Nanofiltration of lactic acid whey prior to spray drying: Scaling up to a semi-industrial scale

Transforming acid whey into a resource by selective removal of lactic acid and galactose using optimized food-grade microorganisms

The presence of lactic acid and galactose makes spray drying of acid whey (AW) a significant challenge for the dairy industry. In this study, a novel approach is explored to remove these compounds, utilizing food-grade microorganisms. For removing lactic acid, Corynebacterium glutamicum was selected, which has an inherent ability to metabolize lactic acid but does so slowly. To accelerate lactic acid metabolism, a mutant strain G6006 was isolated through adaptive laboratory evolution, which metabolized all lactic acid from AW two times faster than its parent strain. To eliminate galactose, a lactose-negative mutant of Lactococcus lactis that cannot produce lactate was generated. This strain was then co-cultured with G6006 to maximize the removal of both lactic acid and galactose. The microbially "filtered" AW could readily be spray dried into a stable lactose powder. This study highlights the potential of utilizing food-grade microorganisms to process AW, which currently constitutes a global challenge.

Modeling of lactic acid rejection from lactose in acidified cheese whey by nanofiltration

The continuously increasing demand of lactic acid opens a window for the integration of membrane technology in the dairy industry, improving the sustainability by avoiding the use of large amounts of chemicals and waste generation. Lactic acid recovery from fermentation broth without precipitation has been studied by numerous processes. In this work, a commercial membrane with high lactose rejection and a moderate lactic acid rejection, enabling a permselectivity up to 40%, is sought to perform the simultaneous removal of lactic acid and lactose separation from the acidified sweet whey from mozzarella cheese production in a single stage. The AFC30 membrane of the thin film composite nanofiltration (NF) type was selected because of its high negative charge, low isoelectric point, and divalent ion rejection, as well as a lactose rejection higher than 98% and a lactic acid rejection lower than 37%, at pH 3.5, to minimize the need of additional separation steps. The experimental lactic acid rejection was evaluated at varying feed concentration, pressure, temperature, and flow rate. As the dissociation degree of lactic acid is negligible in industrially simulated conditions, the performance of this NF membrane was validated by the irreversible thermodynamic Kedem-Katchalsky and Spiegler-Kedem models, with the best prediction in the latter case, with the parameter values: L_p = 3.24 ± 0.87 L × m^-2 × h^-1 × bar^-1 and = 15.06 ± 3.17 L × m^-2 × h^-1, and σ = 0.45 ± 0.03. The results obtained in this work open the way for the up-scaling of membrane technology on the valorization of dairy effluents by simplifying the operation process and the model prediction and the choice of the membrane.

Use of Membrane Technologies in Dairy Industry: An Overview

The use of treatments of segregated process streams as a water source, as well as technical fluid reuse as a source of value-added recovery products, is an emerging direction of resource recovery in several applications. Apart from the desired final product obtained in agro-food industries, one of the challenges is the recovery or separation of intermediate and/or secondary metabolites with high-added-value compounds (e.g., whey protein). In this way, processes based on membranes, such as microfiltration (MF), ultrafiltration (UF), nanofiltration (NF) and reverse osmosis (RO), could be integrated to treat these agro-industrial streams, such as milk and cheese whey. Therefore, the industrial application of membrane technologies in some processing stages could be a solution, replacing traditional processes or adding them into existing treatments. Therefore, greater efficiency, yield enhancement, energy or capital expenditure reduction or even an increase in sustainability by producing less waste, as well as by-product recovery and valorization opportunities, could be possible, in line with industrial symbiosis and circular economy principles. The maturity of membrane technologies in the dairy industry was analyzed for the possible integration options of membrane processes in their filtration treatment. The reported studies and developments showed a wide window of possible applications for membrane technologies in dairy industry treatments. Therefore, the integration of membrane processes into traditional processing schemes is presented in this work. Overall, it could be highlighted that membrane providers and agro-industries will continue with a gradual implementation of membrane technology integration in the production processes, referring to the progress reported on both the scientific literature and industrial solutions commercialized.

Study of Acid Whey Fouling after Protein Isolation Using Nanofiltration

In this paper, nanofiltration (NF) of acid whey after isolation of proteins was studied. Two membranes were tested: NF-99 (Alfa Laval) and DL (Osmonic Desal). Based on previous measurements that determined the highest efficiency in separating lactic acid and lactose whey, the pH was adjusted to 3. First, the most appropriate transmembrane pressure (TMP) was determined based on the highest flux measured. The TMP range was 5-25 bar for the DL membrane and 10-30 bar for the NF-99 membrane. The temperature was kept at 4 °C using a thermostat. The mechanisms of membrane fouling were investigated. The Hermia models and the modified Tansel model were applied to study the fouling mechanism and to determine which membrane would foul earlier and more severely, respectively. The most suitable TMP was determined at 20 bar. Despite the 1.4 times higher flux of the sample at DL, the fouling rate was higher when NF-99 was used. The results showed that the Tansel model is suitable for predicting the fouling time of protein-isolated whey by nanofiltration.

Lactic Acid and Salt Separation Using Membrane Technology

Acid whey is a by-product of cheese and yoghurt manufacture. The protein and lactose within acid whey can be recovered using nanofiltration and electrodialysis, but this leaves a waste stream that is a mixture of salts and lactic acid. To further add value to the acid whey treatment process, the possibility of recovering this lactic acid was investigated using either low energy reverse osmosis membranes or an electrodialysis process. Partial separation between lactic acid and potassium chloride was achieved at low applied pressures and feed pH in the reverse osmosis process, as a greater permeation of potassium chloride was observed under these conditions. Furthermore, lactic acid retention was enhanced by operating at lower temperature. Partial separation between lactic acid and potassium chloride was also achieved in the electrodialysis process. However, the observed losses in lactic acid increased with the addition of sodium chloride to the feed solution. This indicates that the separation becomes more challenging as the complexity of the feed solution increases. Neither process was able to achieve sufficient separation to avoid the use of further purification processes.

How Overlimiting Current Condition Influences Lactic Acid Recovery and Demineralization by Electrodialysis with Nanofiltration Membrane: Comparison with Conventional Electrodialysis

Acid whey is the main co-product resulting from the production of fresh cheeses and Greek-type yogurts. It generally goes through a spray-drying process prior to valorization, but it needs to be deacidified (lactic acid recovery) and demineralized beforehand to obtain a powder of quality with all the preserved compounds of interest such as lactose and proteins. Electrodialysis (ED) is a process actually used for acid whey treatment, but scaling formation at the surface of the ion-exchange membrane is still a major problem. In this work, a combination of two new avenues of ED treatment has been studied. First, the integration of a nanofiltration (NF) membrane in an ED conventional stack was compared to a classical ED stack with an anion-exchange membrane in a standard current condition. Secondly, both configurations were tested in the overlimiting current condition to study the impact of electroconvective vortices on process efficiency. The combined effects of the NF membrane and overlimiting current condition led to a higher lactic acid recovery rate of acid whey (40%), while the conventional ED stack in the overlimiting current condition led to a higher demineralization (87% based on the total cation concentration). Those effects were related to the conductivity, pH, global resistance, and energy consumption of each treatment that are influenced by water splitting phenomenon, which was decreased in the overlimiting condition.

Systematic Study of the Impact of Pulsed Electric Field Parameters (Pulse/Pause Duration and Frequency) on ED Performances during Acid Whey Treatment

Processing acid whey is still a challenge for the dairy industry due to its high lactic acid and mineral contents. Their removal processes represent a high investment and running cost in addition to significant production of polluting effluents. A previous study showed that the use of electrodialysis with the application of pulsed electric fields (PEFs) was sufficiently efficient to produce dryable acid whey with reduced scaling issues during the process. In the present work, eight PEF conditions using different pulse/pause durations and frequencies were tested for 1) process optimization and 2) understanding of the underlying mechanisms involved in PEF process improvements. Best results were obtained for PEF conditions (5 s/5 s) and (15 s/15 s) with almost complete scaling mitigation and minimal energy consumption (5.3 ± 0.4 Wh/g of lactic acid vs. 9.33 ± 1.38 Wh/g for continuous current). Longer pause times also led to better divalent ion demineralization at the expense of sodium elimination induced by stronger affinity with the membrane and longer retention times. For the first time, PEF parameters of relatively low frequencies (<1) were studied in sub-limiting current conditions on a complex solution such as acid whey.

Positive Impact of Pulsed Electric Field on Lactic Acid Removal, Demineralization and Membrane Scaling during Acid Whey Electrodialysis

The drying of acid whey is hindered by its high mineral and organic acid contents, and their removal is performed industrially through expensive and environmentally impacting serial processes. Previous works demonstrated the ability to remove these elements by electrodialysis alone but with a major concern-membrane scaling. In this study, two conditions of pulsed electric field (PEF) were tested and compared to conventional DC current condition to evaluate the potential of PEF to mitigate membrane scaling and to affect lactic acid and salt removals. The application of a PEF 25 s/25 s pulse/pause combination at an initial under-limiting current density allowed for decreasing the amount of scaling, the final system electrical resistance by 32%, and the relative energy consumption up to 33%. The use of pulsed current also enabled better lactic acid removal than the DC condition by 10% and 16% for PEF 50 s/10 s and 25 s/25 s, respectively. These results would be due to two mechanisms: (1) the mitigation of concentration polarization phenomenon and (2) the rinsing of the membranes during the pause periods. To the best of our knowledge, this was the first time that PEF current conditions were used on acid whey to both demineralize and deacidify it.

Short communication: Multi-component interactions causing solidification during industrial-scale manufacture of pre-crystallized acid whey powders

Acid whey (AW) is the liquid co-product arising from acid-induced precipitation of casein from skim milk. Further processing of AW is often challenging due to its high mineral content, which can promote aggregation of whey proteins, which contributes to high viscosity of the liquid concentrate during subsequent lactose crystallization and drying steps. This study focuses on mineral precipitation, protein aggregation, and lactose crystallization in liquid AW concentrates (∼55% total solids), and on the microstructure of the final powders from 2 independent industrial-scale trials. These AW concentrates were observed to solidify either during processing or during storage (24 h) of pre-crystallized concentrate. The more rapid solidification in the former was associated with a greater extent of lactose crystallization and a higher ash-to-protein ratio in that concentrate. Confocal laser scanning microscopy analysis indicated the presence of a loose network of protein aggregates (≤10 µm) and lactose crystals (100-300 µm) distributed throughout the solidified AW concentrate. Mineral-based precipitate was also evident, using scanning electron microscopy, at the surface of AW powder particles, indicating the formation of insoluble calcium phosphate during processing. These results provide new information on the composition- and process-dependent physicochemical changes that are useful in designing and optimizing processes for AW.

How electrodialysis configuration influences acid whey deacidification and membrane scaling

With the rising popularity of Greek-style yogurts in the past few years, the production of acid whey has drastically increased. If sweet whey is usually further processed, the acid whey valorization comes with challenges because its drying is jeopardized by its high mineral and organic acid contents. For this reason, prior demineralization and deacidification are usually performed at industrial scale using a combination of ion exchange resins and electrodialysis. This whole process represents large amounts of resources and energy consumption as well as an important production of effluents. The optimization of the electrodialysis technique, currently the focus of a few studies, could result in the replacement of the serial processes and would provide a cost-effective and eco-efficient alternative. In this work, the demineralization and deacidification of acid whey were compared via 2 electrodialysis configurations: one conventional and one using bipolar membranes. Both configurations allowed to reach interesting demineralization (67%) and deacidification (44%) rates. However, even though the appearance of fouling or scaling has never been reported, scalings of different natures were observed on membranes using both configurations. Amorphous calcium phosphate was identified on the anion exchange membranes for both configurations while calcite and brucite were identified on cation exchange ones using the bipolar membrane configuration. These scaling formations were linked to the migration of divalent ions and water splitting phenomenon caused by a high demineralization rate or by an already formed significant scaling.