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  • GEA Niro - Ebook - Milk Powder Technology UKpdf

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    Neda Aarabi
    270 views301 pages
    GEA, MILK POWDER eBOOK

    Original Title

    GEA Niro - eBook - Milk Powder Technology UKpdf

    Copyright

    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    GEA, MILK POWDER eBOOK

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    270 views301 pages

    GEA Niro - Ebook - Milk Powder Technology UKpdf

    Uploaded by

    Neda Aarabi
    GEA, MILK POWDER eBOOK

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 301

    

    
    
    

    
    
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    NIRO A/S

    Contents

    Introduction............................................................................................13

    Evaporation ............................................................................................15

    Falling Film Evaporators ................................................................................17


    Vapour Recompression TVR ................................................................................. 23
    Mechanical Vapour Recompression MVR............................................................. 29
    Comparison of Energy Consumption in Different Evaporators.............................. 33
    Design of Industrial Evaporators ........................................................................... 35

    Auxiliary Equipment for the Evaporator.........................................................37


    Separators .............................................................................................................. 39
    • Separators with Tangential Vapour Inlet............................................................... 39
    • Wrap-Around Separator ........................................................................................ 39
    Product Distribution System .................................................................................. 39
    • Dynamic Distribution System ............................................................................... 39
    • Static Distribution System..................................................................................... 41
    Preheaters .............................................................................................................. 41
    • Spiral-Tube Preheaters .......................................................................................... 41
    • Straight-Tube Preheaters ....................................................................................... 43
    Pasteurization/Holding Equipment ........................................................................ 43
    • Bacteriological Requirements ............................................................................... 43
    • Heat Classified Skim Milk Powder ....................................................................... 45
    • Keeping Quality of Whole Milk............................................................................ 45
    • High-Heat Heat-Stable Milk Powder..................................................................... 45
    • Instant Whole Milk Powder .................................................................................. 45
    Preheating Equipment to prevent Thermophile Bacteria Growth........................... 49
    • Mid-run cleaning................................................................................................... 51
    • UHT treatment ...................................................................................................... 51
    • Duplex preheating system ..................................................................................... 51
    • Contact preheating by direct steam injection ........................................................ 51
    • Direct contact regenerative preheating.................................................................. 53
    Condensation Equipment ....................................................................................... 53
    • Mixing Condenser ................................................................................................. 55
    • Surface Condenser ................................................................................................ 55
    Vacuum Equipment ............................................................................................... 55
    • Vacuum Pump ....................................................................................................... 57
    • Steam Jet Vacuum Unit......................................................................................... 57
    Cooling Towers ..................................................................................................... 57
    High-Concentrators................................................................................................ 57
    Flash Coolers ......................................................................................................... 59
    Sealing Water Equipment ...................................................................................... 59
    Instrumentation and Automation............................................................................ 59
    • Feed Flow.............................................................................................................. 61

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    The factor deciding if there will be any wetting at all is the interfacial tension between
    the particle surface and the water. Skim milk powder particles will usually be wetted
    easily (provided there is less than 0.03% fat on the surface), as the powder material is
    mainly lactose being in an amorphous phase and protein, both absorbing water readily.
    However, whole milk powder particles are always covered by a layer of fat, making
    them water repellent. The amount of this surface free fat varies between 0.5 and 3% of
    the powder.

    This water repellence of the particles caused by their fat coating may be overcome,
    and an interfacial tension facilitating the wetting may be achieved by adding a surface
    active agent to the surface free fat. It has been known for years that phospholipids
    such as lecithin are well suited for this purpose. Lecithin has the advantage of being a
    natural product and even a natural component of milk, and being both lipophilic and
    hydrophilic it is able to absorb water. See page 249.

    When the particles have been wetted, the individual components of the milk powder
    start dissolving and dispersing, thus forming a concentrated solution of milk around
    the particles. At the same time the particles start sinking to the bottom, but it should
    be mentioned that, in order to make the particles sink, the density of the particles has
    to be greater than that of the water.

    The density of a particle depends on its composition and amount of occluded air. Dur-
    ing the first stages of reconstitution the density of the particles decreases, mainly be-
    cause the lactose and the minerals, which are the heaviest milk components, start dis-
    solving faster than the other components. At the same time, the density of the solution
    being formed is increased because of the dissolving lactose, so that the difference be-
    tween the densities of the particles and of the surrounding liquid is reduced. The par-
    ticle density may even become the same or lower than that of the liquid, so that, after
    the initial sinking, the particles start to rise again. Thus to prevent this, the particle
    density should be high, i.e. the content of occluded air should be low. See page 211.

    The reconstitution of a mass of powder is more complicated. As already mentioned,


    powder is a composite surface with a greatly ramified system of capillaries of various
    dimensions and a complicated geometrical pattern thus having different capillary at-
    traction effects.

    Under these conditions there will be wetting not only on the surface of the water, but
    also of particles lying above the surface, as the water is drawn toward them by capil-
    lary attraction. This replacement of interstitial air by water through capillary penetra-
    tion is very often incomplete, as the amount of penetrating water is insufficient, thus
    leaving air bubbles between the wetted particles. In this way we have all three phases
    going on simultaneously, resulting in the coexistence of their products of varying con-
    centrations. This coexistence is very dangerous, because after a short time the space
    between the particles will be filled with milk of different, including high, concentra-
    tions. This results in a sticky jelly with islands of unwetted powder and residual air.
    Furthermore, lumps, that are wet and swollen outside and dry inside, are created. As

    - 211 -
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    CRYSTALLIZED LACTOSE
    o
    25 C. SEEDED WITH 2 /oo LACTOSE

    40 C. SEEDED WITH 1 o /oo LACTOSE

    HOURS

    Fig. 132 Lactose crystallization as a function of time

    Fig. 133 Evaporator, two flash coolers with crystallization tanks, and a
    compact dryer for continuous production of semi-crystallized
    whey powder

    - 256 -
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    ƒ Crystallization
    • Drying at a temperature of 150°C
    • Moisture content ex chamber 12-15%

    In order to avoid condensation in the cyclones, due to a low outlet temperature (ap-
    prox. 55°C), hot air may be introduced into the cyclones thus reducing the relative
    humidity.

    Bag filters - standard or CIP-able - are not recommended due to the high mois-
    ture/relative humidity in the exhaust air. Wet scrubbers are therefore recommended.

    The high moisture content in the powder means that the crystallization will continue
    in the powder to an even greater extent than in the process featuring fluid beds only,
    as discussed on page 261. This crystallization is improved, if the wet powder is kept
    at the high moisture content for 5-10 min. This is done on a belt conveyor or a rotat-
    ing disc between the chamber outlet and the Vibro-Fluidizer, where the final drying
    takes place, see Fig. 136. The powder will consist of big agglomerates which will
    have a low bulk density and extremely good instant and non-caking properties. The
    bulk density may be increased by a hammer mill treatment.

    Spray Drying of High Concentrated Whey Concentrate


    In an attempt to improve drying economy, the solids content in the concentrate has
    been experimentally increased up to 70-75% TS. To avoid crystallization in the last
    effect, as the lactose becomes supersaturated, the evaporator is equipped with a spe-
    cially designed high concentrator operating with recycling and at a higher boiling
    temperature. Further, the higher temperature is necessary to lower the viscosity of the
    concentrate to avoid blocked tubes.

    When the concentrate has reached its final solids content, it is flash cooled, and the
    crystallization takes place instantaneously. Normal crystallization tanks are not neces-
    sary, only an intermediate tank with agitation. However, the high temperature during
    the long recycling time in the evaporator has its price. The whey proteins are dena-
    tured, and valuable nutritional values are lost. Further, the Maillard reaction will start
    resulting in a pronounced discolouring and bad flavour in the final powder. Therefore,
    even though the economy is attractive the end result - the final powder - does not meet
    international standards.

    Production of Acid Whey Powder

    Not all whey originates from traditional cheese production giving sweet whey with a
    pH of min. 6.3. Cottage cheese, quark, Fromage Frais, Queso Fresco, Mozzarella, or
    similar products give whey with a pH of 4.6 due to the precipitation of the milk.

    - 263 -
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    Commercially, whey proteins are available with three different protein contents: 35%
    WPC, 60% WPC, and 80% WPC.

    If 100 kg of normal sweet whey with 6% solids is used, then approx. 20 kg of 35%
    WPC is discharged from the ultrafiltration module with a solids content of about 10%,
    which is increased by evaporation to 45% before the spray drying. Approx. 8 kg of
    60% WPC is discharged with a solids content of about 15%, evaporated to 42% be-
    fore the spray drying. High protein concentration results in high viscosity, and it is
    necessary to add water (diafiltration) during the final filtration, if 80% WPC is pro-
    duced. 3 kg of 80% WPC is discharged with a solids content of about 28-30%. Due to
    the high protein content it is dried directly.

    Whey protein concentrates can be used direct, together with ordinary milk concen-
    trates, in formulas for baby food thus obtaining a product with a composition similar
    to mother’s milk.

    The whey protein concentrates can also be used in the production of cream cheese or
    other soft type cheeses or as filler (water binder) in sausages replacing the meat.

    The drying of whey protein concentrates is easy, but to maintain a good solubility of
    the product, it is essential to use low outlet air temperatures to avoid denaturation, see
    Fig. 139. Two-stage drying is therefore recommended.

    As the solids content of the concentrate is low due to the high protein content, the
    spray drying plants are always equipped with bag filters after the cyclones. However,
    as the filter fraction may not always have the same quality as the main product, the
    Tall-Form Dryer is often selected, as the special air outlet minimizes the cyclone frac-
    tion and consequently also the filter fraction. See page 75 and Fig. 140.

    The tendency today is to produce agglomerated instant whey proteins. Due to the lack
    of lactose as binder, especially in 80% WPC, the agglomeration is difficult. However,
    by selecting the Multi-Stage Dryer, see page 203, Fig. 85, it is possible to obtain a suf-
    ficient agglomeration. As the proteins are very hydrophilic, they will absorb water in-
    stantaneously at their first contact with water, which makes the dispersion difficult.
    By agglomeration and lecithination the water absorption is delayed just sufficiently to
    allow the powder to be dispersed in the water before the final dissolution.

    The powder has the same applications as the concentrates, but does have the supreme
    advantage of an almost infinite keeping quality.

    Permeate

    The other product from the ultrafiltration is the permeate, usually containing about
    4.5% lactose. The permeate can be used for fermenting, production of glucose-
    galactose or lactylurea, or concentrated, crystallized and then dried.

    - 271 -
    
    

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    NIRO A/S

    As a certain amount of aroma is lost during the drying it is recommended to use aged
    cheese. In order to avoid problems with the odour form the exhaust air this may be fil-
    tered through activated carbon filters.

    Cocoa-Milk-Sugar Mixtures

    This type of powder is used extensively in vending machines for preparation of hot
    chocolate drinks, but the powder is also sold in ordinary retail packages and used in
    households.

    The powder will usually have the following composition:

    Cocoa: 15-35%
    Skim milk solids: 40-60%
    Sugar: 20-40%

    If the amount of cocoa and sugar is not higher than 15% and 20%, respectively, the
    single components may be spray dried as a mixture (which is homogenized) from a
    feed with 45% solids and a drying temperature of 170-180°C. In order to obtain a
    free-flowing powder suitable for vending machines the cyclone fraction is recycled to
    the atomizing device for agglomeration. The powder is after-dried and cooled in a Vi-
    bro-Fluidizer similar to the spray drying agglomeration process, as described in page
    153.

    If the amount of cocoa and sugar is higher, it is recommended to add the exceeding
    amount in dry form. This is done via the fines return system by means of an additional
    blow-through valve and a powder dosing equipment for the pre-mixed cocoa and
    sugar which is stored in a silo. It should be observed that the sugar should be fine
    ground to obtain an optimum agglomeration.

    Coffee-Whitener

    Coffee-whitener - artificial cream with vegetable oil - is another big group of recom-
    bined products that are spray dried.

    The typical composition of a coffee-whitener is as follows:

    Glucose syrup or maltodextrine with a DE of 25-30: 60-65%


    Hydrogenated vegetable fat with melting point 35-40°C: 30-32%
    Na-caseinate: 3-5%
    Artificial cream flavour, colour and emulsifiers: 1-3%
    Phosphates: 1-3%

    - 321 -
    NIRO A/S

    The above ingredients are recombined at 60-70°C in large tanks to solids contents at
    65-70%. The mixture is homogenized in two stages and then spray dried.

    Both rotary and nozzle atomizers can be used, however nozzles are usually preferred,
    as they give a more free-flowing powder. The powder must be instantly soluble in hot
    beverages such as coffee or tea, and an agglomerated powder is therefore necessary.

    In conventional dryers equipped with Vibro-Fluidizers and fines return system a dry-
    ing temperature of 165-170°C is used. The powder is discharged from the drying
    chamber at max. 3.5% moisture to avoid powder deposits due to the high content of
    glucose syrup being thermoplastic and tending to adhere to the drying chamber, if the
    powder is too moist.

    The final drying and cooling is done in a Vibro-Fluidizer. If a Multi-Stage Dryer is


    used, it is possible to use higher drying temperatures (180-200°C) without getting
    problems with powder deposits.

    Cappuccino Powder

    In principle Cappuccino powder is used like coffee-whitener to "whiten" coffee, how-


    ever, with the main purpose of getting a thick stable foam layer on the surface of the
    coffee after reconstitution. A lot of Cappuccino powder is sold already mixed with in-
    stant soluble coffee and sugar - ready to use.

    The foaming ability is achieved when the powder releases the gasses entrained in the
    powder

    • Occluded gas in form of air and CO2; the latter has by purpose been injected into
    the concentrate prior to drying

    • Interstitial air, due to the agglomeration of the product.

    The composition of the concentrate is slightly different from that of coffee-whitener to


    enhance the ability to form a thick layer of stable foam. The typical composition is as
    follows:

    Glucose syrup or maltodextrine with a DE of 25-30: 40-45%


    Vegetable fat with melting point 35-40°C: 20-25%
    Low-Heat skim milk powder: 30-35%
    Artificial cream flavour, colour and emulsifier: 1-3%
    Phosphates: 1-3%

    - 323 -
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