Citrates from Whey for Emulsifying in Processed Cheese
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Solution Overview
Problem
The traditional production of processed cheese relies on synthetic cast iron salts, which generate polluting waste and require additive labeling, necessitating a more sustainable and functional alternative.
Innovation Solution
A process involving the controlled extraction of citrates from a milk fraction, specifically whey, to create an ingredient with a citrate-to-calcium mass ratio greater than 20, utilizing anionic column extraction and regeneration with basic solutions to produce a citrate-rich eluate, which is then mixed with a dairy base to achieve a final ratio between 20 and 130, resulting in an ingredient with emulsifying properties similar to cast iron salts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If synthetic cast iron salts are used to achieve emulsifying character and homogeneous consistency, then the functional performance is improved, but environmental pollution and additive labeling requirements worsen
Solution Approach 1:
The invention extracts citrates from whey through ion exchange chromatography, obtaining a natural citrate source that can replace synthetic cast iron salts. The extraction process uses anionic columns to separate and concentrate citrates from whey, creating an environmentally friendly alternative that maintains emulsifying functionality without synthetic additives
Solution Approach 2:
The invention controls the calcium content parameter throughout the process to maintain a mass ratio between citrates and calcium greater than 20. This parameter control is achieved through selective extraction and controlled addition of calcium sources, ensuring the final ingredient has the required emulsifying properties while remaining environmentally friendly
2Reliability
If synthetic cast iron salts are used to ensure smooth and homogeneous consistency, then the product quality is improved, but additive labeling requirements worsen
Solution Approach 1:
The invention extracts citrates from whey, a natural dairy product, creating an ingredient derived from natural sources rather than synthetic chemistry. This extraction approach allows the ingredient to be obtained without synthetic additives, eliminating the need for additive labeling while maintaining the homogeneous consistency required for processed cheese
Solution Approach 2:
The invention utilizes whey, a byproduct of cheese making, as the source material for citrate extraction. This self-service approach converts a waste product into a valuable ingredient, providing both functional benefits and labeling advantages since the ingredient is derived from natural dairy components
3Object-affected harmful factors
If citrates are extracted from whey with controlled calcium content, then the environmental sustainability is improved, but the process complexity worsens
Solution Approach 1:
The invention uses ion exchange columns as intermediary devices to facilitate the extraction of citrates from whey. These columns act as mediators between the whey feedstock and the final citrate concentrate, enabling selective separation through ion exchange mechanisms while providing a structured approach to controlling calcium content
Solution Approach 2:
The invention replaces complex mechanical separation systems with ion exchange chromatography, which uses chemical affinity differences to separate citrates from whey components. This substitution simplifies the overall process by using a well-established biochemical separation technique rather than requiring complex mechanical filtration or centrifugation systems
4Reliability
If the calcium content is controlled to maintain citrate-to-calcium ratio greater than 20, then the functional performance is improved, but the manufacturing precision requirements worsen
Solution Approach 1:
The invention implements feedback control by monitoring the calcium content throughout the extraction and concentration process. By measuring calcium levels at various stages and adjusting the process accordingly, the system maintains the citrate-to-calcium mass ratio greater than 20, ensuring consistent emulsifying functionality in the final ingredient
Solution Approach 2:
The invention performs preliminary removal of calcium from whey during the extraction process before concentrating the citrates. By controlling calcium content early in the process rather than attempting to adjust it after concentration, the manufacturing precision requirements are reduced and the citrate-to-calcium ratio is more easily maintained throughout subsequent processing
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 yields an ingredient that mimics the functionalities of cast iron salts without the environmental drawbacks and additive labeling requirements, ensuring a smooth and homogeneous consistency in processed cheeses while reducing waste and environmental impact.
Implementation Method 1
passing a whey through an anionic column
Implementation Method 2
by prior treatment of the whey by electrodialysis
Implementation Method 3
the anionic column is regenerated by a basic solution, for example sodium hydroxide or potash
Data Source
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Figure 3~4
Figure 5
AI summary
The invention relates mainly to a method for producing an ingredient having the same functionalities as a melting salt, said method comprising at least one step of extracting citrates contained in a dairy fraction. Preferably, the dairy fraction is a milk serum. Advantageously, the step of citrate extraction is carried out by passing a milk serum through an anionic column and recovering the anionic eluate loaded with citrates. The anionic eluate loaded with citrates is then concentrated, mixed with a drying base, then dried, in order to obtain an ingredient in powder form.