Filtration Technology UF & MF as the Means to Improve Cheese Makes & Standardize Yields November 15, 2016 Milk Molitor Wisconsin Center for Dairy Research Center for Dairy Research Solution Based Research Backed by Experience, Passion and Tradition
Presentation Outline 1. Historical Perspective 2. Goals for Cheese Makers 3. Membrane Fractionation 4. Retention Coefficient Comparisons 5. Utilizing UF Retentate 6. Microfiltration Process Option 7. Conclusions
The good old days When there were far fewer process options, but no shortage of hard work
What Can Filtration Achieve? Realistic Goals for Cheese Makers and Benefit the Bottom Line too How? 1. Consistent Cheese Makes 2. Targeted Cheese Composition 3. Higher Cheese Yields 4. Valuable Products that by Pass the Vat
1. Consistent Cheese Makes A Realistic Goal for Cheese Makers How? Correct for Milk s Seasonal Variation Standardize for Everything that matters Super Standardized Milk = Predictable Vat Ingredient Inputs & Uniform Outcomes for both the Process and Cheese Composition
2. Targeted Cheese Composition A Realistic Goal for Cheese Makers How? Cycle Less Whey Solids through the Vat Mitigate the Issues caused by Excessive Other Solids Retained by the Cheese Too much Lactose > Low ph Too much Serum Protein > Bitter Aged Flavor Too much Calcium > Excessive Buffering
3. Higher Cheese Yields A Realistic Goal for Cheese Makers How? Higher, Specifically Targeted Cheese Yield Higher with more Fat & Casein in the Vat Also Higher due to Retention Increases Even Pre-Cheese that Does Not Utilize Whey Drainage like for some Soft Cheeses
4. The Valuable Co-Products Uniform, High Quality Products Made Directly from Milk / By Passing the Vat 1. β Casein an Exceptional Product that Merits Pharmaceutical Utilization 2. Milk Derived WPC & WPI (Native Whey) has clean bland flavor, is very low fat & has a unique Protein profile 3. Milk (UF) Permeate has clean, milky flavor & is a dream to spray dry * The whey also has unique protein profile
The Membrane Separation categories utilized by Dairies Molecular weight (daltons) 10 100 1,000 10,000 100,000 1,000,000 Milk Component water ions lactose vitamins lactalbumin lactoglobulin BSA lactoglobulin octamers immunoglobulins fat globules nonprotein nitrogen enzymes BSA polymers GMP proteose-peptones casein micelles bacteria viruses yeasts, molds Separation Process Reverse osmosis Nanofiltration Ultrafiltration Microfiltration Traditional filtration Micrometers Ionic range < 0.001 Molecular range 0.01 0.1 1.0 >10.0 Macromolecular range Microparticulate
Protein Fractionation Overview along with other milk components
Van Slyke Cheese Yield Equation Yield = (((%Fat x Fat R.C.)+(%CN x CN R.C.)) x Other Solids R.Factor x 100)/%Cheese Solids 0.8 0.94; The wide range of Fat R.C. 0.96; The standard Casein R.C. If the Other Solids Retention Factor is 1.1, then the combined sum of Serum Proteins, Lactose, Milk minerals, Added NaCl, lactic acid etc., account for ten percent of the fat & Casein mass. So Other Solids is a reliable multiplication factor, but not a coefficient ranging from 0-1 R.C. = Retention Coefficient
Most Cheese Retention Coefficients can be Shifted 1.2 Retention Coefficients Estimate 1 0.8 0.6 0.4 0.2 0 Water Soluble Calcium Serum Protein Casein Butterfat Control UF Retentate MF Retentate
Fractionation Efficiencies Compared (Retention Coefficients Range from 0-1) Various Processes that Fractionate Milk Butterfat Retentions Serum Protein Retentions Casein Retentions Butterfat Separator 0.985 NA NA Typical Cheese Makes 0.8-0.94 <0.1 0.96 Reverse Osmosis & Nanofiltration 1.0 1.0 1.0 Ultrafiltration 1.0 >0.99 1.0 Spiral Microfiltration 0.96 1.o > 0.5 0.99 Ceramic Microfiltration 0.96-1.0 < 0.3 0.99
Retention Coefficient Estimates of Milk Processed by Spiral Microfiltration Individual Proteins Processed by Spiral MF Protein Retentions Estimated Effective Molecular wt. (k Dalton) α-lactalbumin 0.4 14 Solubilized β Casein (Monomer) 0.5 24 β-lactoglobulin 0.5 36 Bovine Serum Albumin 0.6 66 Lactoferrin 0.6 80 Immunogloblins >0.9 150-900 Casein Micelles 1.0 >1 10 3
One Way to Utilize UF Retentate Milk contains too much Lactose! Only a minor percentage of the Lactose is utilized for acid development -Opportunity: Ultrafiltration Gently & Efficiently Concentrates All Fat & True Protein while removing Almost as much Lactose as volume Then Standardize to the Desired Composition
WM UF Retentate Composition Concentration Factor (CF) = Volumetric Ratio of Feed/Retentate WM 1X CF 1.5 X CF 2X CF 3X CF % Butterfat by wt. 3.8 5.7 7.6 11.4 % Casein by wt. 2.6 3.9 5.2 7.8 % True Protein by wt. 3.2 4.8 6.4 9.59 % Lactose by wt. 4.7 4.85 4.97 5.13 Volume Removed 0 1/3 1/2 2/3 % of Lactose Removed as UF Permeate 0 31.1 47.1 63.6 % Total Solids by wt. 12.74 16.48 20.35 27.78 Fat/Casein Ratio 1.46 1.46 1.46 1.46
Skim UF Retentate Composition Centration Factor (CF) = Ratio Feed/Retentate Volume WM 1X CF 1.5 X CF 2X CF 3X CF % Butterfat by wt. 0.06 0.09 0.12 0.18 % Casein by wt. 2.6 3.9 5.2 7.8 % True Protein by wt. 3.2 4.8 6.4 9.59 % Lactose by wt. 4.7 4.85 4.97 5.13 Volume Removed 0 1/3 1/2 2/3 % of Lactose Removed as UF Permeate 0 31.1 47.1 63.6 % Total Solids by wt. 9.00 10.97 12.87 16.56
Reclaimed Water Routine for Lactose Diluted Cheese Milks Whole Milk Acid or Chelator UF UF Perm., ph 6 RO RO Retentate UF Retentate RO Permeate Polisher Standardization Silo or Pasteurizer Balance Tank Potable Water Storage
Chilled Product / Not Water Routine for Lactose Diluted Cheese Milks Whole Milk Acid or Chelator UF UF Perm., ph 6 NF NF Retentate UF Retentate NF Permeate contain some minerals Std. Silo/ Past. B.T. Skip the Polisher & Call the NF Pm. Product, Not Water
Diafiltration; What is it & When to use it Diafiltration, If Added Before UF to wash out more permeate solids Milk Dilution, Not Diafiltration If it s Added After UF Water or? Milk Dilute Perm. Not Good! UF 1 st Stage UF 2 nd Stage UF 1 st Stage UF 2 nd Stage Perm. NOT Diluted Lactose Diluted UF Retentate Lactose Diluted UF Retentate
Does Microfiltration have Advantages over UF? Milk, especially Concentrated Milk contains too much Serum Protein! Why cycle Solids through the Vat that Are Not Retained in the Cheese matrix? And can also Result in Cheese Defects Microfiltration Gently Concentrates All Fat & Casein micelles
No MF Diafiltration for Minimal CN%Protein Increase CDR Warm, Pasteurized Skim MF Retentate 1 st Stage 2 nd 3 rd MF Permeate ~60% Micellular Casein Powder Dryer 1 st Stage 2 nd 3 rd DF Water UF Retentate UF Permeate Dryer Milk Permeate Powder Further Processing Milk Derived WPC 80 or WPI
MF DF with Water for Elevated CN%Protein & MCC80 CDR Warm, Pasteurized Skim MF Retentate DF Water 1 st Stage 2 nd 3 rd MF Permeate 80% Micellular Casein Powder Dryer 1 st Stage 2 nd 3 rd DF Water UF Retentate UF Permeate Dryer Milk Permeate Powder Further Processing Milk Derived WPC 80 or WPI
Ideal DF w/ UF Permeate for High CN%Pr & WPI Yield CDR Warm, Pasteurized Skim MF Retentate DF Water 1 st Stage 2 nd 3 rd MF Permeate Only protein modified ~30% Micellular Casein Powder Dryer 1 st Stage 2 nd 3 rd DF Water UF Retentate UF Permeate Dryer Milk Permeate Powder Further Processing Milk Derived WPC 80 or WPI
MF Diafiltered with UF Permeate to remove the majority of Serum Proteins with negligible Casein concentration No UF Diafiltration Utilized Data from Dec 2014 % True Protein % Casein % Serum (Whey) Protein Casein% of True Protein Pasteurized Skim Milk 3.05 2.52 0.53 82.6 MF Retentate; processed @ 25 C to retain β-cn Milk Derived (native) WPC With Normal β-cn% of True Protein content 2.90 2.56 0.17 93.9 56.4 2.3 54.1 4.1
Part 1, MF Skim Cold to Harvest β-cn with the Serum CDR Cold Pasteurized Skim MF Retentate DF Water 1 st Stage 2 nd 3 rd MF Permeate, β-cn & Serum Proteins Less β-cn Micellular Casein Powder Dryer 1 st Stage 2 nd 3 rd DF Water UF Retentate Milk Permeate Powder Further Processing UF Permeate See Next Slide
Part 2, β-cn is Fractionated from the Serum Proteins CDR Warm β-cn & Serum Protein MF Retentate DF Water 1 st Stage 2 nd 3 rd MF Permeate, the Serum Proteins Patented Dryer 1 st Stage 2 nd DF Water Β-Casein Powder 3 rd UF Retentate UF Permeate Dryer Milk Permeate Powder Further Processing Milk Derived WPC 80 or WPI
CDR Trial to make β-cn Rich Permeate & β-cn Diminished MCC MF operated @ <3 C and Diafiltered with UF Permeate to Harvest More β-cn Data from October 2014 Pasteurized Skim Milk Micellar Casein Concentrate MF process run @ <3 C Cold Temp to solubilize βcn MF Permeate, The Casein is primarily β Casein % True Protein % Casein %Serum (Whey) Protein Casein% of True Protein 3.07 2.49 0.58 81.2 48.3 44.9 3.4 93.0 0.49 0.18 0.31 37.2
Acid Calcium Depleted CDR ph 5.3 Pasteurized Skim Calcium Depleted MF Retentate DF Water 1 st Stage 2 nd 3 rd MF Permeate Ca 2+ Neutralizer Soluble Casein Isolate Dryer 1 st Stage 2 nd 3 rd DF Water UF Retentate Ca 2+ Milk Permeate Powder Further Processing Ca 2+ UF Permeate Heat Stable Milk Derived WPC 80 & WPI Dryer
Comparing the MF Process Options MF Process MF Ret. CN % Prot. Possible Increase MF Ret. %Protein Dry Basis No Diafiltration Low < 65% for Cheese Diafilter with Water Diafilter with UF Permeate Acidified Warm MF Feed & Diafilter with lots of Water High & Majority of Lactose Removed High Up to 95% High High & Targeted for MCC Powder Ranges from 30 to <65%, For Cheese >85%, For Cheese minor Ingredient or Powder WPI Yield low High High High & Heat Stable IF MF Cold, β-casein Yield Very low High High NA
MF Benefits Summarized 1. Microfiltration Concentrates Only what you want to put in the vat, the Casein & Fat 2. We just learned about the path to legally use MF Milk to make Standard of Identity Cheeses? 3. MF can also remove some β-casein which should be pursued for Pharmaceutical use 4. MF permeate (native whey), containing the serum proteins makes unique WPC & Isolate because it by passes the cheese vat 5. Milk permeate is a wonderfully consistent and easy to dry product compared to whey permeate
CDR Process Pilot Plant Front row Custom built Ultrafiltration System Second row- Dairy Experts in training then, now employed Third row Custom built Microfiltration contain two 8.0 vessels
Membranes Offer Great Promise Title and Picture courtesy of Dr. Mark Stephenson, Ag Economist Consistently Reliable and Efficient Process to Fractionate Milk Cool & Gentle Process Relatively inexpensive Can create ideal ingredients for Cheese Milk Standardization
Acknowledgements Current CIT Research on Microfiltration Wisconsin Milk Marketing Board including previous Microfiltration (Native Whey) funding National Dairy Council including previous MF (Native Whey & Micellar Casein) funding Wisconsin Center for Dairy Research Staff; Yanjie Lu & our Director Dr. John Lucey Shane Crowley, FulBright Scholar & PhD Candidate, University College Cork, Ireland Richa Singh, Madison Masters Candidate
Thank You Wisconsin Center for Dairy Research Funded by Dairy Farmers through the Wisconsin Milk Marketing Board, National Dairy Council, and the Dairy Industry Center for Dairy Research Solution Based Research Backed by Experience, Passion and Tradition