Lactose-Free Dairy Process Using Enzyme Recycling
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Solution Overview
Problem
Existing methods for producing lactose-free dairy products are inefficient due to long processing times and the presence of residual enzymes in the final products, which affects profitability and product quality.
Innovation Solution
A process involving ultrafiltration, enzymatic degradation of lactose in a reactor, followed by nanofiltration, and recycling of unreacted lactose and enzyme, ensuring complete lactose removal and enzyme inactivation, allowing for continuous operation and significantly reduced processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional enzymatic degradation methods are used to break down lactose, then lactose is hydrolyzed into glucose and galactose, but the process requires long standing times and leaves residual enzymes in the product
Solution Approach 1:
The patent extracts and removes residual enzymes from the reaction mixture using filtration or centrifugation steps after enzymatic hydrolysis. This separation step eliminates the harmful residual enzymes while preserving the hydrolyzed sugars, resolving the contradiction between complete lactose removal and short processing time by adding a targeted removal step rather than extending the hydrolysis time
Solution Approach 2:
The patent introduces an intermediary separation step (filtration/centrifugation) between the enzymatic reaction and the final product. This intermediary process removes the enzyme catalyst from the mixture, allowing the reaction to be completed quickly without the time-consuming extended standing period, thus resolving the time-quality contradiction
2Manufacturing precision
If conventional enzymatic degradation methods are used, then lactose is broken down, but enzymes remain in the final product affecting quality and profitability
Solution Approach 1:
The patent applies extraction by removing residual enzymes through filtration or centrifugation after the enzymatic reaction. This targeted removal ensures high product quality (lactose-free with no residual enzymes) while maintaining relatively simple processing by using standard separation techniques rather than complex purification systems
Solution Approach 2:
The patent employs self-service by using the enzyme's own catalytic action to complete the lactose breakdown, then allowing simple physical separation methods to remove the enzyme. The system uses natural enzymatic activity followed by passive separation, avoiding the need for complex additional processing steps to achieve high-quality results
3Manufacturing precision
If lactase is added in sufficient amounts for complete lactose degradation, then lactose is fully broken down, but enzyme usage costs increase
Solution Approach 1:
The patent implements continuous enzymatic reaction with controlled addition of lactase, maintaining optimal enzyme concentration throughout the process rather than adding large excess amounts. The reaction proceeds continuously with sufficient but not excessive enzyme, completing lactose hydrolysis efficiently while minimizing enzyme consumption and cost
Solution Approach 2:
The patent optimizes reaction parameters (temperature, pH, residence time) to maximize enzyme efficiency. By controlling these parameters, the process achieves complete lactose hydrolysis with minimal enzyme dosage, reducing enzyme consumption costs while maintaining high manufacturing precision
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
This process results in lactose-free products with less than 0.1% lactose content and no residual enzymes, enhancing throughput and profitability by minimizing enzyme usage and enabling both continuous and discontinuous operation.
Implementation Method 1
the permeate P1 is fed to the enzymatic degradation of the lactose contained therein adding a sufficient amount of lactase
Implementation Method 2
skimmed milk is subjected to ultrafiltration or a combination of dia- and ultrafiltration
Implementation Method 3
subjecting the resulting reaction mixture to nanofiltration
Data Source
Figure 1
AI summary
A process for the production of lactose-free dairy products is proposed, in which (a) skimmed milk is subjected to ultrafiltration or a combination of diafiltration and ultrafiltration, (b) the lactose-free retentate R1 is directed into a storage container and the lactose-containing permeate P1 into an enzyme reactor, (c) a sufficient amount of lactase for the enzymatic degradation of the lactose contained therein is added to the permeate P1, (d) the reaction mixture thus obtained is subjected to nanofiltration, (e) the lactose-free permeate P2 is conveyed into the storage container and mixed with the lactose-free retentate R2, and (f) the retentate R2, which contains unreacted lactose and enzyme, is returned to the enzyme reactor.