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The utilization of whey in manufacturing whey derivatives

Presented By

R.P. Singh (C.E.O)

(Food & Biotech Engineers (I) Pvt. Ltd.)

Business Partner M/s GUTH South Africa (Pty) Ltd

South Africa

A Presentation For SA Society of Dairy

Technology

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Introduction

Established in 1990.

FOOD & BIOTECH ENGINEERS (I) PVT. LTD is a leading manufacturer and engineering consultancy company for

o Project report preparationo Designing of equipmentso Fabrication of equipmentso Projects Executiono Commissioning of plant

Company has an ability to produce multifarious machineries to manufacture all

o Dairy, o Fruits, o Starcho Pharmaceutical products.

We have supplied more than 150 milk and milk products plant like casein, DM whey, WPC etc. in India and abroad.

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Sources & Whey Characteristics

Whey is generated during production of casein and Cheese (cottage, cheddar etc.)

Earlier it was considered as a by product or waste product but since last 3 decades due to strict environment norms & economic competitiveness , whey and whey derivates has emerged as co products of dairy processing unit worldwide.

Technology has developed quite fast to produce value added whey derivatives.

BOD of whey : 1 lit whey: 30-45 lit of O2 demand

BOD5: 300,000 gm O2 / 5days

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Whey Composition

Whey comprises 80-90% of total volume of milk entering

the process and contains about 35-40% of the nutrients in the

original milk: soluble protein, lactose, vitamin and

minerals.

Composition Of Whey

Constituent Cheese Whey Casein Whey

% %

Total Solid 6.4 6.5

Water 93.6 93.5

Fat 0.05 0.04

True Protein 0.55 0.55

NPN 0.18 0.18

(Non Protein Nitrogen)

Lactose 4.8 4.9

Ash 0.5 0.8

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Compositional Characteristics of Whey and Permeates

Cheddar Lactic acid Hydrochloric acid

Rennet

Liquid whey % solids

6.1-6.6 6 5.8-6.1 6.4-6.7

PH 6.1 4 4.6 6.6

Powder (%) of dry matter

Lactose 74-81 65.5 70-76 75-80

Protein 12.8-15.2 12 9.9-12.8 13.8-15.5

Ash 7.6-9.2 12 11.6-19.4 7-8

Lactic acid 2 10 ND ND

Fat 1 0.5 ND ND

Minerals

Ca 0.61-0.78 1.9 2-2.4 0.7-0.8

P 0.76 1.5 2.8-3.2 1-1.4

NaCl 2.5 2.5 2.5 2.5

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Flow Diagram For Different Whey Derivatives

Production

Acid/sweet Whey

WHEY PROTEIN

CONCENTRATE

ULTRA FILTRATION

MEMBRANE

NANO FILTRATION MEMBRANE

DEMINERALIZED

WHEY LACTOSE

WHEY PROTEIN

CONCENTRATE

POWDER

DEMINERALIZED

WHEY POWDER

Evaportaor & dryerEvaportaor & dryer

LACTOSE

POWDER

Washing + Crystallization

+ Dryer

ION EXCHANGE PLANT /

ELECTRODIALYSIS

Whey Clarifier

Whey Pasteurizer

Whey Silo

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Clarification process :

The whey is clarified in order to separate the curd fines from whey.

The curd fines confer a serious risk of blocking heat exchanger or damaging

UF or RO membranes

It may adversely affect the solubility properties and flavor of the end product.

If fines content is high then a self discharging clarifier shall be used.

Processing of Whey

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Separation of fat

Centrifugation is preferably performed by means of a self cleaning cream separator to minimize the fat content in cheese whey.

In a low fines load situation the separator may also serve to clarify the whey or act as a second stage clarifier following the primary clarifier in a high fines load situation.

Pasteurization

The time/ temperature combination of heat treatment is 72-75 deg C /15-20 sec to ensure proper reduction in viable counts to inactivates the phosphatase and rennet enzymes, then it is cooled to 5 deg C for storage.

Processing of Whey

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Demineralization and Concentration of Whey

Nanofiltration:

Whey has a high salt content , about 8-12% calculated on dry matter basis, its usefulness as an ingredient in human food is limited.

The partial demineralization of 30-50% takes place in Nanofiltration.

Small particles like certain monovalent ions e.g Na, K, chloride and small organic molecules like urea and lactic acid can escape through the membrane together with aqueous permeate.

Processing of Whey

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Nanofiltration

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5/6 effects TVR / MVR evaporator:

Falling film evaporator is used for concentration of whey and permeate.

Whey and permeate are evaporated to a solid content suitable for subsequent drying process which may vary from 40-60% TS.

After preheating and pasteurization the product to be concentrated is pumped to the top of the first evaporation stage, is evenly distributed over the inner surfaces of the long vertical tubes and flows as a film down to the vapor separator

The heating medium for the 1st stage is a mixture of this vapor and live steam.

From stage to stage there is a decreasing boiling temp. which is due to existing vacuum differences.

The product is pumped from stage to stage in a continuous flow using the vapor from the previous stage as a heating medium.

The vapor from last stage is condensed by means of cooling water.

Processing of Whey

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P & I Diagram Evaporating Plant

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Crystallization of whey

o To avoid the caking properties of ordinary whey and permeate powder it is important to crystallize the lactose into the no hygroscopic alfa lactose hydrate form.

o With 85-90 % of the lactose crystallized in this form it is possible to spray dry the concentrated why with upto 60% TS.

o Controlled crystallization is achieved by the flash cooling of the concentrate to about 30 deg C followed by seeding with microfines lactose.

o As soon as possible after cooling to 30 deg cC with agitation of the concentrate fine grained alfa lactose monohydrate ia added at a rate of 0.1%.

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Drying of whey and Permeate

o After concentration upto 55-60 % TS and crystallization the material used to feed the dryer results in better powder quality , higher bulk density and greatly reduced propensity for caking through hygroscopicity.

o The Three stage spray dryer (CMD) with disc atomization is used to dry the whey.

o The concentrate from the crystallizer is taken to balance tank, from where is pumped to the disc atomizer through a duplex type filter.

o Hot air is introduced through a ceiling air dispersers. Thedrying starts on the surface of the droplets.

o The first stage of drying is taking place in the upper part of the drying chamber.

o The secondary drying zone takes place in the static fluid bed in the bottom of the drying chamber.

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Drying of whey and Permeate

o The final drying to the desired moisture content and cooling of the powder take place in the vibrofluidizer located below the drying chamber.

o Fines are blown into the drying chamber via the radially mounted below in pipe in the chamber cone, above integrated bed section.

o The vibrofluidizer has two sections; First sections are usedfor the removal of bound water and the other sections arefor cooling of the powder.

o A secondary function of the vibrofluidizer is to blow off fines, resulting in a narrower particle size distribution andless dust in the final product.

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Drying of whey and Permeate

o The fines blown off from the cone as well as Drying chambers are cleaned in cyclone. These fines are conveyedback to the chamber via roots blower and fines return

nozzle.

The powder from the vibrofludizer is taken into a rotary sifter to separate lumps if any .

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Whey

Whey Retentate Whey Permeate

Whey Proteinconcentrate Lactose

Ultrafiltration plant

ULTRAFILTRATION PLANT

(for the production of whey protein concentrate and

Lactose)

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ULTRAFILTRATION

UF is a physicochemical fractionation and concentration technique in

which a pressurized solution flows over a porous membrane .

The process allows the selective separation of the protein from the

lactose, salts and water to varying degrees under the conditions of

PH and Temp.

The retentate flows over the membrane, while under the influence of

pressure water flows through the membrane, together with the low

molecular weight solute.

The protein is retained by the membrane together with any fat

globules, collides or suspended solids.

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Whey Protein Concentrate

o Whey protein concentrates are powder made by drying the retentate

from the Ultra Filtration of whey. They are described in terms of their

protein content , % protein in dry matter basis, ranging from 35% to

85%.

o The concentration of whey proteins is primarily achieved today by UF

and Diafiltration starting either with whey or with protein dissolved in

dilute solution from ion exchange adsorbents.

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WPC Powder Composition

Product 1 2 3 4

Protein 35% 50% 65% 80%In dry matter

Moisture 4.6 4.3 4.2 4.0

Crude protein 36.2 52.1 63.0 81.0(Nx6.38)

True protein 29.7 40.9 59.4 75.0

Lactose 46.5 30.9 21.1 3.5

Fat 2.1 3.7 5.6 7.2

Ash 7.8 6.4 3.9 3.1

Lactic acid 2.8 2.6 2.2 1.2

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Use of WPC

o Infant formulas and weaning foods

o Aerated bakery applications

o Reformed meats/ meat emulsion/ water added meat products

o Aerated confections

o Frozen dessert novelties

o Frozen food entrees

o Microwave products

o Fruit juices with added protein

o Nutritionally fortified snacks foods.

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Whey permeate from UF plant

Falling film Evaporatorto concentrate the whey permeate up to 50% TS

Lactose Powder

Crystallizer (to form the lactose crystals)

Decantation and washing

Fluidized bed dryer

Lactose Manufacturing process

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Use of Lactose

o In the manufacture of infant formulae to raise the lactose content to that of human milk.

o In the pharmaceutical industry for tabletting

o Use in the food industry in general

o As a basic raw material for technical applications

o In the fermentation industry

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Lactose derivative (Lactulose)

o Lactulose is an isomer of Lactose.

o It is formed in small amounts during the heating of milk and is produced commercially from alfa lactose hydrate by isomerization with calcium hydroxide.

o The major commercial form of Lactulose is a fluid, hygroscopic concentrate with 65% TS.

o Use of Lactulose

o In food industry as its is half as sweet as sugar

o Used in Infant formulae

o Used in pharma industry for the treatment of portal systemic encephalopathy and chronic consitpation.

o

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Thanking You!!