Tetra Pak Filtration Solutions. Basic Membrane Filtration and New Innovations

Transkript

1 Tetra Pak Filtration Solutions Basic Membrane Filtration and New Innovations

2 What is a membrane? A membrane can be considered as a selective barrier or as an interface between two phases Phase 1 Membrane Phase 2

3 How does it work? The process needs a driving force ΔC: Dialysis, Forward Osmosis ΔP: MF, UF, NF, RO ΔT: Membrane Distillation ΔE: Electro dialysis Phase 1 Membrane Phase 2

4 Osmotic pressure Forward Osmosis Reverse osmosis Pressure C 1 C 0 Salt water Membrane Water

5 Basic of characterizing membranes Porous Membranes are classified in two groups: Porous (MF and UF) Nonporous (NF and RO) and two types of characterization methods: Structure-related parameters Permeation-related parameters

6 Basic of characterizing membranes Porous Non Porous Membranes are classified in two groups: Porous (MF and UF) Nonporous (NF and RO) and two types of characterization methods: Structure-related parameters Permeation-related parameters

7 Filtration principles Dead-end filtration Feed Crossflow filtration Membrane Filter cake Feed.. Membrane Retentate Permeate Permeate

8 Membrane filtration principles Reverse Osmosis - RO Nanofiltration - NF Bacteria, spores fat globules Lactose, acids, NPN Water Ultrafiltration - UF Casein, whey proteins Minerals Microfiltration - MF

9 Structure of MF membrane

10 RO - thin film membrane Membrane layer Support web (UF): PS - Polysulphone micron PA - Polyamide 0.25 micron Support paper PE - Polyester / PP - Polypropylene micron

11 Production of RO thin film membrane Amine TMC Support web Chemical reaction Drying chamber Membrane Rinse bath Glycerine bath

12 Oxidised RO membrane

13 Membrane modules Ceramic tubular Benefits Chemical and temperature resistant Easy CIP and excellent hygienic properties Durable for long membrane life Sanitizable Polymer spiral-wound Benefits Low cost Compact design Cost-effective processing economy Polymer Plate & Frame Benefits Handles high viscosity products High temperature resistance High configuration versatility

14 SW element

15 4 SW element og ATD

16 Modul med SW elementer Source: Werner Kofod Nielsen (2000): Membrane filtration and related molecular separation technologies

17 Drift - et recirkuleringsloop Permeat Feed Feed Retentat

18 Loop - 5 m 3 /h Permeat 120 m 3 /h Feed 125 m 3 /h 3 /h 10 m 3 /h 10 m 3 /h 115 m 3 /h 5 m 3 /h 5 m 3 /h Retentat

19 UF / MF Pilot plant with one 8 Housing and two 6 Housing all for 3 membranes

20 UF anlæg til WPC produktion

21 UF anlæg til koncentrering af Feta mælk

22 How to identify is a membrane is leaking?

23 M37 Plate & Frame system

24 Flow i et Plate & Frame modul Permeat samlerør Permeat Retentat Føde Endeflange Stop skive Bæreplade Membraner

25 UF anlæg til flødeoste og kvarg

26 Plate & Frame system M37

27 Ceramic membrane Permeate Channel Feed Retentate Support Membrane

28 Structure of ceramic membrane

29 Ceramic Module

30 MF Ceramic system

31 Lactose free milk

32 The lactose free market is growing Only one-third of the population can digest milk

33 Lactose Reduced Milk Production Key step - Hydrolysis Lactase enzyme Hydrolysis into monosaccharides 87% 4,1% 3,4% 4,9% 0,7% Fat Protein Lactose Salts Water Lactose Glucose Galactose One molecule of galactose and one molecule of glucose is much sweeter than one molecule of lactose Residual Lactose < 1 % in hydrolysed lactose reduced milk Residual Lactose < 0,05 % in filtered + hydrolysed lactose free milk

34 Lactose Free Products in Europe

35 Lactose free dairy products Germany

36 Low investment concept Addition of potable water Skim milk Potable water Retentate UF filtration Permeate Retentate (Lactose, acids, soluble salts & water) Salts Mixing/ Standardising Cream Hydrolysis Lactase Enzyme ESL/UHT Aseptic storage Filling

37 Low investment concept Addition of potable water Lowest investment Usage of potable water needs to be declared on the package Dependancy on water quality

38 Lactose Free Milk Production Staying closer to original milk composition Focus on taste closer to original milk composition Calcium-protein ratio close to original milk Recovery of salts from UF retentate NF-retentate (by-product). Further UF separation can produce UF permeate for skim standardization and Protein concentrate for yoghurt & baby food

39 Lactose Free Milk Production Staying closer to original milk composition Skim milk Diafiltration all permeate produced is used MF filtration Cream Lactase Enzyme Mixing/ Standardising Hydrolysis NF filtration UF filtration ESL/UHT Aseptic storage Filling

40 Comparison of product composition Example Reference Tetra Pak low investment concept** Tetra Pak recovery concept** Ash (g/100 ml) Ca (g/100 ml) Cl (g/100 ml) Lactose (g/100 ml) Fat (g/100 ml) K (g/100 ml) Mg (g/100 ml) Na (g/100 ml) ph P (g/100 ml) Protein (g/100 ml) * According to Arla US patent 2013/ , ** Example, has to be confirmed by individual test at specific production sites

41 Addition of lactase for hydrolysis Before or after the final heat treatment Pasteurization ESL/UHT To filling machine ESL/UHT To filling machine Tetra FlexDos

42 Koncentrert yoghurt

43 Protein hitter øget fokus på ernæring Stenalderkost Dukan kuren Protein kuren Low carb Høj protein diæten

44 Protein hitter øget fokus på ernæring Yoghurt naturel udfordres af skyr (Smag og Behag, juni 2012) Protein hitter blandt danskerne (Arla Foods, My news desk, juni 2013) Fokus på protein (L & F, januar 2014) Fedtfattig og fyldt med protein: Vikingernes yoghurt er ikke til at slå ned (Politiken, oktober 2013) Forbrugerne er vilde med fedtfattige proteinbomber (Mejeri, juni 2013)

45 Produkter i Danmark med højt protein indhold

46 Målrettet markedsføring - USA 11 % protein 0 % fedt

47 Typiske protein- og fedtindhold Skyr % Kvark % Greek style % Protein ,5-9 Fedt 0,2 0,2-1 0,1-10 Bekendtgørelse om mejeriprodukter (BEK nr 2 af 04/01/2013) stiller ikke krav til protein- og fedtindhold i produkterne

48 Traditionel fremstilling af koncentrerede produkter Koncentrering ved hhv. afdræning eller centrifuge Syrnede produkter med højt proteinindhold kan også fremstilles ved tilsætning af proteinpulver

49 Ultra Filtrering flere muligheder Koncentrering af mælk inden syrning Fx ymer & hvid ost Fordel: valle kan anvendes til mælkepulver Koncentrering af mælk efter syrning Fx Greek style yoghurt, skyr & kvarg Begrænset anvendelighed af valle Kombineret - forkoncentrering til fx 5 % protein efterfølgende koncentrering til 11 % protein

50 Ultra Filtrering flere muligheder Keramik Spiral Plate & frame

51 Studie af effekten af de 3 filtreringstyper

52 Calcium in permeate Calcium mg/kg 1400 ph 4,6 ph 5,9 ph 6, Concentration factor vcf

53 Calcium content in retentate High calcium gives off flavor Ultrafiltration at ph VCF = 3 mg/kg 6.6 Approx. 2, Approx. 2, Approx. 1,400

54 Proceslinie til syrnede, koncentrerede produkter Forbehandling Skummetmælk/ standardiseret mælk Fermentering Forvarmning Filtrering Køling Permeate Buffer Tapning Kølelager

55 Sammenligning af udbytte UF vs separator Ultra Filtrering Separator (uden thermisering) Separator (med thermisering) Færdigvare (kg) Proteinindhold i færdigvare (%) Proteinindhold i valle (%) (Proteintab) Råvaremængde skummetmælk (kg) Øget råvare forbrug (%) ,00 10,00 10,00 0,2 0,7 0, Separator uden thermisering + 10,1 % Separator med thermisering + 3,3 % 4 Udbytte 3 (Kg) % 10% 11% 12% Protein (%) Separator Filtration

56 Fordele ved Ultra Filtrering Stabil proces Mulighed for håndtering af forskellige produkter på samme anlæg (varierende fedt- og tørstofindhold) Øget udbytte som følge af valleproteiner Forbedret konsistens Forbedrede sensoriske egenskaber (oplevelse af øget fedtindhold, glattere struktur og midre tørhed)

57 Ernæringsmæssige fordele ved Ultra Filtrering Næringsværdi Æg 100 Kasein 77 Valle 104 Ved anvendelse af UF inkluderes valleproteiner i færdigvaren, og herved øges ernæringsværdien

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