NEW TECHNOLOGIES FOR WHEY TREATMENT

NEW TECHNOLOGIES FOR WHEY TREATMENT

WHEY DERIVATIVES Today whey is the basis for many products in the food industry ICE CREAM ENERGY DRINKS WHEY POWDER

WHEY TREATMENT: TRADITIONAL PROCESSES VS MODERN PROCESSES The overall consideration of whey has been changing in the dairy industry over the years. FROM Waste Animal feed One product Low added value Simple technologies Cost TO Product Human food Many derivatives Medium to high added value Advanced technologies Profit

AN OVERLOOK AT WHEY TREATMENT PROCESSES The main purpose of whey treatment is to increase its solid content and/or recover whey proteins. To achieve this, many different processes have been devised and improved over the years. These processes include: membrane filtration technology Thermal treatments (evaporation) Mechanical treatments (microparticulation) Chemical-physical treatments (ion exchange) Some processes are established and widely applied, other are relatively new and represent the state of art in whey treatment. In this presentation we ll focus on the latter.

AN OVERLOOK AT WHEY TREATMENT PROCESSES PROCESS TS% PRODUCTS/FURTHER TREATMENT Reverse Osmosis 18-22% Concentrated whey for reduction of transport costs, evaporation Nanofiltration (demineralization) 18-30% Demineralization with electrodialisys, ionic exchange High pressure Reverse Osmosis Up to 30% Concentrated whey for reduction of transport costs, evaporation Ultrafiltration 10-26% WPC/WPI for evaporation or spray drying or Microparticulation. Permeate (lactose) may be concentrated by RO for subsequent spray drying Evaporation 50-55% Spray drying

CONCENTRATION BY REVERSE OSMOSIS This is the standard concentration process for whey. This is an established process with many installations. It allows to concentrate whey up to 18-22% T.S. Newer High pressure RO plants allow to raise the concentration up to 22-30% T.S. CONCENTRATION + DESALTING BY NF This technique can be considered as an alternative to the traditional whey concentration by reverse osmosis. The resulting product will have the same or higher concentration in proteins but lesser salt content. Advantages of this technique: Less salt content in the concentrated product Lower process pressure than RO, leading to lower running costs Existing RO plants can be retrofitted to work with NF membranes

REVERSE OSMOSIS vs NANOFILTRATION PRODUCT COMPARISON Whey RO concentrate High pressure RO concentrate NF concentrate Concentration Factor x1 x3 x4,5 x4 True Proteins % 0,70 2,10 3,15 2,80 NPN % 0,20 0,60 0,90 0,55 Lactose % 4,50 13,50 20,25 18,00 Ash % 0,55 1,65 2,475 1,30 Fat % 0,05 0,15 0,225 0,20 T.S. % 6,00 18,00 27,00 22,85

PROCESS ECONOMICS IN RO The economic feasibility and extent of treatment to be applied to whey depends in great part on quantity of product available on daily basis. Availability [ton whey/day] TYPICAL TREATMENTS Product <100 Concentration by RO/NF or only evaporation 100-150 Concentration by RO/NF + evaporation >150 Concentration by RO/NF + evaporation + spray drying Concentrated whey for shipping Concentrated whey for shipping Whey powders

ADD MORE VALUE WHEY PROTEIN STANDARDIZATION BY UF Ultrafiltration allows to concentrate whey proteins while leaving unchanged the quantity of other components (lactose, salts, etc.), so the resulting concentrated product will be protein enriched. Furthermore it s possible to standardize the protein content in the concentrate flow thus obtaining a product of constant quality. This product is commonly called WPC (Whey Protein Concentrate) or WPI (Whey Protein Isolate), depending on the protein content.

WHEY PROTEIN STANDARDIZATION BY UF Whey WPC35 WPC60 Permeate Concentration Factor x1 x5 x17 N.A. True Proteins % 0,70 3,59 12,42 0,00 NPN % 0,20 0,27 0,38 0,18 Lactose % 5,00 5,57 6,31 4,86 Acid % 0,03 0,03 0,03 0,03 Ash % 0,52 0,53 0,55 0,52 Fat % 0,05 0,26 0,89 0,00 T.S. % 6,50 10,25 20,58 5,59 Protein/T.S. % 10,77 35,02 60,35 0,00

WHEY PROTEIN STANDARDIZATION BY UF WPC PRODUCT MAIN APPLICATIONS WPC35 Replacement for skimmed milk Stabilizer and fat mimetic in yogurt, bakery mixes, dietetic foods, infant foods, and confections WPC60 Energy drinks Soups Bakery products Dietetic foods Low-fat products Protein-fortified beverages Defatted WPC80-85 powder Egg-white replacer in whipped products such as meringues, ice-cream and toppings

LACTOSE RECOVERY BY RO/NF Permeate from whey UF can be concentrated by reverse osmosis or nanofiltration to increase its T.S. content (mainly lactose) up to 25-26% for subsequent evaporation and spray drying. Whey Permeate Concentrate Concentration Factor x1 x4,5 True Proteins % 0,00 0,00 NPN % 0,18 0,81 Lactose % 4,86 21,87 Acid % 0,03 0,13 Ash % 0,52 2,34 Fat % 0,00 0,00 T.S. % 5,60 25,15

MICROPARTICULATION Microparticulation is a combination of thermal and mechanic treatment of whey. This treatment, starting from whey protein concentrate (WPC), denatures the proteins so to form a particulate with dimensions similar to milk fat globules. This process enhances low fat products sensorial quality, giving them textural qualities (creaminess) similar to traditional, fatty products.

MICROPARTICULATION WHEY ULTRAFILTRATION WPC60 WPC60 PERMEATE MICROPARTICULATION HEATING HOLD MICRO PARTICULATE COOLING

MICROPARTICULATION Microparticulation products Fresh cheese, cheese spread Milk based desserts Milk drinks and fermented drinks Yoghurt Mayonnaise and toppings Ice cream, chocolate and confectionery Bakery products Nutrition products and powder ingredients

EVAPORATION Evaporation is another established process for the concentration of whey. It is often used in combination with Reverse Osmosis to concentrate the RO outlet (18-22% T.S.) up to 50-55% T.S. ADVANTAGES REVERSE OSMOSIS Higher capacity Lower running cost EVAPORATION Higher product concentration DISADVANTAGES Lower product concentration Higher running cost Lower capacity

MILK DERIVED WHEY One of the most recent innovation in whey industry is Milk Derived Whey (MDV). MDV is gotten directly from skim milk via Microfiltration rather than from cheese making. MF Another very interesting product is produced with this process: Micellar Casein Concentrate (MCC). MF allows to concentrate Casein without changing the concentration of whey proteins, thus allowing to get a standardized product regarding Casein/whey protein ratio.

MILK DERIVED WHEY MDW features some significant advantages in product quality over traditional whey: Original milk components remain unaltered in MDW, while they change in traditional whey due to the cheese making process MDW is virtually fat-free. This represents a major advantage when concentrating i.e. to produce WPC80 (WPC80 from whey: 6-7% fat; WPC80 from MDW 0,3% fat) MDW contains many more amino acids and Calcium than standard whey MDW doesn t contain cheese making by-products MDW has improved sensorial characteristics over traditional whey (taste, smell, colour)

MILK DERIVED WHEY Milk derived whey (left) vs. Whey from cheese making (right)

Silo d e 10, 000 L Sin Aislamiento Silo d e 10, 000 L Sin Aislamiento Silo d e 10, 000 L Con Aislam iento 2 201 Silo d e 10, 000 L Con Aislam iento 5 000 Silo d e 10, 000 L Con Aislam iento formula? 9186,53 4902,13 H.PU E=1.97 Polmone siero 2825,86 SALA DE CONTROL 4752,62 Deming Agua 2710 Envío Futuro Futuro Retorno a CIP O. I. C.I.P. 1211,4 N. F. 4044,09 1211,4 Manifold polmon leche 2495,47 POLM 45,420 L 4400 Succión 2247,51 4000 REDA STRENGHT 16221,78 POLM SUERO 100,000 L Manifold suero SUERO 100,000 Reda has the ability and knowhow to design, build and combine these new technologies with other standard pieces of equipment (centrifugal separators, pasteurizers, etc.), which are designed and built by Reda as well, in order to supply the Customer with an integrated solution, from product reception to delivery.

REDA APPLICATIONS PRODUCTOS LACTEOS VACALIN (ARGENTINA) UF FOR WPC35/60: 18000L/H 10000 L/H EKOLAT (SLOVENIA) WHEY RO 15000L/H

REDA APPLICATIONS DERIVADOS DE LECHE LA ESMERALDA (MEXICO) NF FOR WHEY DEMINERALIZATION 15000L/H + PERMEATE POLISHER 11000L/H

REDA APPLICATIONS ROKISKIO SURIS (LITHUANIA) RO FOR LACTOSE CONCENTRATION 17% TO 26% T.S. 20000L/H and many more

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