Mechanisms of flux decline in skim milk ultrafiltration: A review

The effect of calcium removal from skim milk by ion exchange on the properties of the ultrafiltration retentate

New processes are needed to produce concentrated milk feedstocks with tailored calcium content, due to the direct link between calcium concentration and final product texture and functionality. Skim milk treatment with cation exchange resin 1% (w/v) or 2% (w/v) prior to ultrafiltration to a volumetric concentration factor (VCF) of 2.5 or 5 successfully decreased the calcium concentration by 20-30% and produced concentrates with solids content at ∼22-24 g 100 g-1 at a VCF of 5. Calcium reduction partially solubilized the casein micelles, increasing the concentration of soluble protein and individual caseins, leading to decreased turbidity but increased protein hydration and hydrophobicity. Decalcification (2% (w/v) resin treatment) reduced thermal stability, significantly decreasing the denaturation temperature of α-lactalbumin and β-lactoglobulin in the milk by ∼3 °C and ∼1 °C respectively. Filtration was also altered, reducing permeation flux and the gel concentration and increased filtration time. When combined, calcium reduction and filtration altered functional properties including soluble calcium, soluble protein and sedimentable solids, with increased milk protein hydration also contributing to increased viscosity. This study provides a route to produce calcium-reduced milk concentrates with potential for use in retentate-based dairy products with tailored functionality.

Increasing Performance of Spiral-Wound Modules (SWMs) by Improving Stability against Axial Pressure Drop and Utilising Pulsed Flow

Spacer-induced flow shadows and limited mechanical stability due to module construction and geometry are the main obstacles to improving the filtration performance and cleanability of microfiltration spiral-wound membranes (SWMs), applied to milk protein fractionation in this study. The goal of this study was first to improve filtration performance and cleanability by utilising pulsed flow in a modified pilot-scale filtration plant. The second goal was to enhance membrane stability against module deformation by flow-induced friction in the axial direction ("membrane telescoping"). This was accomplished by stabilising membrane layers, including spacers, at the membrane inlet by glue connections. Pulsed flow characteristics similar to those reported in previous lab-scale studies could be achieved by establishing an on/off bypass around the membrane module, thus enabling a high-frequency flow variation. Pulsed flow significantly increased filtration performance (target protein mass flow into the permeate increased by 26%) and cleaning success (protein removal increased by 28%). Furthermore, adding feed-side glue connections increased the mechanical membrane stability in terms of allowed volume throughput by ≥100% compared to unmodified modules, thus allowing operation with higher axial pressure drops, flow velocities and pulsation amplitudes.

Insights into the role of concentration polarization on the membrane fouling and cleaning during the aerobic granular sludge filtration process

The aerobic granular sludge (AGS) effectively mitigates the membrane fouling of a membrane bioreactor. However, the role and effects of the concentration polarization (CP), induced during the AGS filtration process on the membrane fouling and membrane cleaning efficiency, remain unclear. In the present study, the AGS resulted in a higher CP proportion (>50%) and a lower CP resistance (<3 × 10¹² m^-1), compared with the flocculent sludge, owing to the synergistic effect of the hydraulic shear and AGS scouring development, which improved the AGS in suspension and also minimized its deposition on the membrane. High-frequency interactions (contact and collision) between the AGS and membrane enhanced the CP resistance by returning more granular sludge from the cake layer to the CP, which proportionally increased the fouling resistance. Based on the correlation of CP and fouling resistance, the CP resistance was divided into 3 categories: high-intensity (2.76 × 10¹² m^-1), medium-intensity (1.74 × 10¹² m^-1), and low-intensity (0.62 × 10¹² m^-1). At the high-intensity CP, most membrane pores were "sealed" (complete pore blocking [R² > 0.9015]) and the pore blocking condition was the most serious (K-value = 0.0622 s^-1), while the membrane surface became denser and rougher. As a result, the permeability loss after the long-term filtration increased. In the chemical cleaning investigation, the alkaline detergents yielded an enhanced membrane cleaning efficiency to recover permeability. By reducing the CP, the membrane cleaning efficiency was marginally improved. The present study reveals the quantitative role of CP and offers insights into the mechanisms that govern membrane fouling in a membrane bioreactor.

Membrane technologies for sports supplementation

The important developments in membrane techniques used in the dairy industrial processes to whey manufacturing are discussed. Particular emphasis is placed on the description of membrane processes, characterization of protein products, biological issues related to bacteriophages contamination, and modeling of the processes. This choice was dictated by the observed research works and consumer trends, who increasingly appreciate healthy food and its taste qualities.

Influence of Transglutaminase Crosslinking on Casein Protein Fractionation during Low Temperature Microfiltration

Low temperature microfiltration (MF) is applied in dairy processing to achieve higher protein and microbiological quality ingredients and to support ingredient innovation; however, low temperature reduces hydrophobic interactions between casein proteins and increases the solubility of colloidal calcium phosphate, promoting reversible dissociation of micellar β-casein into the serum phase, and thus into permeate, during MF. Crosslinking of casein proteins using transglutaminase was studied as an approach to reduce the permeation of casein monomers, which typically results in reduced yield of protein in the retentate fraction. Two treatments (a) 5 °C/24 h (TA) and (b) 40 °C/90 min (TB), were applied to the feed before filtration at 5 °C, with a 0.1 µm membrane. Flux was high for TA treatment possibly due to the stabilising effect of transglutaminase on casein micelles. It is likely that formation of isopeptide bonds within and on the surface of micelles results in the micelles being less readily available for protein-protein and protein–membrane interactions, resulting in less resistance to membrane pores and flow passage, thereby conferring higher permeate flux. The results also showed that permeation of casein monomers into the permeate was significantly reduced after both enzymatic treatments as compared to control feed due to the reduced molecular mobility of soluble casein, mainly β-casein, caused by transglutaminase crosslinking.

The effect of ultrafiltration on the acid gelation properties of protein-standardised skim milk systems

In this study, we investigated the impact of ultrafiltration (UF) on the acid gelation of milk using two protein-standardised milk systems, consisting of either skim milk and retentate (SR) or permeate and retentate (PR), over different seasons in New Zealand. The composition and the physicochemical properties of the two systems before heating were comparable, whereas the levels of heat-induced α-lactalbumin denaturation and the association of the casein micelles with α-lactalbumin were significantly lower in PR than in SR. PR displayed superior acid gelation properties compared with SR, which was most pronounced in the late season. The structural modifications of the whey proteins and casein micelles that were induced by UF and the re-equilibration of calcium in the milk mixtures may have affected the acid gelation properties of the milk by influencing the denaturation and micelle association of the whey proteins. The results suggest that UF has the potential as a tool for tuning the acid gelation properties of milk.

Prediction of Permeate Flux in Ultrafiltration Processes: A Review of Modeling Approaches

In any membrane filtration, the prediction of permeate flux is critical to calculate the membrane surface required, which is an essential parameter for scaling-up, equipment sizing, and cost determination. For this reason, several models based on phenomenological or theoretical derivation (such as gel-polarization, osmotic pressure, resistance-in-series, and fouling models) and non-phenomenological models have been developed and widely used to describe the limiting phenomena as well as to predict the permeate flux. In general, the development of models or their modifications is done for a particular synthetic model solution and membrane system that shows a good capacity of prediction. However, in more complex matrices, such as fruit juices, those models might not have the same performance. In this context, the present work shows a review of different phenomenological and non-phenomenological models for permeate flux prediction in UF, and a comparison, between selected models, of the permeate flux predictive capacity. Selected models were tested with data from our previous work reported for three fruit juices (bergamot, kiwi, and pomegranate) processed in a cross-flow system for 10 h. The validation of each selected model's capacity of prediction was performed through a robust statistical examination, including a residual analysis. The results obtained, within the statistically validated models, showed that phenomenological models present a high variability of prediction (values of R-square in the range of 75.91-99.78%), Mean Absolute Percentage Error (MAPE) in the range of 3.14-51.69, and Root Mean Square Error (RMSE) in the range of 0.22-2.01 among the investigated juices. The non-phenomenological models showed a great capacity to predict permeate flux with R-squares higher than 97% and lower MAPE (0.25-2.03) and RMSE (3.74-28.91). Even though the estimated parameters have no physical meaning and do not shed light into the fundamental mechanistic principles that govern these processes, these results suggest that non-phenomenological models are a useful tool from a practical point of view to predict the permeate flux, under defined operating conditions, in membrane separation processes. However, the phenomenological models are still a proper tool for scaling-up and for an understanding the UF process.

Evaluation of concentration process of bovine, goat and buffalo whey proteins by ultrafiltration

In this research, the protein concentration, the permeate flux, and the predominant fouling mechanisms were investigated during ultrafiltration of different whey samples. The research was carried out at different values of transmembrane pressure and temperature using an experimental design, and a protein concentration of approximately 37 g L-1 was obtained for the bovine whey powder solution, at 60 kPa and 40 °C. The maximum flux observed was 8.9 and 7.9 kg m-2 h-1, respectively, for the bovine whey powder solution and bovine whey, at 50 kPa and 30 °C. Although goat and buffalo whey presented lower permeate flux, probably due to high solutes and calcium contents, protein concentrates of around 40 g L-1 were obtained using the ultrafiltration process. This demonstrates the potential of ultrafiltration to obtain non-bovine protein concentrates. The best fit, verified by Ho and Zydney model, suggests that the fouling for all analyzed whey occurs due to pore blocking and subsequent deposit on the membrane surface.

Co-fermentation process strongly affect the nutritional, texture, syneresis, fatty acids and aromatic compounds of dromedary UF-yogurt

This work intended to compare dromedary yogurt's characteristics obtained by a co-fermentation process with plant (carob powder) or autochthonous bacteria (Enterococcus faecium and Streptococcus macedonicus). For this reason, the ultrafiltration process (UF) is applied to increase the rate of total solids in dromedary milk within the margin needed to prepare a yogurt. Carob powder or autochthonous bacteria were incorporated at the level of 2% in UF milk. Then mixtures were fermented with the strains Lactobacillus bulgaricus and Streptococcus thermophiles, and the obtained products are named CFC (yogurt with carob), CFS (yogurt with autochthonous strains) and control (yogurt with only L. bulgaricus and S. thermophilus) respectively. All along of 3 weeks at cold, CFC and CFS maintained Streptococcus at appropriate levels (>8 log CFU/g). Moreover, CFC showed the lowest syneresis, highest cohesiveness and springiness values, and oleic acid (C18:1n9; 26.315%). However, CFS yogurt resulted in higher volatile compound formation than CFC and control, where isobornyl propionate was the major one.

Application of nanofiltration and reverse osmosis for treatment and reuse of laundry wastewater

The aim of this study was to investigate the treatment and reuse of laundry wastewater with couple of nanofiltration (NF) and reverse osmosis (RO). In the NF process, optimal values of pH, temperature, transmembrane pressure (TMP) and cross-flow rate were determined using the Taguchi L₁₆ (4⁴) experimental design method. The smaller-the-better signal-to-noise (S/N) ratio was used to analyze the results of experiments. Flux decline caused by fouling was selected as response parameter. A pH of 8.5, temperature of 30 °C, TMP of 12 bar and cross-flow rate of 2 L/min were determined as optimum operating conditions in the NF process. According to analysis of variance (ANOVA), pH was the most effective factor while TMP and cross-flow rate had low effects on the fouling. Membrane fouling was also evaluated with scanning electron microscope (SEM), energy dispersive X-ray spectroscopy (EDX), zeta potential and optical profilometer measurements. In the RO process, the quality of NF permeate obtained from optimum operating conditions was improved by an RO membrane. Although a NF membrane was not effective in reducing chemical oxygen demand (COD), Orto-P and NH₄ ⁺-N, these parameters were almost removed in the NF + RO system. These results showed that, the Taguchi method was successfully applied to determine the optimum operating conditions for the treatment of laundry wastewater with an NF process. Water treated with integrated membrane processes (NF + RO) is sufficient for use as laundry washing water.

Influence of Processing Temperature on Membrane Performance and Characteristics of Process Streams Generated during Ultrafiltration of Skim Milk

The effects of processing temperature on filtration performance and characteristics of retentates and permeates produced during ultrafiltration (UF) of skim milk at 5, 20, and 50 °C were investigated. The results indicate that despite higher flux at 50 °C, UF under these conditions resulted in greater fouling and rapid flux decline in comparison with 5 and 20 °C. The average casein micelle diameter was higher in retentate produced at 5 and 20 °C. The retentate analysed at 5 °C displayed higher viscosity and shear thinning behaviour as compared to retentate analysed at 20 and 50 °C. Greater permeation of calcium and phosphorus was observed at 5 and 20 °C in comparison with 50 °C, which was attributed to the inverse relationship between temperature and solubility of colloidal calcium phosphate. Permeation of α-lactalbumin was observed at all processing temperatures, with permeation of β-lactoglobulin also evident during UF at 50 °C. All UF retentates were shown to have plasmin activity, while lower activity was measured in retentate produced at 5 °C. The findings revealed that UF processing temperature influences the physicochemical, rheological, and biochemical properties of, and thereby govern the resulting quality and functionality of, retentate- and permeate-based dairy ingredients.

Minor acidification of diafiltration water using various acidification agents affects the composition and rennet coagulation properties of the resulting microfiltration casein concentrate

Cheese made from microfiltration (MF) retentate may suffer from textural defects due to a high Ca concentration. The reduction of colloidal minerals by the acidification of milk before MF at pH below 6.0 has been well documented in the literature. This process, however, creates less valuable side streams to the MF process and induces changes in the casein micelles that negatively affect their coagulation properties. The objective of this study was to determine whether a minor reduction in pH by using different acidifiers in the diafiltration (DF) water could induce changes in composition and renneting properties of the MF retentate. A 2-stage filtration process was used, with the first designed to increase the casein concentration to 8% and the second to slightly reduce the casein concentrate by 0.1 pH unit by DF, without influencing the total protein concentration. Four acidifying agents were tested during DF: lactic acid, hydrochloric acid, citric acid, and carbon dioxide. Diafiltration with water was used as a reference. At the start of DF, the retentates of acid DF had a slightly reduced pH, with an average of 0.09, whereas the pH of the reference retentate increased by an average of 0.07 unit. The reference retentate regained its starting pH by the end of DF. The carbonated retentate gradually increased in pH during processing, whereas the pH of the lactic, hydrochloric, and citric acid retentates remained constant. The permeate from the lactic acid and carbonated treatments had a reduced whey protein content compared with the reference. The total P and inorganic phosphate were lowered in the retentate by using carbonation. The total amount of Mg and Na were lowered in the retentate by using citric acid. The ionic Ca content in the retentate increased with use of lactic or hydrochloric acid. The type of acidifier used reduced the rennet clotting time. Combined acidified diafiltration with a slight reduction affects the permeate composition and improves the retentate clotting time despite the minimal mineral modification.

Production of Liquid Milk Protein Concentrate with Antioxidant Capacity, Angiotensin Converting Enzyme Inhibitory Activity, Antibacterial Activity, and Hypoallergenic Property by Membrane Filtration and Enzymatic Modification of Proteins

Liquid milk protein concentrate with different beneficial values was prepared by membrane filtration and enzymatic modification of proteins in a sequential way. In the first step, milk protein concentrate was produced from ultra-heat-treated skimmed milk by removing milk serum as permeate. A tubular ceramic-made membrane with filtration area 5 × 10−3 m2 and pore size 5 nm, placed in a cross-flow membrane house, was adopted. Superior operational strategy in filtration process was herein: trans-membrane pressure 3 bar, retention flow rate 100 L·h−1, and implementation of a static turbulence promoter within the tubular membrane. Milk with concentrated proteins from retentate side was treated with the different concentrations of trypsin, ranging from 0.008–0.064 g·L−1 in individual batch-mode operations at temperature 40 °C for 10 min. Subsequently, inactivation of trypsin in reaction was done at a temperature of 70 °C for 30 min of incubation. Antioxidant capacity in enzyme-treated liquid milk protein concentrate was measured with the Ferric reducing ability of plasma assay. The reduction of angiotensin converting enzyme activity by enzyme-treated liquid milk protein concentrate was measured with substrate (Abz-FRK(Dnp)-P) and recombinant angiotensin converting enzyme. The antibacterial activity of enzyme-treated liquid milk protein concentrate towards Bacillus cereus and Staphylococcus aureus was tested. Antioxidant capacity, anti-angiotensin converting enzyme activity, and antibacterial activity were increased with the increase of trypsin concentration in proteolytic reaction. Immune-reactive proteins in enzyme-treated liquid milk protein concentrate were identified with clinically proved milk positive pooled human serum and peroxidase-labelled anti-human Immunoglobulin E. The reduction of allergenicity in milk protein concentrate was enzyme dose-dependent.

Structural Characterisation of Deposit Layer during Milk Protein Microfiltration by Means of In-Situ MRI and Compositional Analysis

Milk protein fractionation by microfiltration membranes is an established but still growing field in dairy technology. Even under cross-flow conditions, this filtration process is impaired by the formation of a deposit by the retained protein fraction, mainly casein micelles. Due to deposition formation and consequently increased overall filtration resistance, the mass flow of the smaller whey protein fraction declines within the first few minutes of filtration. Currently, there are only a handful of analytical techniques available for the direct observation of deposit formation with opaque feed media and membranes. Here, we report on the ongoing development of a non-invasive and non-destructive method based on magnetic resonance imaging (MRI), and its application to characterise deposit layer formation during milk protein fractionation in ceramic hollow fibre membranes as a function of filtration pressure and temperature, temporally and spatially resolved. In addition, the chemical composition of the deposit was analysed by reversed phase high pressure liquid chromatography (RP-HPLC). We correlate the structural information gained by in-situ MRI with the protein amount and composition of the deposit layer obtained by RP-HPLC. We show that the combination of in-situ MRI and chemical analysis by RP-HPLC has the potential to allow for a better scientific understanding of the pressure and temperature dependence of deposit layer formation.

In situ measurement of deposit layer formation during skim milk filtration by MRI

Filtration and separation via membranes are key processes in food processing. One major application of membrane filtration is in the dairy industry, aiming for the separation of different milk proteins. The various chemical components of milk possess different physiochemical properties and can be used most effectively in food processing if they are separately available and remain in their native state. Microfiltration of skim milk allows a fractionation of the milk proteins casein and whey by size. A deposit is formed on the membrane surface mainly but not exclusively by micellar casein proteins during filtration. Membrane pore blockage by whey proteins and fouling occur during membrane filtration, negatively affecting the yield of the whey protein fraction. Skim milk filtration and the deposit layer formation were measured time and spatially resolved by in situ magnetic resonance imaging (MRI). The nature of the fouling layer was investigated during dead-end filtration in ceramic hollow fiber membranes. MRI was used to further clarify the influence of operating conditions on separation and filtration mechanisms that are responsible for growth of the fouling layer and its reversibility. The MRI measurements were analyzed for a detailed description of skim milk filtration by modeling the signal intensity distribution.

Milk Protein Fractionation by Means of Spiral-Wound Microfiltration Membranes: Effect of the Pressure Adjustment Mode and Temperature on Flux and Protein Permeation

Protein fractionation by means of microfiltration (MF) is significantly affected by fouling, especially when spiral-wound membranes (SWMs) are used. We investigated the influence of the mode of transmembrane pressure (Δp_TM) increase to target level and the deposit layer pressure history on the filtration performance during skim milk MF at temperatures of 10 °C and 50 °C. Two filtration protocols were established: No. 1: Δp_TM was set directly to various target values. No. 2: Starting from a low Δp_TM, we increased and subsequently decreased Δp_TM stepwise. The comparison of both protocols tested the effect of the mode of Δp_TM increase to target level. The latter protocol alone tested the effect of the deposit layer history with regard to the Δp_TM. As expected, flux and protein permeation were both found to be functions of the Δp_TM. Further, both measures were independent of the filtration protocol as long as Δp_TM was held at a constant level or, as part of protocol No. 2, Δp_TM was increased. Thus, we can state that the mode of Δp_TM increase to target level does not affect filtration performance in SWM. We found that after completion of a full cycle of stepping Δp_TM up from 0.5 bar to 3.0 bar and back down, flux and deposit layer resistance were not affected by the deposit layer history at 10 °C, but they were at 50 °C. Protein permeation, however, was lower for both 10 °C and 50 °C, when the Δp_TM cycle was completed. The processing history had a significant impact on filtration performance due to remaining structural compression effects in the deposited layer, which occur most notably at higher temperatures. Furthermore, temperatures of 50 °C lead to deposit layer aging, which is probably due to an enhanced crosslinking of particles in the deposit layer. Apart from that, we could show that fouling resistance does not directly correlate with protein permeation during skim milk MF using SWM.

Performance of nanofiltration process during concentration of strawberry juice

The aim of this study was to evaluate the microfiltration and nanofiltration of strawberry juice. Processes performance was evaluated in terms of resistances-in-series, flux decline modeling and extract quality (maintenance of the phenolic compounds). The results obtained showed that concentration polarization is the main resistance to permeate flux in nanofiltration process, representing around 95% of the total resistance. Microfiltration process suffered more influence of the concentration polarization and fouling, next to 47% for both resistances. For all the processes, Hermia's pore blocking models presented good fitting, with R² over 0.85. The same behavior was observed for a conjugated model which provided a realistic description (R² > 0.76). Also, nanofiltration process allowed phenolic compounds maintenance, demonstrating the efficiency of this process for strawberry juice concentration.

Effect of Ultrafiltration of Milk Prior to Fermentation on Mass Balance and Process Efficiency in Greek-Style Yogurt Manufacture

Ultrafiltration (UF) can be used to concentrate yogurt to produce Greek-style yogurt (GSY) (UF-YOG), but this generates acid whey permeate, which is an environmental issue. However, when UF is applied before fermentation (UF-MILK), a nonacidified whey permeate is generated. For this study, two model GSYs (UF-YOG and UF-MILK) were produced to compare the composition, UF performance, and energy consumption of the two processes. For UF-MILK, skim milk was ultrafiltered with a 30 kDa spiral-wound UF membrane to achieve a 3× volume reduction factor (VRF). The retentate was fermented to a pH of 4.5. The UF-YOG process was the same except that regular yogurt was ultrafiltered. Both GSYs had similar protein (~10%) and solid content (~17%). As expected, lactic acid/lactate was not detected in UF-MILK permeate, while 7.3 g/kg was recovered from the UF-YOG permeate. Permeation flux values (11.6 to 13.3 L m^-2 h^-1) and total flux decline (47% to 50%) were constant during UF-MILK, whereas drastic decreases in these two membrane performance indicators (average flux: 38.5 to 10.9 L m^-2 h^-1; total flux decline: 2% to 38%) were calculated for UF-YOG. Moreover, for UF-YOG, UF membrane performance never recovered, even when drastic and repeated cleaning steps were applied. Energy consumption was 1.6 kWh/kg GSY and remained constant for UF-MILK, whereas it increased from 0.6 to 1.5 kWh/kg GSY for UF-YOG. Our results show that, although the composition of GSYs was similar for both processes, the UF step of yogurt concentration affected process efficiency due to drastic and permanent membrane fouling.

Effect of skim milk treated with high hydrostatic pressure on permeate flux and fouling during ultrafiltration

Ultrafiltration (UF) is largely used in the dairy industry to generate milk and whey protein concentrate for standardization of milk or production of dairy ingredients. Recently, it was demonstrated that high hydrostatic pressure (HHP) extended the shelf life of milk and improved rennet coagulation and cheese yield. Pressurization also modified casein micelle size distribution and promoted aggregation of whey proteins. These changes are likely to affect UF performance. Consequently, this study determined the effect of skim milk pressurization (300 and 600 MPa, 5 min) on UF performance in terms of permeate flux decline and fouling. The effect of HHP on milk proteins was first studied and UF was performed in total recycle mode at different transmembrane pressures to determine optimal UF operational parameters and to evaluate the effect of pressurization on critical and limiting fluxes. Ultrafiltration was also performed in concentration mode at a transmembrane pressure of 345 kPa for 130 or 140 min to evaluate the decline of permeate flux and to determine fouling resistances. It was observed that average casein micelle size decreased by 32 and 38%, whereas β-lactoglobulin denaturation reached 30 and 70% at 300 and 600 MPa, respectively. These results were directly related to UF performance because initial permeate fluxes in total recycle mode decreased by 25% at 300 and 600 MPa compared with nonpressurized milk, critical flux, and limiting flux, which were lower during UF of milk treated with HHP. During UF in concentration mode, initial permeate fluxes were 30% lower at 300 and 600 MPa compared with the control, but the total flux decline was higher for nonpressurized milk (62%) compared with pressure-treated milk (30%). Fouling resistances were similar, whatever the treatment, except at 600 MPa where irreversible fouling was higher. Characterization of the fouling layer showed that caseins and β-lactoglobulin were mainly involved in membrane fouling after UF of pressure-treated milk. Our results demonstrate that HHP treatment of skim milk drastically decreased UF performance.