Progress 10/01/07 to 09/30/12
Outputs
OUTPUTS: 1. Evaluation Of PES Membranes For Processing Whey Into WPC 80: Ultrafiltration with diafiltration is commonly employed in production of WPC 80 from whey. A combination of Ultrafiltration and diafiltration remove soluble components such as lactose, NPN and some minerals from whey while the protein and fat are concentrated. This process increases the relative proportion of protein in the final concentrate. The objective of this study was to evaluate the performance of two PES membranes obtained from Sepro relative to a typical 10 kD PES membrane that is used in production of WPC 80 from whey. Process flux and permeate protein contents were used to compare the relative performance of these membranes. 2. Performance Of Commonly Used PVDF Membranes In Processing Of WPC 34: Microfiltration is generally employed in the production of whey protein isolates from partially concentrated WPC34. In this process, protein aggregates, casein fines and lipid material are retained, and soluble whey protein passes into the permeate stream. This permeate is further processed using ultrafiltration to produce WPI. In the microfiltration process, proper selection of the membrane is essential to optimize the process flux rates, protein yield and fat removal. The objective of this study was to compare the performance of three types of PVDF membranes obtained from Sepro with the performance of three other commonly used PVDF membranes in processing of WPC 34. Process flux, protein yield and fat removal data were used to compare the relative performance of these membranes. 3. Evaluation Of Sepro PES 10 Membrane In Production Of WPC 34 And MPC 80: The ultrafiltration process is generally used in the production of WPC 34 from whey and in production of MPC 80 from skim milk. Generally this process uses 10 kD Polyether sulfone membranes. The objective of this study was to evaluate the performance of Sepro PES 10 membrane in production of WPC 34 from whey and in production of MPC 80 from skim milk. Process flux and permeate protein contents were used to compare the relative performance of these membranes. 4. Testing of a Sepro MPV400H-SPP membrane (spiral configuration) for fat removal from WPC 34: Microfiltration is generally employed in the production of whey protein isolates. In this process protein aggregates, casein fines and lipid material is retained by the membrane and the clear permeate stream obtained is further processed in to WPI. The proper selection of the membrane is essential in optimizing the process flux rates as well as the protein yield and fat removal during microfiltration of WPC. The objective of this study was to compare the performance of MPV 400 H membrane from Sepro membranes with historical data obtained from a 0.5 micron PVDF membrane from a different manufacturer. Process flux, protein yield and fat removal efficiency parameters were used in assessing the performance of the two membranes. PARTICIPANTS: K. Muthukumarappan, L. Metzger, C. Marella, P. Salunke TARGET AUDIENCES: Academia, Dairy Industry, Dairy Processors PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
1. Evaluation Of PES Membranes For Processing Whey Into WPC 80 In the present study, two PES membranes (Sepro PES 10 and Sepro PES2) from Sepro and one 10 kD PES membrane from a different manufacturer were evaluated for their performance in processing of whey into WPC 80. Process flux rates and protein content of the permeates were used as the parameters indicative of process efficiency. Sepro PES 10 had an initial flux of ~ 30 LMH and an average flux of ~20 LMH. Sepro PES2 and 10 kD PES membranes had an initial flux of ~16 LMH and average flux of 10 LMH. The permeates from all the membranes measured 0.12 % protein (N X 6.38). Use of the Sepro PES10 membrane produced a 100% higher flux with no additional loss of protein into permeate when compared to the other two membranes used in the study. 2. Performance Of Commonly Used PVDF Membranes In Processing Of WPC 34 In this study, we compared the performance of three Sepro membranes (MPV400R-SPET, 400H-SPPA and MPV400H - SPP) with three other PVDF membranes (0.2, 0.3 and 0.5 micron PVDF) procured from different manufacturers. Based on overall performance the MPV 400 H- SPP membrane was preferred and had a fat removal efficiency of 92%, Protein yield of 87.5% and average flux of 29 LMH. 3. Evaluation Of Sepro PES 10 Membrane In Production Of WPC 34 And MPC 80 In the present study, the Sepro PES 10 membrane was evaluated for it performance in processing of WPC 34 and MPC 80. The membrane performance was compared with the performance of a 10 kD PES membrane for a different manufacturer. Process flux rates and protein content of the permeate was used as the parameters indicative of process efficiency. In the production of WPC 34, the Sepro PES 10 membrane had an initial flux of ~ 26.3 LMH and an average flux of ~18.7 LMH. These are about 20 and 6% higher than the flux rates obtained with a comparable 10 kD PES membrane used in the study. In the production of MPC 80, the Sepro PES 10 had an initial flux of ~ 16.73 LMH and an average flux of ~7.97 LMH. These are about 12-14 % higher than the flux rates obtained with a comparable 10 kD PES membrane used in the study. Permeate analyticals didn't show any loss of true protein into permeate with either of the membranes used in the study. Use of Sepro PES10 membrane may improve flux rates during processing of WPC 34 and MPC 80. 4. Testing of a Sepro MPV400H-SPP membrane (spiral configuration) for fat removal from WPC 34 In this study, the performance of the MPV400H-SPP membrane was compared with historical data obtained with a 0.5 micron MF membrane used in processing of WPC 34 for the purpose of fat removal work. In order to compare the performance of these two membranes with respect to process flux, protein yield and fat removal efficiency, pilot scale experiments were conducted. The results indicate that the MPV 400 H membrane has a higher fat removal efficiency (~92%), a protein yield of 79% and a higher cumulative flux (22 LMH). From this study, we conclude that use of a MPV 400 H membrane from Sepro may result in higher fat removal efficiency, comparable protein yield and higher flux rates.
Publications
- 1. L. E. Metzger., C. Marella, and P. Salunke. 2012. Performance of spiral wound microfiltration membranes during production of micellular casein concentrate. Journal Dairy Science, Vol. 95, E-Suppl. 2.
- 2. P. Salunke., C. Marella, and L. E. Metzger. 2012. Effect of transglutaminase treatment on the functionality of MPC and MCC: Process cheese product loaf formulations. Journal of Dairy Science, Vol. 95, E-Suppl. 2.
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Progress 01/01/11 to 12/31/11
Outputs
OUTPUTS: Microfiltration process is often used in production of low fat whey protein concentrate (WPC) and whey protein isolate (WPI). In the typical low fat WPC and WPI manufacturing process pasteurized, clarified whey is manufactured into WPC or WPI in a three step process that utilizes a combination of ultra and microfiltration. The basic purpose of microfiltration process is to separate and remove lipid material. However during microfiltration of preconcentrated whey, some protein is lost into the retentate along with the lipid material. Ideal microfiltration process should result into maximized recovery of protein in the permeate stream or minimizing the loss of protein along with lipid material. Protein recovery in excess of 80% is generally considered as good number in terms of protein passage through the microfiltration process. The objective of the present study is to access the protein recovery (Yield of WPI) and to increase WPI yield for a commercial whey processor. Delactosed permeate (DLP) is a byproduct stream obtained from harvesting of proteins and lactose from cheese whey. DLP is composed of milk minerals, acids, residual proteins, residual lactose and water. The concentrations of these solids in DLP depend on the various processes it undergoes and respective efficiencies of those processes. DLP is commonly utilized as animal feed with the rest being field spread. Overall DLP remains with a pH of 5.2 to 5.5 and a dry matter of about 25-30%, consisting of approximately 15% Protein, 15-20% Ash and 60-70% Lactose. This has high COD and disposal is costly. Due to stringent disposal regulations, new approaches have to be developed for further investigations to produce new products from DLP. High water content of DLP (60-75%) makes it difficult to incorporate into food products without further modification. Although utilization of DLP in food products would enhance the profitability of the dairy industry, compositional variations, high mineral and organic acid content are major drawbacks to further its use in food applications. The reasons for stickiness and hygroscopicity of DLP are still unclear, although the presence of organic acids and minerals in DLP are thought to be responsible for both drying problems and post-drying instability. Even though DLP underwent ultrafiltration process during recovery of protein fractions, depending on the type of membrane molecular weight cutoff used some peptides still end up into permeate stream. Up on concentration and heat treatment of permeate during subsequent processing, the peptide fractions form into aggregates. These aggregated peptides can be economically recovered using ultrafiltration of DLP. The objective of the present study is to explore the possibility of recovery of hydrolyzed protein from DLP. PARTICIPANTS: K. Muthukumarappan (PI); L. Metzger (Co-PI); C. Marella (Research Associate) TARGET AUDIENCES: Cheese industry, academics, processors PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
Initial evaluation of the process and operating parameters were studied. Based on the observations it was decided to implement a series of modifications to the existing process. Pressure gauges were installed on all the stages of the microfiltration plant for better control of baseline pressure. Microfiltration process is pressure sensitive process. It was recommended to use base line pressure of 5-7 psi as against the use of 12-14 psi. Modifications were also made to the hydraulics across the microfiltration plant. After implementing the base line corrections and hydraulics, there was visible (turbidity) improvement in the protein passage. Prior to implementation of the recommendations, the yield of protein ranged from 72.5% to 75%, with an average yield of 74%. After implementation of the recommendations the protein yield from the microfiltration process increased by 16%. At regular pH of Delactosed whey permeate, the process flux rates were very low and protein recovery was also very low (20 to 50% for true protein). The mineral content in the DLP was mainly responsible for fouling of the membranes, giving low flux rates. Minerals, especially Ca is more soluble at low pH. Experiments conducted at pH 3.0 resulted into flux rates that were much higher than those obtained when the experiments were conducted at higher pH. From the data collected from the study, it was found that about 90% of the true protein present in the DLP could be recovered in to retentate using either 10 or 50 kD PES membranes. There was no statistically significant difference in the recovery from these two membranes. However the data on flux rates clearly showed higher flux rates for 50 kD PES membrane. The flux rates were almost 2 fold higher when compared to 10 kD membrane.
Publications
- Marella, C., P. Salunke, and L. E. Metzger. 2011. Optimization of spiral wound microfiltration process production of micellar casein concentrate. J. Dairy Sci. Vol. 94, E-Suppl. 1.
- Marella, C., P. Salunke, L. E. Metzger, and K. Muthukumarappan. 2011. Characterization of α- Lactalbumin and β-Lactoglobulin powders obtained from serum whey. J. Dairy Sci. Vol. 94, E-Suppl. 1.
- Salunke, P., C. Marella, and L. E. Metzger. 2011. Use of capillary gel electrophoresis for quantification of individual milk proteins in ultra- and microfiltration retentate. J. Dairy Sci. Vol. 94, E-Suppl. 1.
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Progress 01/01/10 to 12/31/10
Outputs
OUTPUTS: Of the various separation processes, membrane separation process gained popularity due to several advantages of this process over other processes. Membrane separation technology was introduced into dairy processing in early 1970s as an alternative to some thermal as well as non-thermal processes. These processes are based on selective permeability of a porous membrane and differ in membrane material, molecular weight cut off, pore size and operating pressures. In the present work, use of membrane separation processes for production of value added protein ingredients was presented. 1. Native α-Lactalbumin enriched whey protein concentrate: Whey proteins are known for their valuable functional, nutritional and therapeutic properties. Bovine α-Lactalbumin (α-La) has high homology to human α-La and has well documented therapeutic uses. Conventionally Cheese whey is used for production of α-La enriched whey protein concentrate. In this process, the purity of α-La in the final product is heavily influenced by the presence of glycomacropeptide which is present in cheese whey. When compared to cheese whey, serum whey produced by microfiltration of milk is largely absent in glycomacropeptide. Production of α-La enriched concentrate from serum whey should result into higher purity and yield. Thus with the objective of developing α-La enriched concentrate from serum whey, wide pore Ultrafiltration experiments were conducted using four (30, 40, 100 kD Polyvinyledenefluoride and 300 kD Polyethersulfone) membranes and three levels of operating pressure (138, 207 and 276 kilo Pascal (kPa)). In the process serum whey was concentrated to a volume reduction (VR) of 5 and 10. Purity, yield of α-La and α-La/ β-Lg ratio were used as the parameters indicative of process efficiency. 2. Micellar casein concentrate: Micellar casein concentrate is obtained from microfiltration of skim milk during which most of serum protein and non-protein nitrogen components are removed in to permeate there by increasing the ratio of casein to total protein and casein to true protein. The retentate obtained from this process is a concentrated colloidal suspension containing casein in micellar form, lactose, minerals and some serum proteins. Micellar casein concentrate has potential uses in cheese making, process cheese (as rennet casein replacer), nutritional meal replacements, whipped toppings, coffee whiteners etc. To date most of the research on microfiltration of skim milk for production of micellar casein concentrate used ceramic microfiltration membranes. Ceramic membrane systems are capital intensive and membrane replacements are expensive. When compared to these systems, membrane separation systems using polymeric membranes requires less foot print, inexpensive and are familiar with most of the US dairy processors. Thus with the objectives of evaluating the spiral wound microfiltration process for maximizing the serum protein removal and to select optimum levels of operating pressure and diafiltration, microfiltration experiments were conducted. PARTICIPANTS: K. Muthukumarappan (PI) L. Metzger (Co-PI) C. Marella (Post-Doc) TARGET AUDIENCES: Dairy Processors, Dairy Industry, Ingredient Developers PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
1. Native α-Lactalbumin enriched whey protein concentrate: At VR of 5, purity of α-La obtained in the permeate stream ranged from 52 - 96% while the yield of α-La ranged from 15-55%. At VR of 10, there was a marginal decrease of 3-7% in purity and 20 - 35% increase in yield of α-La. For separation of α-La from serum whey there appears to be an optimum operating pressure. From the present results, it appears that 207 kPa pressure is optimum resulting into a 10-25% higher yield when compared to the yield obtained at other pressures used in this study. The results from this study will be helpful in production of highly purified α-La enriched concentrate from serum whey. Regardless of the membrane used in this study, use of 207 kPa operating pressure resulted in α-La enriched product with purity ranging from 52 - 96%. 2. Micellar casein concentrate: At all the transmembrane pressures used in the study, O Flux increased with level of diafiltration. Highest O flux of 28 LMH was obtained with 5 psi pressure and 150% diafiltration. Impact of diafiltration was more pronounced at lower pressures than at the highest pressure used in the study. With controlled diafiltration, instantaneous flux was maintained within 80% of initial flux for entire process run. For all the experiments, casein has 100% rejection by the membrane, while serum protein has the lowest rejection at 5 psi pressure and 150% diafiltration level. Use of lowest pressure (5 psi) and highest diafiltration level (150 %) contributed to 87.5% serum protein removal, taking the casein to true protein ratio to 0.96. The results from this study will help US dairy processors adopt polymeric membrane based processes for production of Micellar casein concentrate.
Publications
- Marella, C., Muthukumarappan, K., and Metzger, L. E. 2010. Evaluation of commercially available, wide pore ultrafiltration membranes for production of α-Lactalbumin enriched whey protein concentrate. J Dairy Sci. doi:10.3168/JDS.2010-3739.
- Marella, C., Salunke, P. Metzger, L. E., and Muthukumarappan, K. 2010. Production of α- Lactalbumin enriched concentrate from serum whey. Presented in Joint Annual Meeting of ADSA-PSA-AMPA-CSAS-ASAS JAM 2010, Denver, CO, July 11-15, 2010. Abstract # 949.
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Progress 01/01/09 to 12/31/09
Outputs
OUTPUTS: Cheese whey contains valuable protein fractions that have unique functional, nutritional and therapeutic properties. The commercial whey protein products available in the market vary widely in their composition and functionality, mainly due to different processing steps used by different manufacturers. Development of whey protein products enriched in individual protein fractions and products with uniform composition and functionality will enlarge the product portfolio of dairy based ingredients. For production of low cost pure/enriched products it is important to develop new methods of recovery and fractionation whey proteins. With the objective of developing a viable, low cost foam fractionation process for enrichment and recovery of valuable whey proteins, experiments were conducted varying the initial feed protein concentration (870, 435, 218 and 109 mg/L) and pH (3.0, 4.0, 4.65, 5.1 and 6.3) of the feed. The effectiveness of the foam fractionation process was assessed in terms of yield and enrichment of total protein, α-Lactalbumin, β-Lactoglobulin and the ratio of α-La/β-Lg. The highest yield of protein of 90.92% was obtained at pH of 3.0 and protein concentration of 870 mg/L. The lowest yield was obtained at a pH of 4.65 and protein concentration of 109 mg/L. The highest enrichment ratio of 5 was obtained with initial protein concentration of 109 mg/L and the lowest enrichment ratio of 1.2 was obtained at a pH of 5.1 and initial protein concentration of 109 mg/L. In enrichment of total whey proteins, higher yields resulted in lower enrichment ratio and vice-versa. α-Lactalbumin was preferentially enriched at a pH of 4.65 while β-Lactoglobulin was preferentially enriched at pH of 6.3. With the objective of developing an efficient membrane based manufacturing process for WPC and WPI that maximizes removal of minerals and lipids, and minimizes thermal treatment during the entire manufacturing process experiments were conducted to alter the mineral content especially divalent ion content of whey protein products and to improve the process efficiency using mineral chelating processing aids. Mineral chelating processing aids such as Disodium phosphate, Trisodium citrate, Ethylene diamine tetra acetic acid and Sodium hexameta phosphate were added to cheese whey at various levels (ranging from 0.04% to 0.37%) during first and second stages of ultrafiltration as well as microfiltration of whey. The addition of Trisodium citrate resulted into reduced Calcium content in the ultrafiltration retentates while the fouling was reduced. A three stage process was developed for production of ultrafiltration retentates with composition similar to WPC 80. The ultrafiltration retentates were further concentrated using nanofiltration process followed by spray drying the product. The WPC 80 produced with the developed process showed optimum functionality when compared to the commercially produced whey protein products. PARTICIPANTS: Chenchaiah Marella TARGET AUDIENCES: Dairy Industry, Cheese Whey Processors PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
The results from the foam fractionation study provided better understanding of the phenomenon of foam fractionation for a multicomponent mixture such as cheese whey. The findings prove that foam fractionation can be exploited as an alternative to high cost processes currently used for development of enriched whey protein products. The process developed for production of low fat and low salt WPC/WPI can be used for production of WPC 80 that will have the highest solubility, the lowest denaturation, better foaming properties. The WPC 80 produced using the process developed will have better gelation and heat stability properties. The WPC/WPI produced from this process, with modified mineral content, lowest lipid content, the highest solubility, the least heat denaturation, higher heat stability will have preferred functionality in beverage applications.
Publications
- Marella, C and Muthukumarappan, K. 2009. Development of foam fractionation process for enrichment and recovery of cheese whey proteins. Submitted for presentation in the 2009 IFT Annual meeting, June 6 - 9, Anaheim, CA. Presentation # 251-06.
- Marella, C, Metzger, L. E. and Muthukumarappan, K. 2009. Effect of processing aids on mineral balance and fouling during ultrafiltration of cheese whey. Presented in Joint Annual Meeting of ADSA-CSAS-ASAS, Montreal, Quebec, Canada, July 12-16, 2009. Abstract # 750.
- Marella, C, Metzger, L. E. and Muthukumarappan, K. 2009. Optimizing the recovery of protein during microfiltration of preconcentrated whey. Presented in Joint Annual Meeting of ADSA-CSAS-ASAS, Montreal, Quebec, Canada, July 12-16, 2009. Abstract # 422.
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Progress 01/01/08 to 12/31/08
Outputs
OUTPUTS: The USA produces 39.7 million tons of cheese whey annually, accounting for 1/4th of world's whey production. Whey is processed in to value added whey protein concentrate, whey protein isolate and individual pure fractions using membrane processing (a combination of Ultrafiltration and Microfiltration processes). In membrane processing of cheese whey among other things, Calcium is mainly responsible for fouling of the membranes by cementing the protein layers formed on the membrane surface. Fouling of the membranes leads to loss of protein in Microfiltration and loss of mass transfer rates in Ultrafiltration. With the objective of using calcium chelating processing aids in lowering fouling, enhancing the recovery of valuable protein fractions in Microfiltration and optimizing the volume reduction ratio and level of diafiltration during Microfiltration, experiments were conducted using cheddar cheese whey. Calcium chelating aids such as Disodium phosphate, Citric acid, Ethylenediaminetetraacetic acid (EDTA) and Potassium citrate were added to the whey at 3 levels each, before membrane processing of the whey. In Microfiltration study, volume reduction of 4x, 5x and 6x and diafiltration levels of 0, 50 and 100% of the volume of feed were used in the study. In Ultrafiltration, addition of Citric acid and EDTA at level 2 resulted in to the highest mass transfer rates, lowest overall and irreversible resistances in Ultrafiltration of whey. The addition of processing aids in Microfiltration didn't show statistically significant difference in overall and irreversible resistances. In terms of protein recovery, EDTA gave the highest recovery. Among the different levels of diafiltration, 100% level resulted into the highest recovery of protein at all the volume reduction ratios. As the volume reduction ratio increased from 4x to 6x, mass transfer rates decreased from 28 to 23 liters per square meter per hour. PARTICIPANTS: K. Muthukumarappan (PI); Chenchaiah Marella (Ph.D, Graduate Research Assistant); Lloyd Metzger (Co-PI) TARGET AUDIENCES: Dairy Processors, Ingredient Manufacturers, Cheese Whey Industry PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
The study provided better understanding of the phenomenon of membrane fouling and its effect on mass transfer rates. The results from the study will help develop commercially viable membrane based processing technologies. A typical 1 million pounds per day whey processing facility can save $23,000 per year resulting into industry wide savings of about $2 million per year.
Publications
- Muthukumarappan, K., and Marella, C. 2008. Fractionation of cheese whey proteins using membrane technology. Proc. 19th Indian convention of food scientists and technologists (India), Indian Institute of Technology, Kharagpur, India.
- Marella, C., and Muthukumarappan, K. 2008. Investigate the effect of diafiltration and processing aids in enhancing the yield and process flux rates during membrane processing of Cheddar cheese whey. 2008 IFT Annual Meeting Book of Abstracts, New Orleans, LA (Abstract # 028-05).
- Muthukumarappan, K. and Marella, C. 2008. Membrane Processing, Chapter 5 In Mohammed Farid (ed.), Mathematical analysis of food processing. CRC Press, In progress.
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