Technologies the production of milk-based ingredients

Nick Adamson Ph.D.

Sub-category Manager

Milk & whey based ingredients

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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

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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

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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

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Composition

Where do the solids go?

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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

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Processing Goals - Ingredients

Many Technologies Employed

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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

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Heat treatment and centrifugation applications

Index

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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

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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

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Membrane Filtration

Index

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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

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Overview of Filtration Processes

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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

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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

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Electrodialysis

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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

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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)

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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

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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

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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

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Typical Operating Costs

Effluent costs dependent on the disposal options available to the site

Evaporation and Drying

Index

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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%

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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

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Membrane pre-concentration before evaporation

Product Range Flexibility

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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

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