration Solution for Spiral Wound s Advantages of GEA MF System Higher permeability of Native Whey Proteins Lower space requirements Less Diafiltration water Lower cost 21
Protein Fractionation in Skim Milk by MF Plant Layout 22
Whey Protein Concentrate / Isolate (WPC / WPI) Ultrafiltration of Whey UltrafIltration of Sweet Whey Produce Whey Protein Concentrates (WPC) and Isolates (WPI) WPC 35, WPC 50, WPC 65, WPC80, WPI 90 Ingredient for dairy products, health foods Applications in Dairy Sweet Whey ph 5.9 6.5, Titrated acidity max. 0.15% as lactic acid Salty Whey or Cooker water not blended. Pasteurized no later than 2 hours of draining from the vats. Pretreatment Removal of fines by fine saver and/or centrifugal clarifier, Residual fines <100 ppm by wt. or 300 ppm by vol. Separation of fat by means of a centrifuge.to < 0.06% by Mojonnier or Rose Gottlieb Entrained air <0.5% by vol Single pasteurization at a maximum of 74 C / 165 F and 15 seconds or similar. (Delta T maximum of 2 C in the heat exchanger when T 50 C). Storage after pasteurization at <5 C, and < 24hours. All equipment used for storage and handling must be CIP d daily. July 27, 2016 23
Whey Protein Concentrate / Isolate (WPC / WPI) WPC Process Raw Whey Storage Pasteurizer Clarifier Separator Whey Storag e RO / NF 9-20%TS UF DF UF Permeate Diafiltration water for WPC 70-83% WPC 35% 10%TS WPC 50% 15-20%TS WPC 80 % 33 %TS Applications in Dairy July 27, 2016 46
Whey Protein Concentrate / Isolate (WPC / WPI) WPI Process Raw Whey Storage Pasteurizer Clarifier Separator Whey Storag e RO / NF 9-20%TS UF MF DF UF Permeate WPC 50% 12-15%TS WPI 90 % 28 %TS Applications in Dairy Diafiltration water for WPC 70-83% Procream 16%TS July 27, 2016 25
Whey Protein Concentrate / Isolate (WPC / WPI) WPC/WPI concentration for Dryer Raw Whey Storage Pasteurizer Clarifier Separator Whey Storag e RO / NF 9-20%TS UF Permeate UF MF DF RO Diafiltration Water for WPC 70-83% WPC 35% 10%TS WPC 35% 15-25%TS WPC 80 % 33 %TS WPI 90 % 28 %TS Procream xx %TS WPC 80 % 38 %TS WPI 90 % 40 %TS Applications in Dairy July 27, 2016 26
Concentration of Sweet Whey / UF Permeate by RO Reverse Osmosis of Sweet Whey Reduction of storage volume Reduction of processing volume Reduced transportation costs (Concentration in the farm) Ingredient for dairy products Pre-concentration prior to Evaporator Sweet Whey ph 5.9 6.5, Titrated acidity max. 0.15% as lactic acid Salty Whey or Cooker water not blended. Pasteurized no later than 2 hours of draining from the vats. Pretreatment for Whey Removal of fines by fine saver and/or centrifugal clarifier, Residual fines <100 ppm by wt. or 300 ppm by vol. Separation of fat by means of a centrifuge.to < 0.06% by Mojonnier or Rose Gottlieb Entrained air <0.5% by vol Single pasteurization at a maximum of 74 C / 165 F and 15 seconds or similar. (Delta T maximum of 2 C in the heat exchanger when T 50 C). Storage after pasteurization at <5 C, and < 24hours. All equipment used for storage and handling must be CIP d daily. Applications in Dairy July 27, 2016 27
Concentration of Sweet Whey / UF Permeate by RO Raw Whey Storage Pasteurizer Clarifier Separator Whey Storag e RO / NF High Pressure Section RO Permeate for water Recovery RO Sweet Whey 28 %TS Whey Permeate 28 % TS NF Sweet Whey 30 %TS Whey Permeate 30 % TS UF WPC UF Permeate RO Sweet Whey 22 %TS Whey Permeate 22% TS NF Sweet Whey 26%TS Whey Permeate 26% TS Addition of sequestering agent such as citric acid required for high concentration Applications in Dairy July 27, 2016 28
Cheese Brine Brine Features Saving salt and water reduce environmental impact Reduce microbiological growth in brine Maintain salt & Calcium level, ph Avoid sludge in the tank No additives to brine Minimal maintenance Micro filtration Spiral wound membranes Low temperature operation Skid mounted design Easy to install and operate Alternate Heat treatment Dead end filters Kieselguhr filtration UV Treatment Preservatives Applications in Dairy July 27, 2016 29
Cheese Brine Clarification by MF COLDSAN Steam Sludge Cond Brine Tank Bag Filters Cooler COLDSAN Six standard sizes Size depends on Brine pool size and turn over rate (4 to six days) Used Brine Clean Brine Sludge Applications in Dairy July 27, 2016 30
31 MICRO FORMULA What is Microparticulation? Definition Heat and mechanical treatment in order to denature whey proteins Heat treatment above 75 C in order to denature whey proteins Mechanical treatment with a high shear effect in order to form particles with a size identical to the particle size of fat globules in milk Combination of heat and shear effect resulting in: Denaturated microparticles with an excellent functionality which can be incorporated in different dairy matrixes and food systems
MICRO FORMULA 32 MICRO FORMULA
Microparticulated WPC Process Line 33 MICRO FORMULA Raw Whey Clarification Fat Separation Pasteurization Pre-treated Whey UF WPC 60 Buffer Deaeration MICRO FORMULA TM MWPC 60 Liquid Stabilizer Liquid Fat Replacer Powder
Product Appearance 34 MICRO FORMULA UF Process MICRO FORMULA TM Whey Permeate WPC 60 WPC 60 MWPC 60
35 MICRO FORMULA MICRO FORMULA - Microparticulated WPC Fat/protein replacer in Most cheese types (yield) Yoghurt and milk desserts Ice cream Dressing and sauces Mayonnaise and fat emulsions Other fat-containing food products Characteristics Sensorics like fat Viscosity as cream Creamy water binding Whitish Particle size 1-10 μm Average particle size 3-5 μm Examples of different cheese applications using MICRO FORMULA
MICRO FORMULA - Microparticulated WPC Cheese Fat in dry matter % addition to cheese milk Extra cheese yield Milk saving index/kg cheese Gouda type 45% 2-3% 8-10% 5% 30% 3-4% 8-12% 6% Quarg/Tvorog 40% 8-10% 16-20% 10% Quarg/Tvorog 3% 8-10% 16-20% 10% Soft cheese 60% 2-3% 5-8% 4% Soft cheese 45% 3-5 7-11% 5% Blue Vein 50% 5-7% 12-17% 11% Examples of different cheese applications using MICRO FORMULA
Cheese Application 37 MICRO FORMULA Yield increase in the cheese when adding MICRO FORMULA product is proportional with the denaturation up to 80% denaturation. Higher than 80% denaturation the yield will not increase. Above 80% of denaturation there is a risk of getting to compact particles resulting in a decrease in the functional properties MICRO FORMULA unit is designed with temperature, time and shear in order to have the optimal denaturation, particle size and getting the best results when adding this to the dairy and food applications. Improvement of apperance especially in low fat cheese Low fat cheese curd easier to handle in molds do not stick to surfaces. Sliceability not changed
MICRO FORMULA 38 MICRO FORMULA Advantages OF GEA MICRO FORMULA Low maintenance costs No scraped surface heat exchangers (SSHE) No tubular heat exchangers (THE) No homogenizer No heat transfer surface Low T Low fouling Ordinary plate heat exchangers (PHE) Ordinary flow components Simple unit - low maintenance costs Long production time between CIP 18-20 hours
GEA Offering We, with our wide process experience, are uniquely positioned to provide both customized plants as well as complete process lines specifically tailored to each customer's needs and requirements. We use commercially available membranes and modules for our processes. The multi-disciplined teams at GEA provide the following value-added services to our customers worldwide. Pilot trials and application development System scale-up Project engineering Process integration Automation System fabrication System installation and start-up Service and plant audits Replacement membrane inventory Replacement & Spare Parts Optimization & Long-Term Support New Applications Integrated Service Process Development Pilot Testing And Process Validation Installation, Commissioning, Training, & Transition Seamless Support Engineering and Project Management Manufacturing Introduction - Webinar April 4 & 8 2016 39
Pilot Plants Pilot plants from Lab to Semi Production Scale are available for in-house and on-site trials. Click to see to see more details http://www.gea.com/global/en/search/index.jsp?q=++pilot+plants - Introduction March 31, 2016 40
GEA Offering Who We Are! WE SUPPLY HYGIENICALLY DESIGNED PROCESS MEMBRANE FILTRATION PLANTS. We partner with membrane manufacturers and we do not manufacture commodity membranes We are not active in water treatment plants drinking / bottled water, municipal water, boiler feed water, well water, surface water municipal, biological waste water treatment plants Polishers for steam condensate in power plants Introduction - Webinar April 4 & 8. 2016 41
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