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Membrane Filtration& Microparticulation

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Dedicated to the dairy industry

Reverse osmosis RO Ultrafltration UF (cont.)

Concentration o- Milk- Whey- UF permeate- Butter milk- White water (nal fush water)

Whey processing- WPC 35/60/80- WPI 90- MWPI 90 milk whey protein isolate

Concentration o butter milk

RO polisher RO-P Microfltration - MF

Polishing o:- RO permeate- NF permeate- Evaporator condensate

Bacteria and spore removal- Cheese milk- Market milk (ESL)- Powder milk- Cheese whey

Protein ractionation Pro-Frac- Cheese milk- Powder milk- Market milk

Deatting o whey- WPI 90

Cheese brine clarication

Nanofltration NF

Demineralisation and concentration o:- Milk- Whey- UF permeate

Ultrafltration UF Microparticulation - MP

Protein standardisation o:- Cheese milk- Market milk- Powder milk

Calcium enriched milk/protein boosted milk- Flavoured milk drinks

Milk protein concentrate- Yoghurt/milk desserts- MPC 50/60/70- MPC 80/85- MPI 90

UF cheese- Feta and Domiati type cheese- Queso Fresco/Burgos type- Fresh cultured cheese like:

Quarg

Skim sot cheese Petite Suisse Labneh Tvorog Mascarpone Cream cheese

The APV LeanCremeTM process- MP o WPC 60:

Low at dairy and ood products Cheese White line products lngredients

Membrane atermarket

Replacement membranes Membrane spares and components Mechanical service Process and application service Upgrading and redesign o used plants

Pilot plants

RO/NF, UF and MF pilot plants MP pilot plants

Product portolio and applications

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Advantages

Proven components and system designVery robust ceramic membranesLong lietime o the ceramic membranesNew generation GP membranesFuture option or SW polymer membranesVery high quality and reliably engineered systemPre-assembled in our workshopOperator- and maintenance-riendly

Specifcations

Field o application Skim milk, whey, cheese milk, cheese brine

Description Microltration is based on a membrane with a veryopen structure allowing most dissolved substancesto pass whereas non dissolved particles, bacteria,spores and at globules are rejected.Depending on the specic application, membranesand process parameters are chosen to secure

optimal perormance o the plantCapacity 5,000 l/h - 50,000 l/h (1,300 - 13,000 U.S. g/h)

Temperature 50C (122F) or ceramic and 10C (50F) or SW

Debacterisation, ractionation and clariication with ceramic and polymermembranes

Microfltration (MF) system

As a leading global provider o mem-

brane technology to the dairy industry,

APV oers a wide range o mem-

branes, membrane systems and dairy

membrane applications.

Proven membranes andsystemsMembranes are available in a number

o physical congurations, each o-

ering a range o advantages in terms

o technical perormance, price and

operating costs.

The most common membrane congu-

rations or dairy applications are:RO, RO Polisher and NF: spiral-

wound systems with organic

polymer membranes

UF: spiral-wound systems or

plate-and-rame systems with

organic polymer membranes

MF: tubular systems with ceramic

membranes as well as spiral-

wound systems with organic

polymer membranes

APV oers a wide range o system

solutions. These comprise stand alone

units, unitised and automated systems

delivering optimal control and perorm-

ance, and complete integrated in-line

systems eaturing pre- and post-

treatment or integration into new and

existing customer process lines.

APV membrane ltration technology isthe result o many years o experience

and close co-operation with world-

leading manuacturers o membranes

and cleaning agents. Our experience

and access to a wide selection o

technology options means that our

specialists can always oer the best

membranes or a particular applica-

tion as well as dedicated support and

service.

A dedicated team ospecialists

World-class innovation, engineerin

sales and service competences

3 decades o experience - more

than 1,100 reerences

Strong know-how platorm

Pioneers in innovative dairy applica

tions and engineering solutions

Innovation centre and pilot plantservice

Customer service on customer

terms

World-wide expertise and local

contacts

Membrane fltration technology

Proven systems and dedicated specialists

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AdvantagesOptimised removal o bacteria and sporesVarious operation concepts (see diagram)Proven process and system designNitrate-ree cheeseLong-lie ESL milkHigh-quality milk/whey powderHigh-quality cheese brineThe MF process can be implemented in various parts o the dairy industry

MF debacterisation

Specifcations

Field o application Debacterisation o cheese milk, ESL milk and milk/whey powder. Further clarication o cheese brineusing SW membranes

Description Microltration or debacterisation in the dairy indus-try is used or reduction o bacteria and spores.In cheese milk production, microltration replacesthe addition o nitrate. In market milk production,microltration is used to extend shel lie and pro-duce value added milk, and in powder milk produc-tion, it is used to reduce the content o spores andthermolic bacteria in the powder

Capacity 5,000 l/h - 50,000 l/h (1,300 - 13,000 U.S. g/h)

Temperature 50C (122F) or ceramic and 10C (50F) or SW(cheese brine)

MF ESL milk

Surplus creamWhole milk

Preheater

separator

Cream

sterilisation

MF Milk

Pasteuriser

Cream

Skimmilk

Retentate

Permeate

Retentate

1

1

2

3

2

3

Retentate

Eective removal o bacteria and spores

Advantages

Proven process and system based on ceramic membranesVery robust, long-lie ceramic membranesProven APV UTP system (uniorm trans-membrane pressure) - alternative: GPmembranes

Future options or polymer membranesCasein standardisation o cheese milkHigh casein milk powder and milk drinks

MF ractionation - Pro-Frac

Specifcations

Field o application Protein ractionation o skim milk or: Protein/caseinstandardisation o cheese milk, high-casein milkpowder and milk drinks

Description The MF process or ractionation has been devel-oped during recent years, concurrently with thedevelopment o new membranes with relevant poresizes. The dierent size o whey proteins and casein

makes it possible to use the membrane technologyor ractionation. The purpose o ractionation is tostandardise casein, e.g. in cheese making

Capacity 5,000 l/h - 50,000 l/h (1,300 - 13,000 U.S. g/h)

Temperature 50C (122F) or ceramic and 10C (50F) or SWpolymer

Market and fermented

milk products

Cheese:

Casein standardisation

Partial concentration

Full concentration

Casein micelle powder

Modified MPC powder

Cheese making powder

Pro-FracTM

SkimmilkDF water

Caseinrich milk

DF waterUF permeateUF with

diafiltration

Ideal whey

Lactose

MWPIretentate

Extracting more value rom milk

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Advantages

Proven components and system designProven membranes or any dairy application

High perormance and long membrane lietimeHigh-quality engineering, standardised systemSpeed controllers on all motorsOptimised utility consumptionPre-assembled in our workshopOperator- and maintenance-riendly

Ultrafltration (UF) SW and P & F systems

Specifcations

Field o application Protein standardisation, milkprotein concentration (MPC),UF cheese and whey protein

concentration (WPC)Description Ultraltration or concentration o

milk or whey is widely used in thdairy industry. UF concentrationis used as a concentration stepin the process o making dierenwhey or milk powder products.Also dierent resh culturedcheeses like cream cheese, Fetaand Queso Fresco can be pro-duced by UF concentration witha substantially higher yield

Capacity Flexible rom 1,000 l/h (250 U.S

g/h) to more than 100,000 l/h(25,000 U.S. g/h)

Temperature 50C (122F), more commonly10C (50F) or quality reasons

For milk and whey protein concentration

Advantages

Proven system and processDierent concepts and optimal integration

Cheese milk: constant protein - better control o processand constant/higher cheese quality - and less rennetProtein and calcium enriched milk drinks

UF protein standardisation and concentration

Specifcations

Field o application Cheese milk, protein milk drinks,milk powder, yoghurt and dairydesserts

Description By means o UF whole milk or skim milk is separated intoa protein rich raction and aprotein ree raction. By control-

ling the exact amount o proteinin a certain amount o milk, theprotein content can be increasedor decreased

Capacity Variable, but typically 5,000 l/hand 75,000 l/h (250 and 25,000U.S. g/h)

Temperature 50C (122F), more commonly10C (50F) or quality reasons

Improving product quality and proitability

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Advantages

Proven membranes or various milk applicationsHigh perormance and long membrane lietimeHigh quality engineering, standardised systemProven process/UF cheese technologyHigh yield and product qualityIncreased protabilityLarge number o reerencesComplete line with pre-treatment and post-treatment (e.g. MF debacterisation or Feta)

Specifcations

Field o application White cheese like Feta and Domiati, Queso Frescolike Burgos, Quesillo and Panella, resh cultured likeQuarg, cream cheese etc.

Description UF is a well-established and proven technology ora wide variety o resh cultured cheeses.The UF based cheese process is a continuous pro-cess with increased yield compared to traditionalcheese processing. The UF technology secures amore homogenous product with stabilising eectrom the whey proteins. Furthermore, the processgives the fexibility o producing dierent kinds ocheeses on the same equipment

Capacity Variable, but typically 3,000 l/h - 20,000 l/h (800 -5,000 U.S. g/h)

Temperature 50C (122F) and 45 - 5C (113 - 41F) or er-mented milk

High yield and quality cheeses

UF cheese systems

Advantages

Proven membranes or MPCHigh perormance and long membrane lietimeHigh quality engineering, standardised systemProven process technologyHigh degree o fexibilityComplete line with pre-treatment and post-treatment

Specifcations

Field o application Skim milk or: MPC 50, 60, 70, 80, 85 and MPI 90

Description Milk protein concentrate is produced by usingultraltration to concentrate skim milk. The result isa product with a high content o protein and a lowcontent o lactose and ashes. MPC and MPI aremade in various grades rom MPC 50 to MPI 90and are used in or instance processed cheeses

and a wide range o other ood applicationsCapacity Variable, but typically 10,000 l/h - 35,000 l/h

(2,500 - 10,000 U.S. g/h)

Temperature 50C (122F), more commonly 10C (50F) orquality reasons

Pasteurisation

MF(optional)

UF(diafiltration)

EvaporationSpray drying

Skimmilk

DF waterRO permeate

UF permeate

MPC

Tailored milk proteins or the ood industry

UF milk protein concentrate - MPC and MPI

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Advantages

Proven membranes or various whey types/qualities

High perormance and long membrane lietimeHigh-quality engineering, standardised systemProven process technologyOptimised fexibilityIn-line process: UF, NF/RO, RO polisherHigh solids WPCLarge number o reerences

Specifcations

Field o application Sweet and acid whey or various whey proteingrades rom WPC 35 to 85 and WPI 90

Description Membrane ltration is widely used when processing

value added whey protein concentrates (WPC andWPI). The conguration/design o the UF systemsgives the possibility o producing a wide range oWPC products on the same plant.By adding water (dialtration) into the UF systemit is possible to concentrate the whey to WPC 85,which means that 85% o the total solids is protein

Capacity Variable - typically rom 5,000 - 100,000 l/h(13,000 - 26,000 U.S. g/h)

Temperature 50C (122F) or more commonly 10C (50F) orquality reasons

Pretreatment: fines & fatremoval

pasteurisation

UF(diafiltration)

EvaporationSpray drying

Whey

DF waterRO permeate

UF permeate

WPC

Adding value to your whey

UF whey processing

Advantages

Proven components and system designProven membranes or NF dairy applicationsOptimised perormance and long membrane lietimeIn-line UF, NF, RO polisherHigh-quality engineering, standardised system

Optimised utility consumptionsPre-assembled in our workshopOperator- and maintenance-riendly

Specifcations

Field o application Whey, UF permeate and skim milk

Description Nanoltration is a RO process in which a moreopen membrane allows small monovalent ions suchas sodium and chloride to pass. This means thatNF combines concentration (like RO) and partialdemineralisation. The NF process can be used or awide range o applications in the dairy industry, e.g

demineralisation o whey, milk and permeate romUF o milk or whey.

Capacity Variable, but typically 5,000 l/h - 100,000 l/h(1,300 - 26,000 U.S. g/h)

Temperature 30C (86F) or more commonly 10 - 12C (50 -53,6F) or quality reasons

For concentration and partial demineralisation

Nanofltration system (NF)

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AdvantagesProven components and system designProven membranes or RO dairy applicationsHigh perormance and long membrane lietimeIn-line process: UF, RO, RO polisherHigh-quality engineering, standardised systemOptimised utility consumptionsPre-assembled in our workshopOperator- and maintenance-riendly

Specifcations

Field o application Whey, UF permeate, skim milk, whole milk andwhite water, sweet buttermilk

Description Reverse Osmosis ltration is based on a very dense

membrane that rejects virtually all substancesexcept water. This is possible due to a very highsystem pressure.RO is used or concentration o liquids to highersolids levels, depending on application.The purpose o RO can be to pre-concentrate priorto evaporation, to minimise transport costs or toincrease capacity in dierent dairy processes.

Capacity Variable, but typically 5,000 l/h - 100,000 l/h(1,300 - 26,000 U.S. g/h)

Temperature 30C, (86F) more commonly 10 - 12C (50 -50 - 57,2F) or quality reasons

For concentration

Reverse osmosis (RO)

AdvantagesProven components and system designProven 8 membranes or RO-P dairy applicationsOptimised perormance and long membrane lietimeIn-line process: UF, NF/RO, RO PolisherHigh-quality water - low COD levelHigh-quality engineering, standardised systemOptimised utility consumptionPre-assembled in our workshopOperator- and maintenance-riendly

Specifcations

Field o application NF or RO permeate and evaporator condensate toproduce process water and lower the COD level

Capacity Variable, but typically 5,000 l/h - 80,000 l/h(1,300 - 26,000 U.S. g/h)

Temperature 30C (86F), more commonly 10 - 14C (50 -57,2F) or quality reasons

A dairy-environmental process

RO polishing system (RO-P)

Cheesewhey

UF

NF/RO

RO-P

Water

WPC

Lactose

TS: 22%

Dimin. 35%

Minerals

TS: 1-4%

Process water

CIP water

LOW COD

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Membrane and ater market service

Specifcations

Field o application APVs established base o mem-brane plants

Description The membrane is the heart o thltration process and decisiveor the perormance and theprotability o the process. APVcan support you with membrane

replacement, membranes andon-site service

Capacity Spiral wound (SW) 8, spiralwound 6, spiral wound 4, hol-low bre (HF), plate and rame,ceramic tubular, tubular organic

Maximising uptime, minimising costs

Advantages

A unique new process ensuring optimal distribution o particle sizeEnsures superior taste in low-at products

Excellent unctional propertiesAbility to vary particle sizesFast pay-back, high ROIProven, high-quality system designEvaporation and spray-dry optionsIncreased yield

APV LeanCreme process

Specifcations

Field o application WPC 35, 60 and 80 rom sweetwhey, lactic acid and HCl caseinwhey

Description The APV LeanCreme proc-ess is a combined thermal andmechanical process using ashear agglemerator to produceLeanCreme (particulate). APVLeanCreme is based on a UFprocess or concentration owhey. The concentrated wheyis then microparticulated bythe shear agglomerator and aproduct with a unique particlesize distribution and excellentunctionality is ormed. The

LeanCreme is a natural ingredient which can be used in variousdairy and ood applications, es-pecially or low at products, withimproved quality and protabilityas a result

Capacity 500 - 3,000 l/h (130 - 800 U.S.g/h)

Microparticulation o whey

Advantages

Expert advice on choice o membrane typeFast delivery o replacement membranesRegular service visitsTroubleshootingCleaning procedures

Operator training, practical and theoretical Process optimisation

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For value-added products

Dairy segments

Applications

Market milk/resh products,drinks,yoghurt,

dessert

Cheese:Fresh, sot..to

hard

Ingredients:Milk/whey

Butter

MF debacterisation X X X -

UF protein standardisation X X X -

MF protein ractionation

Pro-FracTM(X) X X -

UF milk concentration Yoghurt, dessertFresh cheese, eta

etc.MPC 50/85 Butter milk

Microparticulation (MP)

APV LeanCreme processMP o WPC MP o WPC MP o WPC -

UF whey concentration - WPC 35/60WPC 35/60/80

WPI 90/95-

NF Concentration/De-mineralisation

(Demineralised milk) Whey/permeate Whey/permeate -

RO concentration (Milk transport) Whey/permeateWhey/permeate

Milk (transport)Butter milk

RO polishing (X) RO/NF permeateRO/NF permeate +

condensate-

RO white water X X X -

MF brine purication - X - -

Applications in typical dairy segments

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The APV Innovation Centre in

Silkeborg, Denmark, oers short-term

agreements to pilot your innovative

dairy process and products.

APVs process engineers are available

with expert advice under ull conden-

tiality during trials at our Innovation

Centre. Alternatively, we can provide

you with a pilot plant or testing at your

own production acility.

Our specialist team is also available to

work with you to nd costeective sol

tions to the everchanging challenges o

todays marketplace, thus assuring you

o the consistency and quality o your

end-product well beore it is launched

>

The APV Innovation Centre and Pilot Plant rental service

Research and development

APV LeanCreme Pilot Plant for microparticulation of whey

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