Membrane Filtration

Cheese and Whey Applications

ESCUELA SUPERIOR INTEGRAL DE LECHERIA

VILLA MARIA, ARGENTINA SEPTEMBER 13 – 14 2017

 Topics of Presentation

• Whey Processing Overview

• Membrane Filtration Principles
• Membrane Types
• Cheese and Whey Applications
• GEA Offering

Presenter:
• Jose Carlos De la Colina
• Phone: 1-715-410-2408
• Email: jose.delacolina@gea.com

Membrane
Filtration

2
 Cheese and Whey Applications

Whey Processing Overview

• 30 some years ago Whey was a Waste Stream
• Membrane Technology has transformed whey handling and the
dairy industry.
• Introduced in the ’70s
• 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.

Membrane
Filtration

3
Membrane Filtration Principles
Filtration - Dead end vs. Crossflow

• Batch
• Flow perpendicular to
• Continuous
Filter Press
the filter media
• Flow parallel to filter media
• The solids form the
filter media, often • Constant filtrate flow
aided by precoat
• Fine separation based on
• Variable filtrate flow size
• Gross filtration
Cartridge Drum Filter
Membrane Filter • Not hygienic
Filtration

Membrane Filtration - Introduction March 31, 2016 4

Membrane Filtration Principles
Crossflow Filtration
Membrane
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 cost-
effective separation solution.

Microfiltration (MF) Suspended Particles >0.01 micron

Ultrafiltration (UF) High Molecular Weight >1000 Daltons
Nanofiltration (NF) Low Molecular Weight >300 Daltons
Reverse Osmosis (RO) Dissolved Salts

Water 18 Daltons

Membrane
Filtration

5
Filtration Spectrum
Milk Components

10-4 10-3 10-2 10-1 1 10 Microns

Bacteria / spores
Casein

Suspended solids
Fat
Whey Proteins
Water

Minerals

Lactose
bar
psi
15 -300
1–2

MF • Removal of Suspended Matter

Operating Pressure

• Removal of Bacteria & Spores

300-1000 150 - 450 30-150
2 – 10

• Fractionation of Proteins
UF • Purification Proteins
• Concentration of Proteins
20 – 65 10 – 30

NF • Concentration of Liquid Dairy

• Desalting of Liquid Dairy

RO • Concentration of Liquid Dairy

• Water Recovery
Membrane
Filtration

Applications in Dairy July 27, 2016 6

Membrane Types
Membrane 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

Membrane
Filtration

Introduction - Webinar April 4 & 8 2016 7

Membrane Types
Membrane Suppliers

Polymeric Inorganic
Hydranautics KOCH Membrane GEA
Systems • Ceramic membranes
• UF, RO • MF
• MF, UF, NF, RO

Microdyn Nadir DOW TAMI Industries

• Ceramic membranes
• UF • NF, RO • MF, UF

TriSep Alfa Laval PALL Corporation

• Spiral and Plate & Frame • Ceramic membranes
• NF, RO • MF, UF, NF, RO • MF, UF

Synder Filtration Parker Atech Innovations

• Ceramic membranes
• MF, UF, NF • MF, UF, NF, RO • MF, UF

GE Toray Graver Technologies

ScepterR Membrane
• MF, UF, NF, RO • MF, UF, NF, RO
• SS membranes
• MF
Membrane
Filtration

Membrane Filtration - Introduction March 31, 2016 8

Membrane Types
Polymeric - Spiral Wound Membrane

Membrane
Permeate
Tube

Permeate
Spacer
Feed Spacer

Click to see “Hydranautics: Spiral Wound Reverse

Osmosis Elements“
Courtesy - Hydranautics

Membrane
Filtration

Membrane Filtration - Introduction March 31, 2016 9

Membrane Types
Polymeric - Spiral Wound Module

Retentate/concentrate outlet

Permeate/filtrate
Housing

End cap End cap with

permeate/filtrate outlet

Membrane Element

Feed

ATD - Anti Telescoping Device

or
Membrane ESA – Energy Saving ATD
Filtration

Membrane Filtration - Introduction March 31, 2016 10

Membrane 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

Membrane
• Limited pH and temperature tolerance
Filtration

Membrane Filtration - Introduction March 31, 2016 11

Membrane 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

Membrane
Filtration

Membrane Filtration - Introduction March 31, 2016 12

 Cheese and Whey Applications

Membrane
Filtration

13
Milk Standardization
Cheese Milk by Addition of MPC

UF Permeate

Raw Milk Raw Milk Storage Clarifier / Separator UF Plant UF Milk Storage
Pasteurizer

Cheese Milk Cheese Vats

Clarifier / Separator
Membrane Pasteurizer
Filtration Standardize Fat Surplus Cream

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

CIP return
OPTIQUAD-M 4050W -
Raw milk Spectroscopic Inline
10,000 kg/h MPC60 Analyzer
Fat: 4.25 1,035 kg/h
Protein: 3.30 Fat: 0.17
Protein: 9.33

1,049 kg/h
29 kg/h

Membrane
Filtration

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 Cheese Milk Cheese Vats

Membrane Pasteurizer
Filtration Standardize Fat

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

Membrane
Filtration

Applications in Dairy July 27, 2016 17

Protein Fractionation in Skim Milk by MF
Milk Protein Composition
Apparent Nominal
% of Isoelectric
Proteins Molecular weight Particle size
TOP point
[kD] [nm]
Casein micelles
78 - 79 4.6 400 – 2,000 120 (50 - 500)
Whey proteins: 21 - 22 - - -
-lactalbumin 3-4 4.2 - 4.5 14 3-5
-lactoglobulin 10 - 12 5.2 - 5.4 36 3-5
Immunoglobulins 2-3 5.5 - 8.3 LgG: 150, IgA: 385 5 - 15

Bacteria & spores

Casein
Whey Proteins

Fat

Suspended solids
Minerals
Water

Bovin Serum Albumin

Lactose

0.3 - 1 4.7 - 5.1 66 3-5

NPN 5-6 - <1 <1

MF

UF

NF
Membrane
Filtration RO

Applications in Dairy July 27, 2016 18

Protein Fractionation in Skim Milk by MF
MCC and NWPI Production
Ceramic MF Evaporator
Pasteurizer Skim Milk
Raw Milk
Storage Clarifier Storage
Separator

OR
Raw Milk

MCC to Dryer
Spiral Wound MF
MCC for
Ingredient /
Native Whey Cheese milk
Standardization
Storage RO RO Polisher

UF / DF Polished Water

RO Conc. UF
Permeate for
Lactose

Conc. NWPI to
Membrane Dryer
Filtration

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
Membrane life 1 – 2 years 10 Years
Resistance chemicals and temperature Medium High

Ceramic Spiral Spiral

MF (50°C)2) Wound MF Wound MF
(50°C) (10°C)

β Casein in Permeate 1) ”Low” ”Low” ”High”

Expected max. running time 8 - 10 hours 8 - 10 hours 20 hours

1) At low temperatures loss of β Casein in permeate

Reachable CAS/TOP ratio (95%) ”High” ”High” ”High”
due to weak linkage with micellar casein
SP Permeability ”High” ”Medium” ”Medium”
2) Operating Ceramic Membranes at low temperature
cost prohibitive due to low fluxes ”Heat and hold” stabilisation Yes No No
Membrane
Filtration 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 Membranes

Advantages of GEA MF System

• Higher permeability of Native Whey Proteins
• Lower space requirements
• Less Diafiltration water
• Lower cost

Membrane
Filtration

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Protein Fractionation in Skim Milk by MF
Plant Layout

Membrane
Filtration

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

Sweet Whey Pretreatment

• pH 5.9 – 6.5, Titrated acidity max. 0.15% as lactic • Removal of fines by fine saver and/or centrifugal
acid clarifier, Residual fines <100 ppm by wt. or 300
• Salty Whey or Cooker water not blended. ppm by vol.
• Pasteurized no later than 2 hours of draining from • Separation of fat by means of a centrifuge.to <
the vats. 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
Membrane be CIP’d daily.
Filtration

Applications in Dairy July 27, 2016

23
Whey Protein Concentrate / Isolate (WPC / WPI)
WPC Process

Pasteurizer Whey
Raw Whey
Storage Clarifier Storag
e
Separator
RO / NF

9-20%TS

UF Permeate
UF DF

WPC 35% WPC 80 %

10%TS 33 %TS
WPC 50%
15-20%TS
Diafiltration water
Membrane
for
Filtration
WPC 70-83%

Applications in Dairy July 27, 2016

46
Whey Protein Concentrate / Isolate (WPC / WPI)
WPI Process
Pasteurizer Whey
Raw Whey
Storage Clarifier Storag
e
Separator
RO / NF

9-20%TS

UF Permeate
UF MF DF

WPC 50%
12 - 15%TS WPI 90 %
28 %TS

Diafiltration water
for
Membrane Procream
WPC 70-83%
Filtration 16%TS
July 27, 2016

Applications in Dairy 25
Whey Protein Concentrate / Isolate (WPC / WPI)
WPC/WPI concentration for Dryer
Raw Whey Pasteurizer Whey
Storage Clarifier Storag
Separator e
RO / NF

9-20%TS

UF Permeate
UF MF DF RO

WPC 35% WPC 80 % WPC 80 %

10%TS 33 %TS 38 %TS
WPC 35% WPI 90 % WPI 90 %
15-25%TS 28 %TS 40 %TS
Diafiltration Water
for
Procream
Membrane WPC 70-83%
xx %TS
Filtration

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 Pretreatment for Whey

• pH 5.9 – 6.5, Titrated acidity max. 0.15% as lactic • Removal of fines by fine saver and/or centrifugal
acid clarifier, Residual fines <100 ppm by wt. or 300
• Salty Whey or Cooker water not blended. ppm by vol.
• Pasteurized no later than 2 hours of draining from • Separation of fat by means of a centrifuge.to <
the vats. 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
Membrane be CIP’d daily.
Filtration

Applications in Dairy July 27, 2016 27

Concentration of Sweet Whey / UF Permeate by RO

Raw Whey Pasteurizer Whey

Storage Clarifier RO Permeate
Storag
for water
Separator e
High Pressure Recovery
RO / NF Section

RO NF
Sweet Whey Sweet Whey
28 %TS 30 %TS
Whey Whey
Permeate Permeate
28 % TS 30 % TS

RO NF
UF UF Permeate Sweet Whey Sweet Whey
22 %TS 26%TS
Whey Whey
Permeate Permeate
WPC
22% TS 26% TS

Addition of sequestering agent such as citric

acid required for high concentration
Membrane
Filtration

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

Filtration
• 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

Membrane
Filtration

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)

Membrane
Used Brine Clean Brine Sludge
Filtration

Applications in Dairy July 27, 2016 30

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

31 MICRO FORMULA™
MICRO FORMULA™

32 MICRO FORMULA™
Microparticulated WPC Process Line

Clarification
Raw
Whey Fat Separation
Pasteurization

Liquid
Stabilizer
Liquid Fat
Replacer
Buffer MICRO Powder
UF WPC 60 Deaeration FORMULATM MWPC 60
Pre-treated
Whey

33 MICRO FORMULA™
Product Appearance

UF Process MICRO FORMULATM…

Whey

WPC 60
Permeate

WPC 60 MWPC 60

34 MICRO FORMULA™
MICRO FORMULA™ - Microparticulated WPC

Fat/protein replacer in… Characteristics…

• Most cheese types (yield)
• Yoghurt and milk desserts
• Ice cream
• Dressing and sauces
• Mayonnaise and fat emulsions
• Other fat-containing food products
• 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™

35 MICRO FORMULA™
MICRO FORMULA™ - Microparticulated WPC

Milk saving
Fat in dry % addition to Extra cheese index/kg
Cheese matter cheese milk yield 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

• 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

37 MICRO FORMULA™
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

38 MICRO FORMULA™
GEA Offering

We, with our wide process experience, are uniquely positioned to provide both customized
Membrane Filtration 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 New Applications

• Process integration Membrane Process

• Automation Replacement
Integrated
Development
& Spare Parts
• System fabrication Service
Pilot Testing
• System installation and start-up And
• Service and plant audits Optimization & Process
Validation
• Replacement membrane inventory Long-Term Support

Installation,
Commissioning, Seamless Engineering
Training, & Support and Project
Transition Management

Membrane Manufacturing
Filtration

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

Membrane http://www.gea.com/global/en/search/index.jsp?q=Membrane+Filtration+Pilot+plants
Filtration

Membrane Filtration - 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

Membrane
Filtration

Introduction - Webinar April 4 & 8. 2016 41

 Thank You
Q&A
gea.com