Alkali Treatment of Condensed Whey Permeate to Suppress Lactose Crystallization
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Solution Overview
Problem
Condensed whey permeate is difficult to store and handle due to lactose crystallization, which occurs when the temperature drops below a certain threshold, leading to storage and handling challenges and environmental hazards from disposal as waste.
Innovation Solution
Treating condensed whey permeate with an alkali to raise the pH and reduce crystallization, maintaining it within specific solids and water content ranges to prevent lactose crystallization, and using it in animal feed formulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If condensed whey permeate is stored at high temperature to prevent lactose crystallization, then crystallization is reduced, but storage and handling difficulty increases due to energy requirements and temperature maintenance
Solution Approach 1:
The patent changes the pH parameter of condensed whey permeate from acidic/neutral to alkaline conditions. This parameter change fundamentally alters the solubility characteristics of lactose, allowing it to remain in solution at lower temperatures without requiring continuous heating, thus resolving the contradiction between preventing crystallization and reducing energy consumption
Solution Approach 2:
The patent introduces an intermediary substance (alkali such as sodium hydroxide or potassium hydroxide) that mediates between the lactose and the storage conditions. This intermediary changes the chemical environment to prevent crystallization without requiring high temperature maintenance, thereby reducing energy requirements while preventing harmful crystallization
2Quantity of substance
If condensed whey permeate is concentrated to higher solids content to reduce volume for storage and transport, then storage efficiency improves, but lactose crystallization tendency increases
Solution Approach 1:
The patent changes the pH parameter to alkaline conditions, which fundamentally alters the solubility behavior of lactose. This allows the system to achieve higher solids concentration (improving storage efficiency) without the proportional increase in crystallization tendency that would normally occur, as the alkaline environment maintains lactose in solution at concentrations that would otherwise precipitate
Solution Approach 2:
The patent applies preliminary alkaline treatment to the condensed whey permeate before storage or transport. This preliminary action of adjusting pH to alkaline conditions pre-prevents crystallization issues that would arise from high concentration, allowing the material to be concentrated to desired levels without subsequent crystallization problems during storage
3Ease of operation
If condensed whey permeate is disposed of as waste to avoid storage and handling issues, then storage problems are eliminated, but environmental harm increases
Solution Approach 1:
The patent converts the harmful property of lactose (its tendency to crystallize and cause storage problems) into a beneficial outcome by applying alkaline treatment. This transformation allows the material to be stored and handled easily while maintaining lactose in solution, thereby eliminating the need for disposal and preventing environmental pollution while solving the original storage difficulties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The treatment improves storage and handling characteristics by reducing crystallization, allowing for cost-effective storage and utilization of condensed whey permeate, and enables its use in animal feed, reducing environmental impact by utilizing a previously discarded byproduct.
Implementation Method 1
treating the CWP with at least a sufficient proportion of alkali to raise the pH to at least 8
Implementation Method 2
lactose tends to crystallize out of solution from the condensed whey permeate
Data Source
AI summary
A method of improving the storage and handling characteristics of a condensed whey permeate (“CWP”) comprising the steps of: (a) obtaining a CWP that: (i) has a total solids content in the range of about 20% to about 75% by weight and has a water content in the range of about 80% to about 25% by weight; (ii) has a lactose concentration of at least 70% by weight of the total solids content; and (iii) is at a pH of less than 8; and (b) treating the CWP with at least a sufficient proportion of alkali to raise the pH to at least 8. Also, a method comprising the steps of: (a) obtaining a CWP that does not exhibit substantial crystallization; and (b) treating the CWP with at least a sufficient proportion of alkali to reduce the amount of crystallization obtained using a 30 mesh screen for a sample of the treated CWP relative to a sample of the untreated CWP when tested after storing for 7 days at a temperature range having an upper limit that is at least 28° C. (50° F.) below the sufficient temperature to dissolve at a pH of about 7 an equivalent concentration of lactose in water to the concentration of lactose to water that is in the untreated CWP.