View
228
Download
1
Category
Preview:
Citation preview
Technologies the production of milk-based ingredients
Nick Adamson Ph.D.
Sub-category Manager
Milk & whey based ingredients
NAD/2015-10-08
Internal
Agenda
► Ingredient product overview
► Our goals as ingredient processors
► Technology overview
► Closer look at some select technologies− Heat treatment and centrifugation
− Membrane processes
− Demineralisation processes
− Evaporation and drying
► Key Points
NAD/2015-10-08
Internal
NAD/2015-10-08
Internal
Ingredients direct from milk
Whole Milk Concentrates and Powders
Cream
Amorphous Milk Fat
Butter
Frozen Cream
Skim Milk Products
Caseins and caseinates
Direct acid caseins
Rennet caseins
Biological caseins
Milk Protein Concentrate
Micellar Casein
Native Whey
Milk UF permeate
Milk WPI
D90 Native Whey
Ingredients direct from whey
NAD/2015-10-08
Internal
Whey Powders
Standard
Demin 40
Demin 70
Demin 90
De-lactosed(DLWP)
Whey Protein Products
WPC35-59
WPC60-80
WP Isolate
Hi Fat WPC
Permeate Products
Lactose
Lactose Edible
Lactose Refined
Lactose Pharma
Mother Liquor
Permeate powder
Deminpermeate
Value add through protein purification
Product TOP/TS Casein/TOP Ash/TS Lactose/TS
SMP 33-34 76.5 8 55
MPC85 85 76.5 7 8
MCC 90 92 6.5 2.3
MCI 90 97 6.5 0.3
SWP 13 9.7 75
WPC35 35 7 50
WPC80 80 2 10
WPI 90 2 7
DWP40 13 6
DWP70 13.5 2.5
DWP90 13.5 1NAD/2015-10-08
Internal
Composition
Where do the solids go?
NAD/2015-10-08
Internal
Not an exhaustive list but...........
Safe Food
• Pathogens
• Foreign Matter
• Package security
• Total Viable Counts
• Thermodurics & spores
Superior Functionality
• Nutrition, flavour, colour, appearance
• Composition
• Protein purity and denaturation level
• Wettability, dispersability, solubility, BD
• Water binding, viscosity etc
Sustainability & Low Cost
• Water & waste minimisation
• Costs esp, transport and energy
• Material usage
• Operability
Asset Utilisation
• Maximise capacity
• Flexibility
• Minimise non-value add infrastructure
Maximise profit / tonne milk solids
NAD/2015-10-08
Internal
Processing Goals - Ingredients
Many Technologies Employed
NAD/2015-10-08
Internal
WM
P
SM
P
Hig
h F
ree F
at
WM
P
MP
C
MC
C / M
CI
Nativ
e W
PI
Whey
Pow
der
DeLact
ose
d W
hey
DW
P40
DW
P70
DW
P90
WP
C35-6
0
WP
C60-8
0
WP
I
Perm
eate
Pow
der
Lact
ose
Edib
le
Moth
er
Liq
uor
Lact
ose
Pharm
a
Mic
ropart
icula
ted
Wh
ey
Clarification
Separation
Bactofugation Option Option Option Option Option
Pasteurization
RO or HiRO
Nanofiltration (NF) Option Option
Electrodialysis Option
Ion Exchange Option
Wet Blending Option
Ultrafiltration
Microparticulation
Microfiltration
Ultrafiltration-Diafiltration
High Concentration NF
De Calcification Option
Decolorisation
Evaporation Option Option
Crystallization Tanks
Washing
Decanting
Sieve Centrifugation
Drying (Spray WB / TWB) Option Option
Drying (Spray TFB) Option Option Option Option Option Option Option Option Option
Drying (Fluid Bed)
Dry Addition Fluid Bed
Post-crystallization Option Option
Powder Handling Option
Milling Option Option
Powder transport & storage
Packing 25 kg
Packing Bulk Bag
Whey Derivatives
UnitO
perations
Milk Derivatives
Focus for Today
Milk or Whey Heat Treatment CentrifugationMembrane
filtration
Demineralisation technologies
EvaporationCrystallisationSpray Drying
Powder Handling
NAD/2015-10-08
Internal
Heat treatment and centrifugation applications
Index
Internal
NAD/2015-10-08
Managing the competing objectives of killing bacteria and preserving
product quality (protein denaturation, flavour, colour)
7°C 15°C 40°C 45°C 62°C 72°C 90°C 118°C
NAD/2015-10-08
Internal
Heat Treatment
Psychotrophic
growth
Thermophilic
thermoduric
danger zone
BSA
denaturation
irreversible
Mesophile
pasteurisation
α-LAC
denaturation
irreversible
Spore kill
starts
Β-LAC
denaturation
irreversible
Whey protein
denaturation
reversible
Centrifugation
Clarification
Impurity removal for
milk
Cheese fines recovery
Fat Separation
Hot & cold milk
separation
Whey separation
Butteroil & AMF
Spore & Bacteria Removal
Milk for ESL, powder and
cheese
Whey cleaning
NAD/2015-10-08
Internal
Membrane Filtration
Index
Internal
NAD/2015-10-08
Basic principles of filtration
MF
Retentate
UF
Retentate
NF
Retentate
RO
Retentate
Pure water
Feed
Permeate/
Feed
Bacteria, spores,
fat globules
Casein,
whey proteins
Lactose,
acids, NPNMinerals Water
Permeate/
Feed
Permeate/
Feed
NAD/2015-10-08
Internal
Overview of Filtration Processes
NAD/2015-10-08
Internal
Microfiltration Ultrafiltration Nanofiltration Reverse Osmosis
Fractionation of casein and
whey proteins in skim milk
WPC 35 (8-10 % TS)
WPC50-75 (15-25% TS)
WPC80-84 (30-33% TS)
WPI (MF permeate)
Skim 26% TS, 20% desal
Sweet whey 30% TS, 40% desal
Acid whey 21% TS, 25% desal
Salt whey desalination
Skim milk 34% TS
Whole milk 30% TS
Sweet whey 30% TS
Acid whey 17-20% TS
Fat separation for WPI 90+ % MPC42-MPC85
MPI/MCI MF Retentate
Native WPC80
Sweet UF permeate
25% TS, 40% desal
Acid UF permeate
22% TS, 30% desal
Sweet UF permeate 25% TS
Acid UF permeate 18-22% TS
Sweet buttermilk 26% TS
Bacteria removal from skim
milk, whey and cheese brine
Sweet buttermilk (retentate for
food ingredients, powder)
Special products, yoghurt,
desserts
WPC80 36% TS
WPI 38% TS
WPC35 32% TS
Cleaning of CIP solutions
White water concentration
RO & NF permeate polishing
Evaporator condensate
NPN losses associated with concentration
NAD/2015-10-08
Internal
Value assumptions
Whey €511/tonne TS €3,927/tonne TOP
Skim €1,667/tonne TS €4,065/tonne TOP
Electrodialysis and ion exchange applications
Index
Internal
NAD/2015-10-08
Electrodialysis
NAD/2015-10-08
Internal
Electrodialysis
► Typically operated between 10 - 45°C
► Effluent treatment, electrical power, cleaning chemicals and steam
make up operating costs
► Thin membranes give low electrical resistance and reduce cost
► Fouling of membranes by proteins and calcium phosphate contribute
to maintenance costs
► Electro-dialysis is best below 70% demineralisation where operating
costs are competitive with ion-exchange
► Very good for removal of organic acids; typically D55-60 gives
acceptable product from acid whey
NAD/2015-10-08
Internal
Ion Exchange
► Cation Exchange: R – H + Na+ = R – Na + H+ (resin in H+ form)
► Anion Exchange: R – OH + Cl– = R – Cl + OH– (resin in OH–
form)
► Sulphonic groups -SO3-H+ (strong acid cation exchanger)
► Carboxyl groups -COO-H+ (weak acid cation exchanger)
► Quatenary amine N+ OH- (strong base anion exchanger)
► Tertiary amines NH+ OH- (weak base anion exchanger)
NAD/2015-10-08
Internal
Demineralisation Processes
D30-40
NF
D50-D70
NF ED
D50-D70
IEX1 NFACID HTST
STD
D90 Acidic
IEX1 NF EDACID HTST
IEX2 STD
D90 Basic
NF ED IEX STD
NAD/2015-10-08
Internal
Parameter
pH 6.4 – 6.7
Fat (% on DS) < 1.25
Total protein (% on DS) < 100
Ash (% on DS) < 0.90
Calcium (mg/100g DS) < 100
Magnesium (mg/100g DS) < 50
Sodium (mg/100g DS) < 20
Potassium (mg/100g DS) < 300
Chloride (mg/100g DS) < 20
Phosphorus (mg/100g DS) < 160
Parameter Typical Yield
Total solids 85%
Total protein 84%
Whey proteins 97%
NPN 44%
Lactose 97.5%
Fats 98%
Organic acids 4%
Bacteria Count
Mesophilic Bacteria < 5000 cfu/ml
Thermophilic Bacteria < 100 cfu / ml
NAD/2015-10-08
Internal
Eurodia acidic D90 process
Product Quality and Yields
D90 process
Cost per Tonne D90
Hydrochloric acid 24
Caustic Soda 11
Compressed Air 0.4
Ultrasil 15
Power 10
Chilled Water 8
Steam 3
Resins, membranes etc 30
101
NAD/2015-10-08
Internal
Typical Operating Costs
Effluent costs dependent on the disposal options available to the site
Evaporation and Drying
Index
Internal
NAD/2015-10-08
Typical Operating Total Solids
Product Feed TS Concentrate
TS
Whole milk 12.5 – 25% 52% (MH)
Skim milk 9 – 18% 50% (MH)
Sweet whey 18 - 23% 64%
D40 – D90 18 – 22% 58-62%
UF permeate 18 – 25% 67%
MPC85 18% 26%
WPC35 10% 45%
WPC80 / WPI Not used 36-40% (NF)
MCC 10% 21-23%
NAD/2015-10-08
Internal
Falling Film Vacuum Evaporation
Balancing energy consumption against quality & yield loss
Cost Item (€/tonne
water removed)
Skim
RO
18%
Skim
RO
30%
MVR
Skim
Electrical Power 0.7 0.7 1.2
Steam 0.1 0.1 0.7
NPN Loss 1.2 1.6
CIP chemicals 0.7 0.7 0.4
Water & Waste 0.2 0.3 0.3
Maintenance % 3% RV 0.4 0.4 0.2
Depreciation @ 5% 0.1 0.2 0.4
Interest @ 5% 0.1 0.1 0.2
Total 3.7 4.3 3.6
NAD/2015-10-08
Internal
Membrane pre-concentration before evaporation
Product Range Flexibility
NAD/2015-10-08
Internal
Spray Drying
Key Points
► Normally protein loss and value for improved functionality outweigh
energy savings; be careful when optimising.
► RO pre-concentration worthwhile but consider protein loss
► Acidic ion exchange superior for D90
► Distinguish between routine flexibility and emergency flexibility.
► Dryers and evaporators can be quite flexible if designed for upfront
but allow time for this
► Line optimisation requires balancing complex and competing
priorities for each unit operation and the specific applications
NAD/2015-10-08
Internal
Recommended