Manufacture of a novel cultured micellar casein concentrate ingredient for emulsifying salt free process cheese products applications

Micellar casein concentrate (MCC) is a high protein ingredient that is typically produced using 3 stages of microfiltration with a 3× concentration factor and diafiltration. Acid curd is an acid protein concentrate, which can be obtained by precipitating the casein at pH 4.6 (isoelectric point) using starter cultures or direct acids without the use of rennet. Process cheese product (PCP) is a dairy food prepared by blending dairy ingredients with nondairy ingredients and then heating the mixture to get a product with an extended shelf-life. Emulsifying salts are critical for the desired functional characteristics of PCP because of their role in calcium sequestration and pH adjustment. The objectives of this study were to develop a process to produce a novel cultured micellar casein concentrate ingredient (cMCC; culture-based acid curd) and to produce PCP without emulsifying salts using different combinations of protein from cMCC and MCC in the formulations (2.0:1.0, 1.9:1.1, and 1.8:1.2). Skim milk was pasteurized at 76°C for 16 s and then microfiltered in 3 microfiltration stages using graded permeability ceramic membranes to produce liquid MCC (11.15% total protein; TPr and 14.06% total solids; TS). Part of the liquid MCC was spray dried to produce MCC powder (75.77% TPr and 97.84% TS). The rest of the MCC was used to produce cMCC (86.9% TPr and 96.4% TS). Three PCP treatments were formulated with different ratios of cMCC:MCC, including 2.0:1.0, 1.9:1.1, and 1.8:1.2 on the protein basis. The composition of PCP was targeted to 19.0% protein, 45.0% moisture, 30.0% fat, and 2.4% salt. This trial was repeated 3 times using different batches of cMCC and MCC powders. All PCP were evaluated for their final functional properties. No significant differences were detected in the composition of PCP made with different ratios of cMCC and MCC except for the pH. The pH was expected to increase slightly with elevating the MCC amount in the PCP formulations. The end apparent viscosity was significantly higher in 2.0:1.0 formulation (4,305 cP) compared with 1.9:1.1 (2,408 cP) and 1.8:1.2 (2,499 cP). The hardness ranged from 407 to 512 g with no significant differences within the formulations. However, the melting temperature showed significant differences with 2.0:1.0 having the highest melting temperature (54.0°C), whereas 1.9:1.1 and 1.8:1.2 showed 43.0 and 42.0°C melting temperature, respectively. The melting diameter (38.8 to 43.9 mm) and melt area (1,183.9 to 1,538.6 mm²) did not show any differences in different PCP formulations. The PCP made with a 2.0:1.0 ratio of protein from cMCC and MCC showed better functional properties compared with other formulations.

Process intensification through waste fly ash conversion and application as ceramic membranes: A review

Improper disposal of huge quantities of fly ash generated by thermal power plants and few other industries contributes to both air and water pollution, and therefore, recent advancements in research are focused toward utilizing this waste material in fabricating useful membranes. This article presents an overview of various methods used to fabricate fly ash-based membranes and critical parameters affecting the same. Fly ash-based membranes also act as the support for fabricating composite membranes and therefore, different means of coating the support membranes are discussed in this paper. Among various methods of membrane fabrication, extrusion method can be considered for bulk production of membranes, which is a pre-requisite for industrial implementation. The article also throws light on a wide range of wastewater that have been successfully treated using these fly ash-based ceramic membranes. However, the use of these membranes should be avoided in acidic solutions as it may cause leaching of heavy metals present in fly ash, causing health hazards. Most of these membranes function on the basis of size exclusion principle, whereas membranes with charge-based separation are also well known. Both of these types of membranes are discussed in this work. Utilization of fly ash-based membranes in separation processes not only reduce the cost associated with the process, but will also intensify the process through various other means such as reduced energy consumption, environmental safety and so on. Thus, the main focus of this review is to present the readers with development and important future directions in this research topic.

Production and storage stability of concentrated micellar casein

Concentrated micellar casein (CMC) is a high-protein ingredient that can be used in process cheese product formulations. The objectives of this study were to develop a process to produce CMC and to evaluate the effect of sodium chloride and sodium citrate on its storage stability. Skim milk was pasteurized at 76°C for 16 s and cooled to ≤4°C. The skim milk was heated to 50°C using a plate heat exchanger and microfiltered with a graded permeability (GP) ceramic microfiltration (MF) membrane system (0.1 μm) in a continuous feed-and-bleed mode (flux of 71.43 L/m² per hour) using a 3× concentration factor (CF) to produce a 3× MF retentate. Subsequently, the retentate of the first stage was diluted 2× with soft water (2 kg of water: 1 kg of retentate) and again MF at 50°C using a 3× CF. The retentate of the second stage was then cooled to 4°C and stored overnight. The following day, the retentate was heated to 63°C and MF in a recirculation mode until the total solids (TS) reached approximately 22% (wt/wt). Subsequently, the MF system temperature was increased to 74°C and MF until the permeate flux was <3 L/m² per hour. The CMC was then divided into 3 aliquots (approximately 10 kg each) at 74°C. The first portion was a control, whereas 1% of sodium chloride was added to the second portion (T1), and 1% of sodium chloride plus 1% of sodium citrate were added to the third portion (T2). The CMC retentates were transferred hot to sterilized vials and stored at 4°C. This trial was repeated 3 times using separate lots of skim milk. The CMC at d 0 (immediately after manufacturing) contained 25.41% TS, 21.65% true protein (TP), 0.09% nonprotein nitrogen (NPN), and 0.55% noncasein nitrogen (NCN). Mean total aerobic bacterial counts (TBC) in control, T1, and T2 at d 0 were 2.6, 2.5, and 2.8 log cfu/mL, respectively. The level of proteolysis (NCN and NPN values) increased with increasing TBC during 60 d of storage at 4°C. This study determined that CMC with >25% TS and >95% casein as percentage of TP can be manufactured using GP MF ceramic membranes and could be stored up to 60 d at 4°C. The effects of the small increase in NCN and NPN, as well as the addition of sodium chloride or sodium citrate in CMC during 60 d of storage on process cheese characteristics, will be evaluated in subsequent studies.

Effect of Different Temperature-Controlled Ultrasound on the Physical and Functional Properties of Micellar Casein Concentrate

Micellar casein concentrate (MCC) is a novel dairy ingredient with high protein content. However, its poor functional properties impair its potential for further application, highlighting the importance of using innovative processing methods to produce modified MCC, such as ultrasound (US). This work investigated the impact of US on the physical and functional properties of MCC under temperature-controlled and -uncontrolled conditions for different time intervals. Under temperature-controlled ultrasound (TC-US) treatment, a reduction was found in the supernatant particle size of casein micelles. Soluble calcium content and hydrophobicity increased following ultrasound treatment at 20 °C, resulting in a remarkable improvement in emulsification. However, long-time ultrasonication led to an unstable state, causing the MCC solutions to show shear thinning behavior (pseudoplastic fluid). Compared with 50 °C temperature-controlled ultrasonication, ultrasonication at 20 °C had a greater influence on particle size, viscosity and hydrophobicity. These findings indicate that 20 °C TC-US could be a promising technology for the modification of MCC.

Viscosity changes and gel formation during storage of liquid micellar casein concentrates

Our objective was to determine the effects of temperature and protein concentration on viscosity increase and gelation of liquid micellar casein concentrate (MCC) at protein concentrations from 6 to 20% during refrigerated storage. Skim milk (~350 kg) was pasteurized (72°C for 16 s) and filtered through a ceramic microfiltration system to make MCC and replicated 3 times. The liquid MCC was immediately concentrated via a plate ultrafiltration system to 18% protein (wt/wt). The MCC was then diluted to various protein concentrations (6-18%, wt/wt). The highest protein concentrations of MCC formed gels almost immediately on cooling to 4°C, whereas lower concentrations of MCC were viscous liquids. Apparent viscosity (AV) determination using a rotational viscometer, gel strength using a compression test, and protein analysis of supernatants from ultracentrifugation by the Kjeldahl method were performed. The AV data were collected from MCC (6.54, 8.75, 10.66, and 13.21% protein) at 4, 20, and 37°C, and compression force test data were collected for MCC (15.6, 17.9, and 20.3% protein) over a period of 2-wk storage at 4°C. The maximum compressive load was compared at each time point to determine the changes in gel strength over time. Supernatants from MCC of 6.96 and 11.61% protein were collected after ultracentrifugation (100,605 × g for 2 h at 4, 20, and 37°C) and the nitrogen distributions (total, noncasein, casein, and nonprotein nitrogen) were determined. The protein and casein as a percent of true protein concentration in the liquid phase around casein micelles in MCC increased with increasing total MCC protein concentration and with decreasing temperature. Casein as a percent of true protein at 4°C in the liquid phase around casein micelles increased from about 16% for skim milk to about 78% for an MCC containing 11.6% protein. This increase was larger than expected, and this may promote increased viscosity. The AV of MCC solutions in the range of 6 to 13% casein increased with increasing casein concentration and decreasing temperature. We observed a temperature by protein concentration interaction, with AV increasing more rapidly with decreasing temperature at high protein concentration. The increase in AV with decreasing temperature may be due to the increase in protein concentration in the aqueous phase around the casein micelles. The MCC containing about 16 and 18% casein gelled upon cooling to form a gel that was likely a particle jamming gel. These gels increased in strength over 10 d of storage at 4°C, likely due either to the migration of casein (CN) out of the micelles and interaction of the nonmicellar CN to form a network that further strengthened the random loose jamming gel structure or to a gradual increase in voluminosity of the casein micelles during storage at 4°C.

Optimization of Spiral-Wound Microfiltration Process Parameters for the Production of Micellar Casein Concentrate

A systematic selection of different transmembrane pressures (TMP) and levels of diafiltration (DF) was studied to optimize these critical process parameters during the manufacturing of micellar casein concentrate (MCC) using spiral-wound polymeric membrane filtration. Three TMPs (34.5, 62.1, and 103.4 kPa) and four DF levels (0, 70, 100, and 150%) were applied in the study. The effect of the TMP and DF level on flux rates, serum protein (SP) removal, the casein-to-total-protein ratio, the casein-to-true-protein ratio, and the rejection of casein and SP were evaluated. At all transmembrane pressures, the overall flux increased with increases in the DF level. The impact of DF on the overall flux was more pronounced at lower pressures than at higher pressures. With controlled DF, the instantaneous flux was maintained within 80% of the initial flux for the entire process run. The combination of 34.5 kPa and a DF level of 150% resulted in 81.45% SP removal, and a casein-to-true-protein ratio of 0.96. SP removal data from the lab-scale experiments were fitted into a mathematical model using DF levels and the square of TMPs as factors. The model developed in this study could predict SP removal within 90-95% of actual SP removal achieved from the pilot plant experiments.

Progress in micellar casein concentrate: Production and applications

Micellar casein concentrate (MCC) is a novel ingredient with high casein content. Over the past decade, MCC has emerged as one of the most promising dairy ingredients having applications in beverages, yogurt, cheese, and process cheese products. Industrially, MCC is manufactured by microfiltration (MF) of skim milk and is commercially available as a liquid, concentrated, or dried containing ≥9, ≥22, and ≥80% total protein, respectively. As an ingredient, MCC not only imparts a bland flavor but also offers unique functionalities such as foaming, emulsifying, wetting, dispersibility, heat stability, and water-binding ability. The high protein content of MCC represents a valuable source of fortification in a number of food formulations. For the last 20 years, MCC is utilized in many applications due to the unique physiochemical and functional characteristics. It also has promising applications to eliminate the cost of drying by producing concentrated MCC. This work aims at providing a succinct overview of the historical progress of the MCC, a review on the manufacturing methods, a discussion of MCC properties, varieties, and applications.

Microfiltration and Ultrafiltration Process to Produce Micellar Casein and Milk Protein Concentrates with 80% Crude Protein Content: Partitioning of Various Protein Fractions and Constituents

The objective of the study reported in this research paper was to produce micellar casein concentrate (MCC) and milk protein concentrate (MPC) with 80% crude protein relative to total solids (TS) using MF and UF processes respectively. Additionally, capillary gel electrophoresis (CGE) was used to study the protein fractions in retentate and permeate. For MCC production, 227 L of pasteurized SM was subjected to MF using 0.5-micron spiral wound polyvinylidene fluoride membrane. During the process, diafiltration (DF) water was added at six intervals, totaling 100% of the feed volume. For MPC production, 227 L of pasteurized SM from the same lot was subjected to UF using 10 kDa Polyethersulfone membranes. During the process, DF water was added at four different intervals, with a final total addition of 40% of the feed volume. Both processes used a volume reduction of five. There were significant (p < 0.05) differences in all of the compositional parameters, except fat and casein for the MF retentate (MFR) and UF retentate (UFR). UFR had a higher crude protein (CP), TS, lactose, ash and calcium content as compared to MFR and this affected the CP/TS ratio found in both the retentates. The differences in membrane pore sizes, operating pressures and level of DF used all contributed to the differences in final CP/TS ratio obtained. The CGE analysis of individual protein fractions present in the UFR and MFR showed that UFR has a β-lactaglobulin to α-lactalbumin (α-LA) ratio similar to SM, whereas the MFR has a higher ratio, indicating preferential transmission for α-LA by the MF membrane. The results from this study show that MF and UF processes could be used for production of MCC and MPC with similar CP/TS ratio with careful selection of operating parameters, and that CGE can be used for detailed analysis of various protein fractions.

Efficiency of removal of whey protein from sweet whey using polymeric microfiltration membranes

Our objective was to measure whey protein removal percentage from separated sweet whey using spiral-wound (SW) polymeric microfiltration (MF) membranes using a 3-stage, 3× process at 50°C and to compare the performance of polymeric membranes with ceramic membranes. Pasteurized, separated Cheddar cheese whey (1,080 kg) was microfiltered using a polymeric 0.3-μm polyvinylidene (PVDF) fluoride SW membrane and a 3×, 3-stage MF process. Cheese making and whey processing were replicated 3 times. There was no detectable level of lactoferrin and no intact α- or β-casein detected in the MF permeate from the 0.3-μm SW PVDF membranes used in this study. We found BSA and IgG in both the retentate and permeate. The β-lactoglobulin (β-LG) and α-lactalbumin (α-LA) partitioned between retentate and permeate, but β-LG passage through the membrane was retarded more than α-LA because the ratio of β-LG to α-LA was higher in the MF retentate than either in the sweet whey feed or the MF permeate. About 69% of the crude protein present in the pasteurized separated sweet whey was removed using a 3×, 3-stage, 0.3-μm SW PVDF MF process at 50°C compared with 0.1-μm ceramic graded permeability MF that removed about 85% of crude protein from sweet whey. The polymeric SW membranes used in this study achieve approximately 20% lower yield of whey protein isolate (WPI) and a 50% higher yield of whey protein phospholipid concentrate (WPPC) under the same MF processing conditions as ceramic MF membranes used in the comparison study. Total gross revenue from the sale of WPI plus WPPC produced with polymeric versus ceramic membranes is influenced by both the absolute market price for each product and the ratio of market price of these 2 products. The combination of the market price of WPPC versus WPI and the influence of difference in yield of WPPC and WPI produced with polymeric versus ceramic membranes yielded a price ratio of WPPC versus WPI of 0.556 as the cross over point that determined which membrane type achieves higher total gross revenue return from production of these 2 products from separated sweet whey. A complete economic engineering study comparison of the WPI and WPPC manufacturing costs for polymeric versus ceramic MF membranes is needed to determine the effect of membrane material selection on long-term processing costs, which will affect net revenue and profit when the same quantity of sweet whey is processed under various market price conditions.

Transmission of Major and Minor Serum Proteins during Microfiltration of Skim Milk: Effects of Pore Diameters, Concentration Factors and Processing Stages

Effects of pore diameters (100, 50, and 20 nm), concentration factors (1-8) and processing stages (1-5) on the transmission of major serum proteins (β-lactoglobulin and α-lactalbumin) and minor serum proteins (immunoglobulin (Ig) G, IgA, IgM, lactoferrin (LF), lactoperoxidase (LPO), xanthine oxidase (XO)) during ceramic microfiltration (MF) of skim milk were studied. Holstein skim milk was microfiltered at a temperature of 50 °C, a transmembrane pressure of 110 kPa and a crossflow velocity of 6.7 m/s, using a tubular single stainless steel module that consisted of three ceramic tubes, each with 19 channels (3.5 mm inner diameter) and a length of 0.5 m. For MF with 100 nm and 50 nm pore diameters, the recovery yield of major serum proteins in permeate was 44.3% and 44.1%, while the recovery yield of minor serum proteins was slightly less by 0%-8% than 50 nm MF. MF with 20 nm pore diameters showed a markedly lower (by 12%-45%) recovery yield for both major and minor serum proteins, corresponding with its lower membrane flux. Flux sharply decreased with an increasing concentration factor (CF) up to four, and thereafter remained almost unchanged. Compared to the decrease (88%) of flux, the transmission of major and minor serum proteins was decreased by 4%-15% from CF = one to CF = eight. With increasing processing stages, the flux gradually increased, and the recovery yield of both major and minor proteins in the permeate gradually decreased and reached a considerably low value at stage five. After four stages of MF with 100 nm pore diameter and a CF of four for each stage, the cumulative recovery yield of major serum proteins, IgG, IgA, IgM, LF, LPO, and XO reached 95.7%, 90.8%, 68.5%, 34.1%, 15.3%, 39.1% and 81.2% respectively.

Determination of the efficiency of removal of whey protein from sweet whey with ceramic microfiltration membranes

Our research objective was to measure percent removal of whey protein from separated sweet whey using 0.1-µm uniform transmembrane pressure ceramic microfiltration (MF) membranes in a sequential batch 3-stage, 3× process at 50°C. Cheddar cheese whey was centrifugally separated to remove fat at 72°C and pasteurized (72°C for 15 s), cooled to 4°C, and held overnight. Separated whey (375 kg) was heated to 50°C with a plate heat exchanger and microfiltered using a pilot-scale ceramic 0.1-µm uniform transmembrane pressure MF system in bleed-and-feed mode at 50°C in a sequential batch 3-stage (2 diafiltration stages) process to produce a 3× MF retentate and MF permeate. Feed, retentate, and permeate samples were analyzed for total nitrogen, noncasein nitrogen, and nonprotein nitrogen using the Kjeldahl method. Sodium dodecyl sulfate-PAGE analysis was also performed on the whey feeds, retentates, and permeates from each stage. A flux of 54 kg/m² per hour was achieved with 0.1-µm ceramic uniform transmembrane pressure microfiltration membranes at 50°C. About 85% of the total nitrogen in the whey feed passed though the membrane into the permeate. No passage of lactoferrin from the sweet whey feed of the MF into the MF permeate was detected. There was some passage of IgG, bovine serum albumen, glycomacropeptide, and casein proteolysis products into the permeate. β-Lactoglobulin was in higher concentration in the retentate than the permeate, indicating that it was partially blocked from passage through the ceramic MF membrane.

Manufacture and characterization of acid-coagulated fresh cheese made from casein concentrates obtained by acid diafiltration

This study aimed to investigate the production of acid-coagulated fresh cheese by using slightly acid diafiltered (DF) microfiltered (MF) casein concentrates (8% protein). Three different acidifying agents were tested during DF: carbon dioxide, lactic acid, and citric acid. Fresh cheese was manufactured using acid-DF casein concentrates, or casein concentrates DF with just water, and compared with cheese manufactured using MF casein concentrates without DF. The fresh cheeses were characterized for composition, rheological, and sensorial properties. Acid-DF casein concentrates improved acidification kinetics during cheesemaking and reduced casein leakage to cheese whey, compared with cheese from regular MF casein concentrate. Among the rheological properties investigated in this study, the storage modulus of the fresh cheese was higher when DF of the casein concentrate was performed with nonacidified DF water or when DF water was acidified with citric acid. However, fresh cheese made from casein concentrate diafiltered with DF water acidified by citric acid was most liked in a sensory ranking test.

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.

Transmembrane Pressure and Recovery of Serum Proteins During Microfiltration of Skimmed Milk Subjected to Different Storage and Treatment Conditions

Milk pre-processing steps-storage at 4 °C (with durations of 48, 72 or 96 h) and methods for microbiological stabilization of milk (1.4 μm microfiltration, thermization, thermization + bactofugation, pasteurization) are performed industrially before 0.1 µm-microfiltration (MF) of skimmed milk to ensure the microbiological quality of final fractions. The objective of this study was to better understand the influence of these pre-processing steps and their cumulative effects on MF performances (i.e., transmembrane pressure, and transmission and recovery of serum proteins (SP) in the permeate). Results showed that heat treatment of skimmed milk decreased ceramic MF performances, especially after a long 4 °C storage duration (96 h) of raw milk: when milk was heat treated by pasteurization after 96 h of storage at 4 °C, the transmembrane pressure increased by 25% over a MF run of 330 min with a permeation flux of 75 L.h^-1.m^-2 and a volume reduction ratio of 3.0. After 48 h of storage at 4 °C, all other operating conditions being similar, the transmembrane pressure increased by only 6%. When milk was 1.4 µm microfiltered, the transmembrane pressure also increased by only 6%, regardless of the duration of 4 °C storage. The choice of microbiological stabilization method also influenced SP transmission and recovery: the higher the initial heat treatment of milk, the lower the transmission of SP and the lower their recovery in permeate. Moreover, the decline of SP transmission was all the higher that 4 °C storage of raw milk was long. These results were explained by MF membrane fouling, which depends on the load of microorganisms in the skimmed milks to be microfiltered as well as the rate of SP denaturation and/or aggregation resulting from pre-processing steps.

Effects of depleting ionic strength on 31P nuclear magnetic resonance spectra of micellar casein during membrane separation and diafiltration of skim milk

Membrane separation processes used in the concentration and isolation of micellar casein-based milk proteins from skim milk rely on extensive permeation of its soluble serum constituents, especially lactose and minerals. Whereas extensive literature exists on how these processes influence the gross composition of milk proteins, we have little understanding of the effects of such ionic depletion on the core structural unit of micellar casein [i.e., the casein phosphate nanocluster (CPN)]. The ³¹P nuclear magnetic resonance (NMR) is an analytical technique that is capable of identifying soluble and organic forms of phosphate in milk. Thus, our objective was to investigate changes to the ³¹P NMR spectra of skim milk during microfiltration (MF) and diafiltration (DF) by tracking movements in different species of phosphate. In particular, we examined the peak at 1.11 ppm corresponding to inorganic phosphate in the serum, as well as the low-intensity broad signal between 1.5 and 3.0 ppm attributed to casein-associated phosphate in the retentate. The MF concentration and DF using water caused a shift in the relevant ³¹P NMR peak that could be minimized if orthophosphate was added to the DF water. However, this did not resolve the simultaneous change in retentate pH and increased solubilization of micellar casein protein. The addition of calcium in combination with orthophosphate prevented micellar casein solubilization and simultaneously contributed to preservation of the CPN structure, except for overcorrection of retentate pH in the acidic direction. A more complex DF solution, involving a combination of phosphate, calcium, and citrate, succeeded in both CPN and micellar casein structure preservation while maintaining retentate pH in the region of the original milk pH. The combination of ³¹P NMR as an analytical technique and experimental probe during MF/DF processes provided useful insights into changes occurring to CPN while retaining the micellar state of casein.

Effect of ceramic membrane channel diameter on limiting retentate protein concentration during skim milk microfiltration

Our objective was to determine the effect of retentate flow channel diameter (4 or 6mm) of nongraded permeability 100-nm pore size ceramic membranes operated in nonuniform transmembrane pressure mode on the limiting retentate protein concentration (LRPC) while microfiltering (MF) skim milk at a temperature of 50°C, a flux of 55 kg · m(-2) · h(-1), and an average cross-flow velocity of 7 m · s(-1). At the above conditions, the retentate true protein concentration was incrementally increased from 7 to 11.5%. When temperature, flux, and average cross-flow velocity were controlled, ceramic membrane retentate flow channel diameter did not affect the LRPC. This indicates that LRPC is not a function of the Reynolds number. Computational fluid dynamics data, which indicated that both membranes had similar radial velocity profiles within their retentate flow channels, supported this finding. Membranes with 6-mm flow channels can be operated at a lower pressure decrease from membrane inlet to membrane outlet (ΔP) or at a higher cross-flow velocity, depending on which is controlled, than membranes with 4-mm flow channels. This implies that 6-mm membranes could achieve a higher LRPC than 4-mm membranes at the same ΔP due to an increase in cross-flow velocity. In theory, the higher LRPC of the 6-mm membranes could facilitate 95% serum protein removal in 2 MF stages with diafiltration between stages if no serum protein were rejected by the membrane. At the same flux, retentate protein concentration, and average cross-flow velocity, 4-mm membranes require 21% more energy to remove a given amount of permeate than 6-mm membranes, despite the lower surface area of the 6-mm membranes. Equations to predict skim milk MF retentate viscosity as a function of protein concentration and temperature are provided. Retentate viscosity, retentate recirculation pump frequency required to maintain a given cross-flow velocity at a given retentate viscosity, and retentate protein determination by mid-infrared spectrophotometry were all useful tools for monitoring the retentate protein concentration to ensure a sustainable MF process. Using 6-mm membranes instead of 4-mm membranes would be advantageous for processors who wish to reduce energy costs or maximize the protein concentration of a MF retentate.

Influence of casein on flux and passage of serum proteins during microfiltration using polymeric spiral-wound membranes at 50°C

Raw milk (approximately 1,800 kg) was separated at 4°C, pasteurized (at 72°C for 16s), and split into 2 batches. One batch (620 kg) was microfiltered (MF) using pilot-scale ceramic uniform transmembrane pressure Membralox membranes (model EP1940GL0.1 μA, 0.1-μm alumina; Pall Corp., East Hills, NY) to produce retentate and permeate. The permeate from the MF uniform transmembrane pressure was casein-free skim milk (CFSM). The CFSM was MF using polymeric spiral-wound (SW) membranes (model FG7838-OS0x-S, 0.3 μm; Parker-Hannifin Corp., Process Advanced Filtration Division, Tell City, IN) at a concentration factor of 3× and temperature of 50°C. Following the processing of CFSM, the second batch of skim milk (1,105 kg) was processed using the same polymeric membranes to determine how casein content in the feed material for MF with polymeric membranes affects the performance of the system. There was little resistance to passage of milk serum proteins (SP) through a 0.3-μm polyvinylidene fluoride (PVDF) SW membrane at 50°C and no detectable increase in hydraulic resistance of the membrane when processing CFSM. Therefore, milk SP contributed little, if any, to fouling of the PVDF membrane. In contrast, when processing skim milk containing a normal concentration of casein, the flux was much lower than when processing CFSM (17.2 vs. 80.2 kg/m(2) per hour, respectively) and the removal of SP from skim milk with a single-pass 3× bleed-and-feed MF system was also much lower than from CFSM (35.2 vs. 59.5% removal, respectively). Thus, when processing skim milk with a PVDF SW membrane, casein was the major protein foulant that increased hydraulic resistance and reduced passage of SP through the membrane.