High Protein Lactose Permeate Production via Casein Dust Integration
Solution Overview
Problem
Current methods for producing whey-derived products do not effectively utilize waste casein dust to create a high protein lactose permeate with enhanced nutritional value, limiting the application and efficiency of dairy by-products in animal feeds.
Innovation Solution
A method involving membrane nanofiltration, evaporator concentration, lactose crystallization, and drying, with the addition of liquid casein protein dust to standard lactose permeate concentrate before or after crystallization, to produce a high protein lactose permeate powder with specific composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If casein dust is separated from whey using centrifugation, then casein dust can be obtained for further processing, but the remaining whey loses valuable protein content and requires additional processing steps to recover proteins
Solution Approach 1:
The invention merges casein dust with lactose permeate concentrate to create a combined product. Instead of treating casein dust as a separate waste stream, it is integrated into the lactose permeate processing flow, allowing simultaneous recovery of both lactose and casein in a single final product that utilizes all valuable components from the original whey.
Solution Approach 2:
The invention recovers casein dust that would otherwise be discarded or used only for animal feed. By adding casein dust back to the lactose permeate concentrate and processing it together, the invention transforms a low-value by-product into a high-value protein-enriched ingredient suitable for human consumption and various industrial applications.
2Productivity
If standard lactose permeate is produced without casein addition, then the processing is simpler and faster, but the protein content remains low (0.3-0.6%) limiting nutritional value and application range
Solution Approach 1:
The invention performs preliminary action by adding casein dust to the lactose permeate concentrate before the final evaporation and drying steps. This allows the casein to be incorporated into the product matrix during the concentration process, ensuring uniform distribution and proper integration without requiring separate mixing steps later in the process.
Solution Approach 2:
The invention changes the composition parameters of the lactose permeate by introducing casein dust, transforming it from a low-protein product (0.3-0.6% protein) to a high-protein product (7-12% protein). This parameter change enables the product to meet nutritional requirements for human consumption and expand its application range beyond animal feed.
3Quantity of substance
If casein dust is added to lactose permeate concentrate, then protein content increases to 7-12%, but the product composition becomes more complex requiring precise control of multiple parameters
Solution Approach 1:
The invention utilizes the existing evaporation and drying equipment to simultaneously concentrate the lactose permeate and integrate the casein dust. The process leverages the natural functions of the equipment - evaporation removes water while concentrating both lactose and casein, and drying produces the final powder - without requiring additional specialized equipment or complex control systems.
Solution Approach 2:
The invention makes the lactose permeate processing system multi-functional by enabling it to produce both lactose crystals and a high-protein powder from the same concentrate. The evaporation and drying steps serve dual purposes: concentrating the lactose for crystal formation and simultaneously concentrating and drying the casein to produce a protein-rich powder, maximizing the utility of each process step.
4Ease of manufacture
If waste casein dust is used for animal feed or disposal, then the processing cost is lower, but the ecological value and nutritional benefit are significantly reduced
Solution Approach 1:
The invention converts the harmful factor of waste disposal (casein dust that would otherwise be discarded or used for low-value animal feed) into a beneficial high-value ingredient. By incorporating casein dust into the lactose permeate product, the invention transforms a waste stream into a valuable protein source, eliminating disposal costs and creating an additional revenue stream while reducing environmental impact.
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 method results in a high protein lactose permeate powder with improved nutritional value, enhancing the energy content and balancing the nutritional value of animal feeds, and facilitating the use of waste materials in ecological product development.
Implementation Method 1
pre-concentration by means of membrane nanofiltration
Implementation Method 2
subsequent concentration in an evaporator to 54-58% dry weight
Implementation Method 3
lactose crystallisation
Implementation Method 4
drying
Data Source
AI summary
The present invention relates to a method for producing a powdered high protein lactose permeate, a powdered high protein lactose permeate obtained by this method and a product containing high protein lactose permeate. The method involves concentration of lactose permeate, lactose crystallisation and drying in the presence of casein.