Lactose processing: From fundamental understanding to industrial application

Selective anomer crystallization from aqueous solution: Monitoring lactose recovery under mutarotation limitation via attenuated total reflection Fourier-transform spectroscopy and theoretical rate analysis

Lactose is typically produced via cooling crystallization either from whey or whey permeate (edible grade) or from aqueous solution (pharmaceutical grade). While in solution, lactose is present in 2 anomeric forms, α- and β-lactose. During cooling crystallization under standard process conditions, only α-lactose crystallizes, depleting the solution of α-anomer. In practice, mutarotation kinetics are often assumed to be much faster than crystallization. However, some literature reports limitation of crystallization by mutarotation. In the present research, we investigate the influence of operating conditions on mutarotation in lactose crystallization and explore the existence of an operation regimen where mutarotation can be disregarded in the crystallization process. Therefore, we study crystallization from aqueous lactose solutions by inline monitoring of concentrations of α- and β-lactose via attenuated total reflection Fourier-transform spectroscopy. By implementing a linear cooling profile of 9 K/h to a minimum temperature of 10°C, we measured a remarkable increase in β/α ratio, reaching a maximum of 2.19. This ratio exceeds the equilibrium level by 36%. However, when the same cooling profile was applied to a minimum temperature of 25°C, the deviation was significantly lower, with a maximum β/α ratio of 1.72, representing only an 8% deviation from equilibrium. We also performed a theoretical assessment of the influence of process parameters on crystallization kinetics. We conclude that mutarotation needs to be taken into consideration for efficient crystallization control if the crystal surface area and supersaturation are sufficiently high.

Ultrasound-assisted enzymatic synthesis of galacto-oligosaccharides using native whey with two commercial β-galactosidases: Aspergillus oryzae and Kluyveromyces var lactis

Native whey obtained during casein micelle microfiltration was used as a novel source to produce galacto-oligosaccharides (GOS). Since the presence of macromolecules and other interferers reduces biocatalyst performance, this work evaluated the effect of different ultrasound processing conditions on GOS synthesis using concentrated native whey. Ultrasonic intensities (UI) below 11 W/cm² tended to increase the activity in the enzyme from Aspergillus oryzae for several minutes but accelerated the inactivation in that from Kluyveromyces lactis. At 40 °C, 40 % w/w native whey, 70 % wave amplitude, and 0.6 s/s duty-cycle, a UI of 30 W/cm² was achieved, and the increased specific enzyme productivity was similar to the values obtained with pure lactose (∼0.136 g GOS/h/mg_E). This strategy allows for obtaining a product containing prebiotics with the healthy and functional properties of whey proteins, avoiding the required purification steps used in the production of food-grade lactose.

Molecular profiling of whey permeate reveals new insights into molecular affinities related to industrial unit operations during lactose production

Lactose powder production from whey permeate generates various side-streams. Molecular profiling of these side-streams and lactose powder can help to detect minor compounds affecting lactose crystallization, lactose powder properties and document the composition of the underutilized side-streams. In this study, whey permeate, lactose powder and intermediate streams from trial lactose productions were analyzed using gas chromatography-mass spectrometry (GC-MS) and proton nuclear magnetic resonance (¹H NMR) spectroscopy. In total, 110 compounds were identified and 49 were quantified. Linking the molecular profiles to in-process steps revealed differential compositional attenuation by the unit operations. Small molecules (e.g. methanol) and a few larger molecules (e.g. fatty acids) permeated reverse osmosis membrane, while twenty-three compounds (e.g. hydroxypyruvic acid, malonic acid, gluconic acid and ribonic acid) co-crystallized with lactose and ended up in lactose power. These results help to better understand and control lactose powder production and highlights possibilities to develop new food ingredients.

Scaling up continuous eutectic freeze crystallization of lactose from whey permeate: A pilot plant study at sub-zero temperatures

Eutectic freeze crystallization is explored as an alternative to the state-of-the-art evaporation process for the recovery of lactose from whey permeate. At the so-called eutectic freezing point, both water (the solvent) and lactose (the solute) crystallize and can be removed continuously while continuously feeding whey permeate. This continuous process is demonstrated on a pilot scale at sub-zero temperatures. In the first instance, only freeze concentration of whey permeate took place at -4 °C. It was possible to reach a lactose concentration of 30 wt% and hardly any nucleation was observed. The resulting ice had high purity, with a lactose concentration of ±2 wt%. Next, the eutectic phase was reached, and lactose and ice crystallized simultaneously and were continuously removed from the system, the resulting crystals had parallelogram morphology with an average size of 10 µm. Ice was recovered at a rate of 60 kg/h and lactose was recovered at a rate of 16 kg/h, yielding over 80% of the feed lactose. A conceptional design was proposed for an improved yield and reduction of energy. Yields of at least 80% and up till 95% could be achieved. Compared to the state-of-the-art mechanical vapor recompression (MVR), EFC is 80% more energy efficient.

Lactose Mother Liquor Stream Valorisation Using an Effective Electrodialytic Process

The integrated electrodialysis (ED) process supports valorisation of a lactose-rich side stream from the dairy industry, creating an important source of milk sugar used in various branches of the industry. This work focuses on the optimization of the downstream processes before the crystallization of lactose. The process line includes a pre-treatment and desalination by ED of the industrial waste solution of the lactose mother liquor (LML). The LML was diluted to 25% total solids to overcome hydraulic issues with the ED desalination process. Two different levels of electrical conductivity reduction (70% and 90%) of the LML solutions were applied to decrease the mineral components and organic acids of the LML samples. The ED performance parameters such as ash transfer rate (J), the specific capacity (C_F) of the ED and specific electric energy consumption (E) were determined and the influence of the LML solution on the monopolar ion-exchange membranes has been investigated. A higher degree of desalination is associated with higher electric energy consumption (by 50%) and lower specific capacity (by 40%). A noticeable decrease (by 12.8%) in the resistance of the anion exchange membranes was measured after the trials whereas the resistance of the cation exchange membranes remained practically unchanged. Any deposition of the alkaline earth metals on the membrane surface was not observed.

The Optimisation of Carrier Selection in Dry Powder Inhaler Formulation and the Role of Surface Energetics

This review examines the effects of particle properties on drug-carrier interactions in the preparation of a dry powder inhaler (DPI) formulation, including appropriate mixing technology. The interactive effects of carrier properties on DPI formulation performance make it difficult to establish a direct cause-and-effect relationship between any one carrier property and its effect on the performance of a DPI formulation. Alpha lactose monohydrate remains the most widely used carrier for DPI formulations. The physicochemical properties of α-lactose monohydrate particles, such as particle size, shape and solid form, are profoundly influenced by the method of production. Therefore, wide variations in these properties are inevitable. In this review, the role of surface energetics in the optimisation of dry powder inhaler formulations is considered in lactose carrier selection. Several useful lactose particle modification methods are discussed as well as the use of fine lactose and force control agents in formulation development. It is concluded that where these have been investigated, the empirical nature of the studies does not permit early formulation prediction of product performance, rather they only allow the evaluation of final formulation quality. The potential to leverage particle interaction dynamics through the use of an experimental design utilising quantifiable lactose particle properties and critical quality attributes, e.g., surface energetics, is explored, particularly with respect to when a Quality-by-Design approach has been used in optimisation.

An exploration of the solvent- and acid-catalyzed mutarotation mechanisms of lactose in aqueous solution

Exploration of the solvent- and acid-catalyzed mutarotation mechanisms of lactose to reveal the ease of the mutarotation varying with the acidity of the catalyst.

Cooling curve in production sweetened concentrated milk supplemented with whey: Influence on the size and microstructure of lactose crystals

The aim of this work was to develop a methodology to calculate the cooling curve for the sweetened condensed milk with added whey powder production and to assess the cooling regime effect on the distribution of lactose crystals' size and their microstructure. It is proposed to use a two-stage cooling curve. At the first stage, the cooling is carried out at a high speed, and at the second with a speed that varies depending on the rate of lactose crystallization. Electron microscopic studies have confirmed the cooling regime effect on the crystals' microstructure. The practical use of the developed regime showed that the two-stage cooling regime allows to reduce the size of lactose crystals (P < 0.05) and improve the quality of the finished product.