Concentration of Whey-based Ingredients

Tetra Pak
Concentration of whey based ingredients
Gerard Pasma
Business Manager Evaporators
October 14th 2015
Public
GPA / 10.14.2015
Wh t is
What
i whey?
h ?
Public
GPA / 10.14.2015
Whey is mainly a cheese co-product but can also come
from casein, yoghurt production or skim milk microfiltration
►
Rennet-precipitated cheeses/ casein give high
quality sweet whey containing casein GMP
quality,
−
►
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Skim milk microfiltration gives ‘ideal whey’ which
is high quality with interesting properties
Culture-precipitated cheeses and casein can
give highly problematic acid whey often
with low protein
−
►
Cheddar, Gouda, Edam, Mozzarella, Swiss,
Emmental, Parmesan
Cottage cheese, tvorog, Greek yoghurt,
lactic casein
Direct-acidification cheeses or casein can give
varying properties depending on the process
−
Mineral acid casein, paneer,
directly-acidified Mozzarella
Rennet cheese
Cheese milk ~
9,000-10,000 kg
1,000 kg
Sweet whey
8 000-9 000 kg
8,000-9,000
Casein
Ski milk
Skim
ilk ~
9,200 kg
280 kg
Casein whey
8,920 kg
Public
GPA / 10.14.2015
Whey composition and quality
I
Important
t t aspects
t
Protein
structure
Fouling of evaporators,
p
on crystallization,
y
,
impact
can be too high for nutrition
Un-crystallized lactose, lactic
acid, citric acid, galactose and
glucose make drying difficult
Calcium &
minerals
Sticky
components
Target-controlled denaturation
Fat & fines
Microbiological
quality
Fouling of filtration
plants and impact on
powder functionality
Heat resistant bacteria & spores
inactivate starter culture and
enzymes
Public
GPA / 10.14.2015
Whey quality – process considerations
Time is the enemy
– old whey creates
h d h
headaches
Temperature kills
bacteria but
denatures protein
and
d precipitates
i it t
calcium phosphate
Heating-cooling
cycles create fines
and
d ffouling
li
Long run times
can cause
thermophilic spore
problems
High quality whey
Public
GPA / 10.14.2015
Characteristics of various whey types
Whey type
Characteristics
High level,
level good quality protein – fines relatively easy to remove
Bactofuges/microfiltration now used to control gas-forming spores –
good microbiological quality, can contain nitrates to control this
► Higher end of fat range but easily separated
► Lower
o e TS
S due to wash
as water
ate
►
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Semi-hard
Cheddar
Mozzarella
►
►
►
High level, good quality protein – fines relatively easy to remove
Spores good if cheese milk pasteurization run length is < 8 h
Low fat achieved with good recipe and cutting control < 0.25%
►
►
►
►
High level, good quality protein – fines relatively easy to remove
S
Spores
good
d if cheese
h
milk
ilk pasteurizer
t i
run llength
th iis < 8 h
Higher levels of galactose (sticky) due to culture types
Lower pH and stickier to dry due to some direct acidification
Public
GPA / 10.14.2015
Characteristics of various whey types
Whey type
Grana
Padano/
Parmigiano
Reggiano
Cottage/
tvorog
HCl casein
Characteristics
High level, good quality protein
Contains lysozyme added to control bloom during maturation
Contains copper from use of copper vats
Thermophilic starters can increase galactose,
lactic acid and bacterial risks
► Gravity separation of fat at 12-20°C increases bacterial counts
►
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Often lower level of protein with higher enzymatic breakdown
High levels of lactic acid which makes it very difficult to spray dry
Higher calcium which reduces evaporator run time
►
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High level, good protein – low fat since made from skim milk
Hi hl corrosive
Highly
i d
due tto chloride
hl id – high
hi h calcium
l i
Public
GPA / 10.14.2015
Most common whey products
Whey
powders
Standard
Demin 40
Demin 70
Delactosed
(DLWP)
Demin 90
WPC60-80
Whey
protein
products
Permeate
products
WPC35-59
Permeate
powder
WP isolate
High fat
WPC
Lactose
edible
Mother
liquor
Lactose
pharma
h
Public
GPA / 10.14.2015
Typical Investments Behaviour of Whey Processors
Whey Volume
lbs/day
Strategy
Typical Equipment
< 50,000
Disposal options mostly
< 0.5 million
Concentrate and sell
Clarifier, Chilling, RO-NF and occasionally
Evaporator
0.5 – 1.5 million
Fractionate, concentrate and sell
Clarifier, Separator, Pasteuriser, UF, RO, NF or
E
Evaporator
t
1.5 – 2.0 million
Standard Whey Powder or WPC35 +
permeate to liquid feed sales
Pre-treatment, RO-NF, evaporator, crystallization,
drying
2.0 – 3.0 million
Whey powder, demineralised whey
powder, milk powders to balance milk
Pre treatment, NF, ED, IEX, evaporation,
Pre-treatment,
crystallization, drying, powder handling
3.0 – 5.0 million
WPC & Permeate
Common: Pre-treatment, UF
WPC: NF, drying, powder handling
P
Permeate:
t NF,
NF evaporation,
ti
crystallization,
t lli ti
postt
crystallizing dryer, powder handling
> 5.0 million
WPC + Lactose
As above substituting lactose line for permeate line
Public
GPA / 10.14.2015
Global Market Situation Summary
►
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►
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WPC, lactose and permeate projected to grow the fasts
Whey and demineralised whey continue to grow strongly
North America continues to dominate supply of protein & permeate
products
Central & West Europe continue to dominate the supply of
demineralised whey
Eastern Europe and Latin America growing suppliers of
demineralised whey
Data source: 3A Business Consulting; OECD-FAO
Public
GPA / 10.14.2015
Product yield considerations
per Whey
Wh Line
Li solution
l ti
Public
GPA / 10.14.2015
Product yields
Wh
Where
do
d the
th whey
h solids
lid go?
?
100%
Disposal
Mother liquor
Protein powder
Bulk powder
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Whey
Wh
powder
DWP40
DWP70
DWP90
WPC35 +
permeate
WPC80 +
permeate
WPC80 +
lactose
Public
GPA / 10.14.2015
C
Concentration
t ti ttypes
Public
GPA / 10.14.2015
Concentrating of whey based products by Filtration
(Tetra Pak Filtration Engineering - Minneapolis)
MF
UF
NF
Bacteria
RO
Fat globules
Casein
Whey protein
NPN
Lactose
Salts
Water
200
20 000 100,000
20,000
100 000
500 000
500,000
MW
(Molecular weight)
0
0.001
0.01
0.1
1.0
Public
GPA / 10.14.2015
Concentrating of whey
based products by
Evaporation
((Tetra Pak Inc - Winsted))
►
Evaporation can be done
by either using steam or
electricity
e
ect c ty as tthe
ed
driving
g
force, or a combination
−
Steam = Thermal Vapour
p
Recompression (TVR)
Public
GPA / 10.14.2015
Concentrating of whey based products by Evaporation
(Tetra Pak Inc - Winsted)
−
Electricity = Mechanical
p
Recompression
p
Vapour
(MVR)
Energy sources
►
Evaporator running on steam = Thermal Vapour Recompression (TVR
Evaporator)
►
Evaporator running on electricity = Mechanical vapour Recompression
(MVR Evaporator)
When choosing TVR or MVR or combination?
Depending on price of steam and electricity
Depending on evaporator size
Depending
p
g on reliability
y of electricity
y
Commonly used type of
concentrations
t ti
per product
d t
Public
GPA / 10.14.2015
Concentration of Whey Protein products
(UF of sweet whey)
Concentration by
Filtration
Concentration by
Evaporation
WPC35
Not used
Up to ~45%TS
WPC80
As high as possible
(~35-38%TS)
Most of the time not used
WPI
A high
As
hi h as possible
ibl
(~35-38%TS)
Most of the time not used
Public
GPA / 10.14.2015
Way of Concentration for Whey
and UF Whey
Whey-Permeate
Permeate
Pre-concentration
Final concentration
TVR Evaporator
TVR Evaporator
1985 – 2000
MVR Evaporator
TVR Evaporator
2000 – 2010
Filtration (RO) or MVR
Evaporator
TVR Evaporator
2010 – 2015
Filtration (RO)
MVR Evaporator or
combination with
ith TVR
Evaporator
Future
Filtration (RO)
MVR Evaporator
Period up to 1985
Public
GPA / 10.14.2015
Latest
Whey + Whey
Whey-Permeate
Permeate
Concentration lines
Pre-concentration by Filtration
(RO and/or NF)
and
final concentration by MVR
Evaporation
Public
GPA / 10.14.2015
Thank you
Contact details for Evaporator and Dryer enquiries
Erin Davis
Product and Application Manager Evaporation and Drying
Tetra Pak Inc.
600 Bunker Ct, Vernon Hills, IL 60061, USA
Mobile: +1 320 582 1014
Erin.Davis@tetrapak.com
Public
GPA / 10.14.2015