PRODUCTION LINE FOR DEMINERALISED WHEY POWDER

PRODUCTION LINE FOR DEMINERALISED WHEY POWDER

The idea behind the project was to build a complete technological line for the management of whey from cheese and curd production.
The main idea was to develop a whey preparation technology based fully on membrane processes.

• MF ceramic microfiltration – with a capacity of 15,000 l/h whey. MF’s task is to clean whey of dust, mineral deposits, residual fat and bacteria.
  Function: preparation of the raw material for further membrane processes and microbiological protection.
• Nanofiltration NF – with a capacity of 15,000 l/h, concentration to a level of 26% DM, with partial demineralisation.
  Function: concentration of whey constituents with partial separation of minerals for improved ED process performance.
• RO-polisher – coupled to the NF plant. Reverse osmosis plant based on spiral membranes.
  Function: recovery of water from the NF permeate and its reuse in the plant for CIP cleaning processes. The process ensures 80% water recovery from the raw material.
• ED electrodialysis – with a capacity of 2000-4000 l/h of whey concentrate, relative to the desired degree of demineralisation in the finished product. The unit is adapted to achieve demineralisation of: D40, D50, D70 and D90.
• Nanofiltration NF-CIP – NF 2000 l/h plant – purification of chemical solutions from the central CIP station and evaporator.
  The use of nanofiltration technology in chemical purification has allowed the plant to significantly reduce costs associated with chemical purchases, plant energy expenditure and wastewater discharge. The cost of purchasing alkaline and acidic chemicals has fallen by more than 50%, and there has also been a significant reduction in emissions and wastewater neutralisation costs associated with replacing used detergents. The system is characterised by low energy consumption and water, which is only used for inter-operational rinsing and ejection. In addition to the financial benefits, there are other equally important aspects, an important example of which is the environmental impact through reduced energy consumption and reduced wastewater emissions.

The technical task involved the design and delivery of a complete demineralised whey concentrate preparation line for drying, with a processing capacity of 300,000 litres of whey per day.