Assessment of the performance of three ultrafiltration membranes for fractionation of ovine second cheese whey

Innovative applications of whey protein for sustainable dairy industry: Environmental and technological perspectives-A comprehensive review

Industrial waste management is critical to maintaining environmental sustainability. The dairy industry (DI), as one of the major consumers of freshwater, generates substantial whey dairy effluent, which is notably rich in organic matter and thus a significant pollutant. The effluent represents environmental risks due to its high biological and chemical oxygen demands. Today, stringent government regulations, environmental laws, and heightened consumer health awareness are compelling industries to responsibly manage and reuse whey waste. Therefore, this study investigates sustainable solutions for efficiently utilizing DI waste. Employing a systematic review approach, the research reveals that innovative technologies enable the creation of renewable, high-quality, value-added food products from dairy byproducts. These innovations offer promising sustainable waste management strategies for the dairy sector, aligning with economic interests. The main objectives of the study deal with, (a) assessing the environmental impact of dairy sector waste, (b) exploring the multifaceted nutritional and health benefits inherent in cheese whey, and (c) investigating diverse biotechnological approaches to fashion value-added, eco-friendly dairy whey-based products for potential integration into various food products, and thus fostering economic sustainability. Finally, the implications of this work span theoretical considerations, practical applications, and outline future research pathways crucial for advancing the sustainable management of dairy waste.

Sheep's Second Cheese Whey Edible Coatings with Oregano and Clary Sage Essential Oils Used as Sustainable Packaging Material in Cheese

Sheep's second cheese whey (SCW), the by-product resulting from whey cheese production, was used as a component of cheese coatings containing oregano (Origanum compactum) and clary sage (Salvia sclarea) essential oils (EOs). SCW powder was obtained by the ultrafiltration/diafiltration of SCW followed by reverse osmosis and freeze drying. The coatings were produced with a mixture of SCW and whey protein isolate (WPI) using glycerol as plasticizer. Model cheeses were produced with cow´s milk and those containing SCW:WPI coatings; those with and without EOs were compared to controls without coating and with a commercial coating containing natamycin. At the end of ripening (28 days), the cheeses containing EOs presented higher water activity (ca. 0.930) and moisture content, as well as lower titratable acidity. Concerning color parameters, significant differences were also observed between products and as a result of ripening time. However, the use of SCW:WPI coatings did not significantly influence the color parameters at the end of ripening. Regarding texture parameters, the cheeses containing SCW:WPI coatings presented significantly lower values for hardness, chewiness, and gumminess. Significant differences were also observed for all microbial groups evaluated either between products and as a result of ripening time. In all cases, lactobacilli and lactococci counts surpassed log 7-8 CFU/g, while the counts of yeasts and molds increased steadily from ca. log 3 to log 6 CFU/g. The lowest counts of yeasts and molds were observed in the samples containing natamycin, but nonsignificant differences between products were observed. In conclusion, SCW:WPI cheese coatings can successfully substitute commercial coatings with the advantage of being edible packaging materials manufactured with by-products.

Sustainable Approaches in Whey Cheese Production: A Review

Whey cheeses have been produced from the very early steps of cheesemaking practices as a sustainable way to utilize whey, which is the main by-product of cheesemaking. Traditional whey cheeses, manufactured with similar processes, are Ricotta, Ricotta salata or Ricottone, and Ricotta fresca in Italy; Anthotyros, Myzithra, Manouri, Xynomyzithra, and Urda in Greece; Urda in Serbia and Romania as well as in other countries such as Israel; Lor in Turkey; Anari in Cyprus; Skuta in Croatia and Serbia; Gjetost and Brunost in Norway; Mesost and Messmör in Sweden; Mysuostur in Iceland; Myseost in Denmark; Requeijão in Portugal; and Requesón in Spain and Mexico. The production of whey cheese is based on the denaturation of whey proteins by heating to 88–92 °C. The specific processing conditions and aspects of the microbiology of whey cheeses are discussed. The special characteristics of whey cheeses, which are high pH and high moisture content, make them susceptible to microbial growth. Due to the limited shelf life of these products, extended research has been carried out to extend the shelf life of whey cheese. The sustainable preservation approaches, such as modified atmosphere packaging, addition of herbs and/or plant extracts, and bio-preservation methods are reviewed. Moreover, novel whey cheeses focused on functional properties have developed during the last 10 years.

Evaluation of the Characteristics of Sheep's and Goat's Ice Cream, Produced with UF Concentrated Second Cheese Whey and Different Starter Cultures

Second cheese whey (SCW) is the by-product resulting from the manufacture of whey cheeses. In the present work, sheep (S) and goat (G) SCW concentrated by ultrafiltration (UF) were used in the production of ice creams. Concentrated liquid SCW samples with inulin added as a prebiotic were fermented with yoghurt, kefir and probiotic commercial cultures before being frozen in a horizontal frozen yoghurt freezer. The physicochemical, microbiological and sensory properties of the products were evaluated over 120 days of frozen storage. The products presented significant differences regarding these properties, specifically the higher total solids and protein contents of sheep's ice creams, which were higher compared to their goat ice cream counterparts. Sheep's ice creams also presented higher hardness and complex viscosity, which increased with storage. These ice creams also presented higher overrun and lower meltdown rates. The color parameters of the ice creams showed significant differences between formulations resulting from storage time. In all cases, Lactobacilli sp. cell counts were higher than log 6 CFU/g at the first week of storage. In the case of sheep's ice creams these values were maintained or increased until the 30th day, but decreased until the 60th day. Lactococci sp. counts surpassed log 7 CFU/g in all products, and these values were maintained until the end of storage, except in the case of G-Yoghurt and G-Kefir. Concerning the products containing probiotics, the sum of Lactococci sp. and Lactobacilli sp. counts was of the order log 8-9 CFU/g until the 60th day of storage, indicating that the probiotic characteristics of ice creams were maintained for at least 2 months. All products were well accepted by the consumer panel. Sheep's SCW ice creams were better rated regarding aroma, taste and texture. However, only the ranking test was able to differentiate preferences among formulations.

Membrane Technology for Valorization of Mango Peel Extracts

Mango peel is rich in nutritional and functional compounds, such as carbohydrates, dietary fibers, proteins, and phenolic compounds, with high potential to be applied in the food industry. Most of the investigation about recovery of bioactive compounds from fruit bioproducts involves extraction techniques and further separation of target compounds. There is still a lack of information about the potential of membrane processes to recover the nutritive/functional compounds present in aqueous extracts of those bioproducts. This research is addressed to study the performance of ultrafiltration (UF), followed by nanofiltration (NF) of UF permeates, to fractionate the compounds present in aqueous extracts of mango peel. Both UF and NF concentration processes were carried up to a volume concentration factor of 2.0. Membranes with molecular weight cut-offs of 25 kDa and 130 Da were used in the UF and NF steps, respectively. UF and NF concentrates showed antioxidant activity, attributed to the presence of phenolic compounds, with rejections of about 75% and 98.8%, respectively. UF membranes totally rejected the higher molecular weight compounds, and NF membranes almost totally concentrated the fermentable monosaccharides and disaccharides. Therefore, it is envisaged that NF concentrates can be utilized by the food industry or for bioenergy production.

A review on membrane separation processes focusing on food industry environment-friendly processes

Food processing industries have led to several environmental impacts due to their high water and energy consumption, as well as soil and water bodies' contamination through improper waste disposal. Membrane Separation Processes (MSP) emerge as an important alternative to enable the adoption of sustainable processes by food industries, since satisfying the requests of innovative processes and equipment design, such as smaller, cleaner, more energy-efficient processes (mild conditions) without the usage of chemical agents. Membrane-based processes fulfill these requirements, and their potential has been broadly recognized in the last few years. This review provides a comprehensive and up-to-date overview of the application of MSP in sustainable processes in the different segments of the food industry over the last 10 years. Waste and wastewater treatment, recovery of valuable compounds and water for reuse, and alternatives to high energy consumption processes were identified as sustainable processes in this context. One trend found is the potential for adding value to production chains by obtaining valuable compounds that have not been explored yet. As a perspective for future research, this review showed that it is advisable to implement MSP in different industrial environments in order to make current processes environmentally sustainable and less polluting.

Performance evaluation of whey flux in dead-end and cross-flow modes via convolutional neural networks

Effluent originating from cheese production puts pressure onto environment due to its high organic load. Therefore, the main objective of this work was to compare the influence of different process variables (transmembrane pressure (TMP), Reynolds number and feed pH) on whey protein recovery from synthetic and industrial cheese whey using polyethersulfone (PES 30 kDa) membrane in dead-end and cross-flow modes. Analysis on the fouling mechanistic model indicates that cake layer formation is dominant as compared to other pore blocking phenomena evaluated. Among the input variables, pH of whey protein solution has the biggest influence towards membrane flux and protein rejection performances. At pH 4, electrostatic attraction experienced by whey protein molecules prompted a decline in flux. Cross-flow filtration system exhibited a whey rejection value of 0.97 with an average flux of 69.40 L/m²h and at an experimental condition of 250 kPa and 8 for TMP and pH, respectively. The dynamic behavior of whey effluent flux was modeled using machine learning (ML) tool convolutional neural networks (CNN) and recursive one-step prediction scheme was utilized. Linear and non-linear correlation indicated that CNN model (R² - 0.99) correlated well with the dynamic flux experimental data. PES 30 kDa membrane displayed a total protein rejection coefficient of 0.96 with 55% of water recovery for the industrial cheese whey effluent. Overall, these filtration studies revealed that this dynamic whey flux data studies using the CNN modeling also has a wider scope as it can be applied in sensor tuning to monitor flux online by means of enhancing whey recovery efficiency.

Antihypertensive Peptides from Ultrafiltration and Fermentation of the Ricotta Cheese Exhausted Whey: Design and Characterization of a Functional Ricotta Cheese

Aiming at valorizing the ricotta cheese exhausted whey (RCEW), one of the most abundant by-products from the dairy industry, a biotechnological protocol to obtain bioactive peptides with angiotensin-I-converting enzyme (ACE)—inhibitory activity was set up. The approach was based on the combination of membrane filtration and fermentation. A Lactobacillus helveticus strain selected to be used as starter for the fermentation of the ultrafiltration protein-rich retentate (R-UF) obtained from RCEW. The fermented R-UF was characterized by a high anti-ACE activity. Peptides responsible for the bioactivity were purified and identified through nano-LC–ESI–MS/MS. The sequences identified in the purified active fractions of the fermented R-UF showed partial or complete overlapping with previously reported κ-casein antihypertensive fragments. The fermented R-UF was spray-dried and used to enrich ricotta cheese at different fortification level (1 and 5% w/w). An integrated approach including the assessment of the microbiological, chemical, functional, textural, and sensory properties was used to characterize the fortified products. A significantly higher anti-ACE activity was found in the ricotta cheese fortified with fermented R-UF as compared to the control and to the samples obtained with the unfermented R-UF fraction at the same levels of fortification. In particular, a 100 g portion of the ricotta cheese produced at 5% fortification level contained circa 30 mg of bioactive peptides. The fortification led to a moderate acidification, increased hardness and chewiness, and decreased the milk odor and taste of the ricotta cheese as compared to the control, while flavor persistence and sapidity improved.

Integration of Membrane Processes for By-Product Valorization to Improve the Eco-Efficiency of Small/Medium Size Cheese Dairy Plants

Goat and second cheese whey from sheep’s milk are by-products of the manufacture of goat cheeses and whey cheeses from sheep. Due to their composition which, apart from water—about 92%—includes lactose, proteins, fat, and minerals, and the elevated volumes generated, these by-products constitute one of the main problems facing to cheese producers. Aiming to add value to those by-products, this study evaluates the efficiency of ultrafiltration/diafiltration (UF/DF) for the recovery of protein fraction, the most valuable component. For a daily production of 3500 and using the experimental results obtained in the UF/DF tests, a membrane installation was designed for valorization of protein fraction, which currently have no commercial value. A Cost–Benefit Analysis (CBA) and Sensitivity Analysis (SA) were performed to evaluate the profitability of installing that membrane unit to produce three new innovative products from the liquid whey protein concentrates (LWPC), namely food gels, protein concentrates in powder and whey cheeses with probiotics. It was possible to obtain LWPC of around 80% and 64% of crude protein, from second sheep cheese whey and goat cheese whey, respectively. From a survey of commercial values for the intended applications, the results of CBA and SA show that this system is economically viable in small/medium sized cheese dairies.

Valorization of Goat Cheese Whey through an Integrated Process of Ultrafiltration and Nanofiltration

Goat cheese whey is a co-product that comes from goat cheese manufacture. Due to its high organic load, adequate treatment is necessary before its disposal. Additionally, the recent growing interest in caprine products, attributed to their specific nutritional and nutraceutical characteristics, such as the lower allergenicity of their proteins and higher content of oligosaccharides, compared with bovine products, made the recovery of goat cheese whey a challenge. In this study, an integrated process for the recovery of sweet goat whey components was carried out. It includes filtration, centrifugation and pasteurization, followed by sequential membrane processes, ultrafiltration/dilution, nanofiltration of ultrafiltration permeates in dilution mode and the concentration/dilution of nanofiltration retentates. Ultrafiltration was performed with membranes of 10 and 1 kDa. Membranes of 10 kDa have higher permeate fluxes and, in a single stage of dilution, allowed for better protein retention and higher lactose purity, with a separation factor of 14. The concentration of lactose by nanofiltration/dilution led to the retention of almost all the lactose in retentates and to a final permeate, whose application in cheese dairy plants will allow for the total recovery of whey. The application of this integrated process in small- or medium-sized goat cheese dairies can represent an important contribution to their sustainability.

Dairy By-Products: A Review on the Valorization of Whey and Second Cheese Whey

The search for new food products that promote consumers health has always been of great interest. The dairy industry is perhaps the best example regarding the emergence of new products with claimed health benefits. Cheese whey (CW), the by-product resulting from cheese production, and second cheese whey (SCW), which is the by-product of whey cheese manufacture, have proven to contain potential ingredients for the development of food products with improved nutritional characteristics and other functionalities. Nowadays, due to their nutritional quality, whey products have gained a prominent position among healthy food products. However, for a long time, CW and SCW were usually treated as waste or as animal feed. Due to their high organic content, these by-products can cause serious environmental problems if discarded without appropriate treatment. Small and medium size dairy companies do not have the equipment and structure to process whey and second cheese whey. In these cases, generally, they are used for animal feed or discarded without an appropriate treatment, being the cause of several constraints. There are several studies regarding CW valorization and there is a wide range of whey products in the market. However, in the case of SCW, there remains a lack of studies regarding its nutritional and functional properties, as well as ways to reuse this by-product in order to create economic value and reduce environmental impacts associated to its disposal.

Production of the Polyhydroxyalkanoate PHBV from Ricotta Cheese Exhausted Whey by Haloferax mediterranei Fermentation

In the last decade, the dairy industry underwent a rapid expansion due to the increasing demand of milk-based products, resulting in high quantity of wastewater, i.e., whey and ricotta cheese exhausted whey (RCEW). Although containing high content of nutritional compounds, dairy by-products are still disposed as waste rather being reintroduced in a new production chain, hence leading to environmental and economic issues. This study proposes a new biotechnological approach based on the combination of membrane filtration and fermentation to produce poly-hydroxyalkanoates (PHA), biodegradable bioplastics candidate as an alternative to petroleum-derived plastics. The protocol, exploiting the metabolic capability Haloferax mediterranei to synthesize PHA from RCEW carbon sources, was set up under laboratory and pilot scale conditions. A multi-step fractionation was used to recover a RCEW fraction containing 12.6% (w/v) of lactose, then subjected to an enzymatic treatment aimed at releasing glucose and galactose. Fermentation conditions (culture medium for the microorganism propagation, inoculum size, time, and temperature of incubation) were selected according to the maximization of polymer synthesis, under in-flasks experiments. The PHA production was then tested using a bioreactor system, under stable and monitored pH, temperature, and stirring conditions. The amount of the polymer recovered corresponded to 1.18 g/L. The differential scanning calorimetry (DSC) analysis revealed the poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) as the polymer synthesized, with a relatively high presence of hydroxyvalerate (HV). Identity and purity of the polymer were confirmed by attenuated total reflectance-Fourier transform infrared (ATR-FTIR) and X-ray photoelectron (XPS) spectroscopy analyses. By combining the fractionation of RCEW, one of the most abundant by-products from the agri-food industry, and the use of the halophile Hfx mediterranei, the production of PHBV with high purity and low crystallinity has successfully been optimized. The process, tested up to pilot scale conditions, may be further implemented (e.g., through fed-batch systems) and used for large-scale production of bioplastics, reducing the economical and environmental issues related the RCEW disposal.

Performance Evaluation of Tight Ultrafiltration Membrane Systems at Pilot Scale for Agave Fructans Fractionation and Purification

Ceramic and polymeric membrane systems were compared at the pilot scale for separating agave fructans into different molecular weight fractions that help to diversify them into more specific industrial applications. The effect of the transmembrane pressure of ultrafiltration performance was evaluated through hydraulic permeability, permeate flux and rejection coefficients, using the same operating conditions such as temperature, feed concentration and the molecular weight cut-off (MWCO) of membranes. The fouling phenomenon and the global yield of the process were evaluated in concentration mode. A size distribution analysis of agave fructans is presented and grouped by molecular weight in different fractions. Great differences were found between both systems, since rejection coefficients of 68.6% and 100% for fructans with degrees of polymerization (DP) > 10, 36.3% and 99.3% for fructooligosaccharides (FOS) and 21.4% and 34.2% for mono-disaccharides were obtained for ceramic and polymeric membrane systems, respectively. Thus, ceramic membranes are better for use in the fractionation process since they reached a purity of 42.2% of FOS with a yield of 40.1% in the permeate and 78.23% for fructans with DP > 10 and a yield of 70% in the retentate. Polymeric membranes make for an efficient fructan purification process, eliminating only mono-disaccharides, and reaching a 97.7% purity (considering both fructan fractions) with a yield of 64.3% in the retentate.

Effect of transmembrane pressure control on energy efficiency during skim milk concentration by ultrafiltration at 10 and 50°C

The efficiency of the ultrafiltration process during skim milk concentration was studied using both dynamic and constant (465 or 672kPa) transmembrane pressure experiments at refrigerated temperature (10°C) and high temperature (50°C). The pilot-scale module was equipped with a 10-kDa polyethersulfone spiral-wound membrane element with a surface area of 2.04m². Permeation flux, resistance-in-series model, mineral and protein rejection, and energy consumption were studied as a function of temperature and transmembrane pressure applied. Higher permeation flux values were systematically obtained at 50°C. Also, a significant temperature effect was found for calcium rejection, which was lower at 10°C compared with 50°C. Total hydraulic resistance and reversible fouling resistance were higher at 50°C than at 10°C. No change in protein rejection was observed, depending on the operating mode studied. Permeation flux, which was higher at 50°C, had lower pumping energy consumption compared with ultrafiltration at the colder temperature. Also, the low ultrafiltration temperature required a higher total energy consumption to reach the 3.6× retentate compared with ultrafiltration at 50°C. Overall, our study shows that the operating parameters and temperature can be optimized using an energy efficiency ratio.

A review on the use of membrane technology and fouling control for olive mill wastewater treatment

Olive mill effluents (OME) by-produced have significantly increased in the last decades as a result of the boost of the olive oil agro-industrial sector and due to the conversion into continuous operation centrifugation technologies. In these effluents, the presence of phytotoxic recalcitrant pollutants makes them resistant to biological degradation and thus inhibits the efficiency of biological and conventional processes. Many reclamation treatments as well as integrated processes for OME have already been proposed and developed but not led to completely satisfactory and cost-effective results. Olive oil industries in its current status, typically small mills dispersed, cannot afford such high treatment costs. Furthermore, conventional treatments are not able to abate the significant dissolved monovalent and divalent ions concentration present in OME. Within this framework, membrane technology offers high efficiency and moderate investment and maintenance expenses. Wastewater treatment by membrane technologies is growing in the recent years. This trend is owed to the fact of the availability of new membrane materials, membrane designs, membrane module concepts and general know-how, which have promoted credibility among investors. However, fouling reduces the membrane performances in time and leads to premature substitution of the membrane modules, and this is a problem of cost efficiency since wastewater treatment must imply low operating costs. Appropriate fouling inhibition methods should assure this result, thus making membrane processes for wastewater stream treatment both technically and economically feasible. In this paper, the treatment of the effluents by-produced in olive mills, generally called olive mill wastewaters, will be addressed. Within this context, the state of the art of the different pretreatments and integral membrane processes proposed up to today will be gathered and discussed, with an insight in the problem of fouling.