See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/287478969

All-inclusive utilisation of sour whey components in different prototypes based

on membrane separation

Article  in  Milchwissenschaft · January 2012

CITATION READS

1 214

11 authors, including:

Arpad Novak Solveig Bukovics

Hungarian Dairy Research Institute Hungarian Dairy Research Institute
1 PUBLICATION   1 CITATION    2 PUBLICATIONS   1 CITATION   

SEE PROFILE SEE PROFILE

Klara Pasztor Huszar

Szent István University, Godollo
35 PUBLICATIONS   94 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Novák Á.:Application of membrane filtration in the production of milk protein concentrates. Bull of IDF. No. 311. 26-27 (1996) View project

Novák Á.: Milk protein concentrate. IDF S.I. No. 9201, P51-66 (1991) View project

All content following this page was uploaded by Klara Pasztor Huszar on 06 July 2016.

The user has requested enhancement of the downloaded file.

All-inclusive utilization of sour whey components in different prototypes based
on membrane separation
ATTILA LŐRINCZ,1 ANDRÁS UNGER,1 ÁRPÁD NOVÁK,1 KATALIN SZABÓ,1
GÁBOR CSÁSZÁR,1 SOLVEIG BUKOVICS1 and ATTILA FÜLÖP1 * CSABA BALLA,2
LÁSZLÓ FRIEDRICH2 and KLÁRA PÁSZTOR-HUSZÁR2 * LAJOS SZALAI3
1
Hungarian Dairy Research Institute, Inc., 24 Lucsony Street, 9200 Mosonmagyaróvár, Hungary
2
Department of Refrigeration and Livestock Products Technology, Faculty of Food Science, Corvinus University
of Budapest, 43-45 Ménesi Street, 1118 Budapest, Hungary
3
Department of Grain and Industrial Plant Processing, Faculty of Food Science, Corvinus University of
Budapest, 29-43 Villányi Street, 1118 Budapest, Hungary

The Hungarian companies producing about 31 thousand tons quark per year. Like the by-
product of the quark production arose about 200 thousand tons sour whey per year in
Hungary and 145 million tons per year worldwide. The biggest part of the sour whey gets into
the animal foraging, and small part will be spray drying. Because the inadequate utilization
of the sour whey, in every year 15 thousand tons of milk component gone, whereof 500 tons
whey protein, 11 thousand tons milk sugar, 1,5 thousand tons calcium and other minerals, 1,3
thousand tons of NPN materials, 1,2 thousand tons lactic acid and the utmost part is the
water. Just the value of the non-utilized milk sugar, whey proteins and lactic acid is about ten
million EURO per year in Hungary. The structure of Hungarian quark production system is a
model which represents the all Middle European quark production situation. The central
processing of the sour whey (e.g. milk sugar or lactic acid manufacturing, etc.) is not really
solution due to the large distance between the quark production plants and the high
investment costs.
Considering these viewpoints we elaborate a membrane separation technology, which can
convert the sour whey components to high value human food products in the site of the quark
production plants. We developed product models based on the separated sour whey
components such as sour creams, kefirs, yoghurts and bread. The new technology can be
reason a new complex profit source of the quark producers.

Keywords Ultrafiltration, Nanofiltration, Sour whey, Sour cream, Yoghurt, Bread.

INTRODUCTION

Our research project is intended to prepare the utilization of sour whey by novel methods.

Sour whey is a translucent liquid remaining after the precipitation and removal of milk
casein and a part of the whey proteins during quark production. It represents about 85% of the
milk volume and retains 50% to 55% of milk nutrients (Siso 1996; Jelen 2003; Ghaly et al.
2004). Among the most abundant of these nutrients are lactose (4.0 to 4,5 g/100g), true
proteins /TN-NPN*6,38/ (0,1 to 0.3 g/100g), lipids (0,1 to 0.5 g/100g), and mineral salts (0,5-
0,8g/100g) ((Paraskevopoulou et al. 2003). Two main whey varieties produced are sweet and
sour whey (Siso 1996). Sweet whey (pH 5.9 to 6.5) is a byproduct of the manufacture of hard
and semi hard cheese, whereas sour whey (pH 4.4 to 4.8) is obtained from the manufacture of
fresh cheese, including quark, and casein (Irvine and Hill 1985; Zayed and Hunter 1991).
The dairy industry has a whey surplus problem. It has been estimated that annually as
much as 145 million tons of liquid whey are produced worldwide (Siso 1996), and only
approximately 50% of the whey produced is used to formulate products. The remainder is
treated as waste. Due to its high levels of lactic acid and minerals, e.g., calcium and

1
potassium, sour whey is not commonly used for human consumption. Whey has traditionally
been dumped into surface water or fed to livestock. However, current environmental
regulations and levies are forcing cheese makers to treat whey before disposal, and because of
factory centralization the cost of transporting whole whey for feed use has become
prohibitive. Therefore, whey has become a liability and a great amount of research has been
focused on converting this liability to an asset (Irvine and Hill 1985; Ben-Hassan and Ghaly
1995).
Approximately 30% to 40% of the wastewater load in quark production plants comes
from non-utilized acid whey, which could substantially be reduced by membrane separation
techniques. Several authors have reported on the use of nanofiltration for desalination or
deacidification of acid whey (Kelly and Kelly 1995; Barrantes and Morr 1997; Nguyen et al.
2003), however, there are very few publications on the further utilization of the nanofiltered
concentrate of ultrafiltered whey permeate. Dec and Chojnowsky (2007) suggested that
nanofiltered acid whey concentrate be used as an ingredient in various dairy foods such as ice
cream or yogurt. Besides, whey is often implicated as having an undesirable flavor that is
unpleasant to consumers, which limits its use in bland or delicately flavored foods such as
health beverages or baking mixes (Whetstine et al. 2003).
Membrane processes were first used in whey processing in the dairy industry (Maubois
1991). The dairy industry has been one of the pioneers in the development of ultrafiltration
(UF) equipment and techniques. An important factor is the utilization of the by-product
resulting from the permeate of UF. The biological oxygen demand (BOD) of whey is about
35,000 mg O2/L and the BOD of the permeate from ultrafiltered whey is reduced by 15 to
30% from that of the whey. Thus, whey solids account for much pollution each year (Zall
1984). Nanofiltration (NF) or reverse osmosis (RO) can be used with other membrane
processes in the concentration of whey and ultrafiltered permeates of whey to produce whey
protein concentrates, lactose, and waste streams with reduced BOD (Spangler and Amundson
1986; van der Horst et al. 1995; Bálint and Okos 1995; Alkhatim et al. 1998). In the recent
years complex membrane filtration methods (microfiltration, ultrafiltration, nanofiltration and
reverse osmosis) were developed for whey processing (Kümmel and Robert 2000; Cheryan
1998; Rektor and Vatai 2004).
The main objective of the present research was to find novel methods to utilize acid whey
and develop delicious and high-value food products containing the various components
concentrated by the method developed.

MATERIALS AND METHODS

Membrane separation of sour whey components

The aim of the research is the separation of sour whey components by membrane filtration
techniques (ultrafiltration, nanofiltration) and utilization the separated components in different
food prototypes. Sour whey was first separated to remove fat and curd fines. After separation
sour whey was ultrafiltered with concentration factor 30 on 20 °C temperature (membrane
type: GR70PE-4338/48, cut off: 10 kDa, surface: 6,7 m2, Alfa-Laval). The valuable whey
proteins got to the UF concentrate and lactose and other water soluble components to the UF
permeate. In the second phase UF permeate was separated by nanofiltration with
concentration factor 4,2 on 20 °C temperature (membrane type: NF-3840/30-FF, cut off: 300
Da, surface: 7,5 m2, DOW Filmtec, USA). During this process the solids content accumulated
in the ultra- and nanofiltered concentrates and technological water was the by-product. Figure
1. shows the basic separation scheme of sour whey.

2
 Sour whey 100.000L

Ultrafiltration(UF) Permeate 90.000L

Nanofiltration / Revers osmosis Water 70.000L

UF-concentrate 10.000L NF/RO concentrate 20.000L

Figure 1 Basic separation scheme of sour whey with mass balance

According to the mass balance, from 100 parts of sour whey by ultrafiltrating (UF) 10
parts of ultrafiltered whey protein concentrate and 90 parts ultrafiltered permeate can be
produced. The 10 parts of ultrafiltered concentrate is colloidal solution whose true protein part
consists alone whey proteins, its macrocompostition is similar to skim milk. This composition
can be chosen according to the aim of utilization. The 90 parts ultrafiltered permeate can be
separated by nanofiltration to nanofiltered (NF) „water” and nanofiltered concentrate. In
theoretical model from 90 parts of UF sour whey permeate 70 parts of NF water and 20 parts
of NF concentrate arises. The 20 parts of NF concentrate is a „syrup” that has as it were 20,0-
21,0% dry matter content, which consists approximately 18,0-19,0% lactose and its
derivatives (glucose, galactose), furthermore 1,5-2,0% minerals (calcium, potassium, sodium,
magnesium, etc.), lactic acid, acetic acid and other acids.

Prototype development

Prototype development is bi-directional. On the one hand its basis is the ultrafiltered whey
protein concentrate from sour whey arises after membrane separation, on the other hand the
lactose concentrate arises after nanofiltrating the ultrafiltered permeate.
The raw material of the prototypes belonging to the first group is ultrafiltered whey
protein concentrate, whose protein content consists only whey proteins with remarkably high
biological value. With the utilization of whey protein concentrate, we produced such dairy
products with modified protein content, excellent nutritional properties, high biological value
and easy digestibility, additive-free whose have important role, in particular nutrition for
childen, elderly people and those who suffer in digestive tract disorders.
The raw material of prototypes belonging to the second group is the nanofiltered
concentrate of the ultrafiltered sour whey permeate.

Prototypes based on ultrafiltered sour whey protein concentrate

 yoghurts,
 kefirs,
 sour creams.

Prototype based on ultrafiltered sour whey permeate nanofiltered concentrate

 breads.

3
RESULTS AND DISCUSSION

Results of sour whey membrane separation

In the presented model, first the sour whey was skimmed to remove the solid particles and fat,
afterwards it has been ultrafiltered and the ultrafiltered permeate has been nanofiltered. The
macrocomponent and main chemical composition (Table 1), the macro-and micro element
composition (Table 2) and the acid profile (Table 3) of sour whey and the ultra- and
nanofiltered concentrate and permeate fractions were determinate.

Table 1 Compositional and chemical parameters of sour whey and the ultra- and nanofiltered
concentrate and permeate fractions
Sample Dry matter Fat Protein (TNx6,38) NPNx6,38 Minerals Lactose Acidity Titratable acidity
g/100g pH SH
Raw quark whey 5,98 0,41 0,31 0,20 0,72 4,54 4,61 21,20
Skimmed quark whey 5,50 0,10 0,30 0,20 0,73 4,44 4,60 21,60
Ultrafiltrated concentrate 12,04 2,48 3,26 0,66 0,81 5,49 4,68 32,40
Ultrafiltrated permeate 5,18 0,00 0,21 0,20 0,71 4,27 4,69 19,16
Nanofiltrated concentrate 20,58 0,03 0,68 0,33 1,98 17,89 4,74 71,20
Nanofiltrated permeate 0,36 0,00 0,07 0,07 0,21 0,08 4,70 4,00

The lactose and minerals represents the utmost part of the dry matter of sour whey.
Lactose is from the unfermented milk lactose, mineral content is from milkplasma and casein
micelles that were cleaved at isoelectric point (pH 4,6). True protein content of sour whey
depends on the production technology and is typically 0,1-0,3 g/100g.
The true proteins concentrated in ultrafiltered concentrate. By the physical, chemical and
biological properties of whey proteins, novel type foods can be produced with high biological
value and excellent sensory properties. In the presented model, compositon of ultrafiltered
concentrate is milk-like, its total protein content (TN*6,38) is 3,26 g/100g, fat content is 2,48
g/100g. Ultrafiltration membranes are permeable for lactose and the minerals thus in the
ultrafiltered concentrate and permeate the typical lactose and mineral content same as the sour
whey. The growth of the lactose and mineral content in UF concentrate is small scale due to
the concentration polarisation. The ultrafiltered permeate is practically protein-free. NPN,
lactose and minerals compose the utmost part of its dry matter, whose concentration is similar
to lactose and mineral content of sour whey.
During the nanofiltration of the ultrafiltered sour whey permeate as the lactose, so the
minerals are being concentrated. Different dry matter content can be set in the nanofiltered
concentrate, in the function of concentration factor (CF). According to the measurement of
flux in case of continuous production lines, as it were 20 g/100 g is optimal to set dry matter
content to, where the utmost part (as it were 85-90%) is lactose.

4
Table 2 Element composition of sour whey and the ultra- and nanofiltered concentrate and
permeate fractions
Macro-and microelements Skimmed quark whey Ultrafiltrated Ultrafiltrated Nanofiltrated Nanofiltrated
concentrate permeate concentrate permeate
mg/kg
Ca 1020 1150 950 4960 36
K 1520 1350 1300 2850 340
Mg 100 110 93 500 <0,05
As 0,014 0,022 0,019 0,197 <0,01
Ba 0,116 0,08 0,07 0,731 <0,01
Cd 0,017 0,02 0,022 0,168 0,035
Co <0,01 <0,01 <0,01 0,049 <0,01
Cr 0,01 0,245 0,01 0,07 <0,01
Cu 0,028 0,187 0,019 0,112 <0,01
Fe 0,13 3 0,41 0,66 0,16
Mn 0,033 0,071 0,045 0,389 0,022
Mo 0,055 0,065 0,051 0,508 0,02
Ni 0,011 0,132 0,02 0,153 0,011
Pb <0,01 0,039 <0,01 0,063 <0,01
Sb <0,01 0,023 <0,01 0,064 <0,01
Se <0,01 0,029 <0,01 0,06 <0,01
Sn <0,01 0,019 <0,01 0,08 <0,01
Zn 2,687 3,042 2,221 18,848 0,084

It can be observed that calcium, potassium and magnesium content of sour whey as it
were two third of typical value of milk, which means that at the production of quark the most
valuable ash elements drained off in great volume with the whey. The nanofiltered
concentrate has very remarkable mineral content as it were 1,98 g/100 g, whose nearly one
fourth part (0,5 g/100 g) is biological utilizable calcium. Low COD value (lower than 100
mg/kg) nanofiltered permeate yielded from whey in plants can be utilized as technological
water, which means a very remarkable water usage cost-saving (e.g. in case of quark,
produced from 100 thousand litres milk, 56 m3 of water can be reclaimed).

Table 3 Lactic- and acetic acid content of sour whey and the ultra- and nanofiltered
concentrate and permeate fractions
Sour whey fractions Lactic acid content Acetic acid content
g/100g
Skimmed quark whey 0,68 0,045
Ultrafiltrated concentrate 0,6 0,072
Ultrafiltrated permeate 0,54 0,033
Nanofiltrated concentrate 1,22 0,077
Nanofiltrated permeate 0,16 0,023

Acid, especially lactic and acetic acid content of components define their potential
utilization. The product development intended to research the potential utilization of
components.

Results of prototype development

We have been doing sour cream (10 and 20 g/100g fat), kefir, yoghurt and whey drink
development on whey protein concentrate basis. Up to the present we defined the optimal
casein: whey protein ratio, respectively the main technological parameters of the products.
We examined the physical, chemical, microbiological and organoleptic characteristics of the
developed prototypes so far.

Preparation of sour cream prototypes

In case of sour cream prototype design, to define the optimal composition, respectively
heat treatment technology and optimal technological parameters were the main objectives. For
sour creams we have used ultrafiltered protein concentrate to replace liquid milk. We defined
the optimal liquid milk, milk fat and whey protein concentrate ratio.
During the researches, we have produced sour cream prototypes containing 10 and 20
g/100 g fat. It was a difficulty that in the production of sour creams whey proteins denatured

5
on the used heat treatment temperature (80-90°C). During the denaturation the whey proteins
formed agglomerates and this will give sand-like taste and will loose fat and whey in the
product. By the elaborated technology this problem has been eliminated successfully, in
addition better structured, microbiological more stabile and better cooking resistant sour
creams have been produced than the original sour creams.

Production of kefir and yoghurt prototypes

During the production of kefir and yoghurt, we took the sour cream production process for
utilization of whey protein concentrate as a raw material. We assessed that the protein content
of whey concentrate basically determinate the structure and stability of the products.
The macro-component compositions of the prepared sour creams with 10 and 20 g/100g
fat content, respectively the 3 g/100g fat content kefir and yoghurt prototypes are shown in
Table 4.

Table 4 Physical and chemical characteristics of ultrafiltered whey protein concentrate based
sour creams, yoghurts and kefirs

Dry matter Fat Protein (TN*6,38) Lactose Minerals Acidity

Prototype model
g/100g pH
Sour cream with 10 g/100g fat 18,75 10,00 4,05 4,26 0,54 4,60
Sour cream with 20 g/100g fat 27,62 20,00 3,47 3,66 0,39 4,60
Yoghurt and kefir 12,33 3,00 3,98 4,66 0,67 4,60

Liquid milk can be replaced by whey protein concentrate by 37% in case of 10 g/100g,
50% in case of 20 g/100g fat consisting sour creams, 20-25% in case of kefirs and yoghurts.
So that their structure will be appropriate or better than the applied control products that were
produced alone from milk and milk fat.
The prepared technology can be fit into the traditionally applied production lines; the
optimal technological parameters can be realized in those. The technology can be applied in
both cases of coagulation in container and whipped sour creams too.

Sour whey ultrafiltered permeate, nanofiltered concentrate based prototype bread.

From nutritional and economical aspect the aim was to design such special
products that e.g. high rye flour level contained breads and a “Graham”-like, whole
grain products whose desire the presence of natural acids. By the utilization of
nanofiltered concentrate the technological characteristics of dough have been changed
in positive direction.
The baking experiments have been conducted according to the European Baking
Test. The applied technological steps were fermenting, kneading, leavening, rising and
baking. The characteristics of the elaborated industrial bread are shown in Table 5.

6
Table 5 Characteristics of the elaborated industrial bread

Component Used quantity Technology

Wheat flour 34,07% Dough

leavning
Rye flour 22,71% Time 20 – 40 min.
Water 18,74%
Nanofiltered 18,74% Rising
concentrate
Yeast 3,99% Temperature 30 oC
Salt 0,85% Time 60 min.
Pork fat 0,56%
Ground cumin 0,17% Baking
Hop flavor 0,17% Temperature 220 oC

Ascorbic acid 0,01% Time 31 min.

During the experiments, the optimal water-nanofiltered concentrate ratio was 50-50%.
Due to the bitter taste, caused by high mineral content of nanofiltered concentrate, hop
flavour, for the harmonic taste and smell cumin were added. By utilizing the high acid content
of the nanofiltered concentrate, the fermenting step was successfully skipped and with this the
opportunities of production have been widened.

CONCLUSIONS

The project aimed all–inclusive utilization of sour whey. By the ultra- and nanofiltration
methods, the sour whey was separated to its basic components in the filtrated concentrate and
permeate fractions. These separated and concentrated fractions were utilized as the raw
materials of high added value food products.
The favourable biological and physiological value of the elaborated prototypes the
enlarged high biological value whey protein content according to the control products. Based
on the elaborated technologies such products can be produced wherein more than 50% of the
protein content is from whey proteins. Further novelty is that beside certain technological
parameters, techno-functional properties of whey proteins can be used to create the
appropriate structure of products so additives will not be required.
Originating from its composition, sour whey ultrafiltered permeate, nanofiltered
concentrate primarily offers a novel, value-adding potential utilization as food additive. Its
accentuated area is ice cream production and, respectively bakery industry.
Comparing the energy demand of membrane separation to other water abstracting,
concentrating methods (e.g. evaporation, spray-drying) the energy input is – at same
concentration factor – 60-70% less. The aimed method promises further energy savings by the
fact that it will only concentrate the basic components to the level that is required for the
product processing.
The result of the project may basically offer technological-scientifical novelties for more
target groups.
The first group is the dairy plants where sour whey arises, which regarding to today’s
possibilities can only be utilized as swine forage, associated with certain environmental
concerns. For this group the technology aimed by us offers opportunity for value added,
human aimed and environment friendly utilization of whey, in certain case a brand new or
leastwise novelty products.
The second group could be the circle – and hereby we mean primarily bakery industry
which can utilize the arising nanofiltered concentrate as food additive in their products.

7
 Thereunto, a realistic chance may be guaranteed by composition of nanofiltered concentrate
and result of several previously conducted experiment.
The third group is the consumer self, who will be able to get novel dairy products that
exceed the present knowledge’s by their nutritional properties (e.g. digestibility), are additive-
free and presumably cheaper than the extents.

The product lines that are aimed in the project can be well machined and automatized,
operated in closed system with low labour demand.

ACKNOWLEDGEMENTS

This study was performed within the framework of National Development Plan – reference
GOP-1.1.1-08/1-2008-0016 funded by Hungarian Economic Development Centre Private
Limited Company (MAG).

REFERENCES
Alkhatim H S, Aleaiua M I, Soriano E, Iborra M I and Areal J (1998) Treatment of whey effluents from dairy
industries by nanofiltration membranes. Desalination 119 177-183.
Á Bálint and M R Okos (1995) Computer aided design in whey processing. Periodica Polytechnica Chemical
Engineering 39 119-128.
Barrantes L D, Morr C V (1997) Partial deacidification and demineralization of cottage cheese whey by
nanofiltration. Journal of Food Sciences 62 338-341.
Ben-Hassan R M, Ghaly A E (1995) Transaction of the ASAE 38 1121–1127.
Cheryan M (1998) Ultrafiltration and Microfiltration Hand-book. Lancaster PA: Technomic
Dec B, Chojnowsky W (2007) Application of Nanofiltration for Demineralization and Deacidification of Twarog
Acid Whey. Polish Journal of Natural Sciences 22 320-332.
Ghaly A E, Kamal M A (2004) Submerged yeast fermentation of acid cheese whey for protein production and
pollution potential reduction. Water Research 38 631–644.
Irvine D M, Hill A R (1985) In Comprehensive Biotechnology Vol. 3, pp. 523–565. Moo-Young M, Blanch H
W, Drew S, Wang D I C eds. Oxford, New York, Toronto, Sydney, Frankfurt: Pergamon Press
Jelen P (2003) In Encyclopedia of Dairy Sciences Vol. 4, pp. 2739–2745. H. Roginski J W, Fuquay P F, eds.
Amsterdam, Boston, London, New York, Oxford, Paris, San Diego, San Francisco, Singapore, Sydney,
Tokyo: Fox Academic Press & Elsevier Science
Kelly J, Kelly P (1995) Desalination of acid casein whey by nanofiltration. International Dairy Journal 5 291-
303.
Kümmel R and Robert J (2000) Application of membrane processes in food technologies in: K Bélafi-Bakó, L
Gubicza and Mulder M eds. Integration of Membrane Processes into Bioconversions. New York: Kluwer
Academic/Plenum
Maubois, J L (1991) New applications of membrane technology in the dairy industry. Australian Journal of
Dairy Technology 46 91-95.
Nguyen M, Reynolds N, Vigneswaran S (2003) By-product recovery from cottage cheese production by
nanofiltration. Journal of Cleaner Production 11 803-807.
Paraskevopoulou A, Athanasiadis I, Kanellaki M, Bekatorou A, Blekas G, Kiosseoglou V (2003) Functional
properties of single cell protein produced by kefir microflora. Food Research International 36 431–438.
Rektor A, Vatai Gy (2004) Membrane filtration of Mozzarella whey. Desalination 162 279-286.
Siso M I G (1996) The biotechnological utilization of cheese whey: A review. Bioresource Technology 57 1-11.
Spangler P L and Amundson C H (1986) Concentration of Milk and Whey Using Composite, Spiral Wound,
Reverse Osmosis Membranes. Journal of Dairy Sciences 69 1498-1509.
van der Horst H C, Timmer J M K, Robbersten T and Leenders J (1995) Use of nanofiltration for concentration
and demineralization in the dairy industry: Model for mass transport. Journal of Membrane Sciences 104
205.
Whetstine C J, Parker J D, Drake M A, Larick D K (2003) Determining flavor and flavor variability in
commercially produced liquid Cheddar whey. Journal of Dairy Sciences 86 439-448.
Zall R R (1984) Trends in whey fractionation and utilization. A global perspective. Journal of Dairy Sciences 67
2621.
Zayed G, Hunter J (1991) Ethanol production from salt whey using free and agarose immobilized yeasts.
Milchwissenschaft 46 3–7.

View publication stats