Whole Milk Powder

Cold Milk Separation

Cold Milk Separated Milk, Fat and Protein Standardized Whole milk powder with or
without vitamin and lecithin addition.

0 EM 2021-06-11

Creation Date: Approval Date:

Rev.: Creator: Approver Comments:
(yyyy-mm-dd) (yyyy-mm-dd)

Main process Storage End product Raw material Side product Processing aids Process flow Alternative(s)

GEA LPT Block Diagram & Process Description Approver : Date:

Creator: EM Date 2021-06-11

This document is only for presentation of conceptual layout of process/technical solution.
DP-MP-01-BDP-102-Whole milk powder – cold
This means that the contents may not be considered as part of any firm offer or estimate. ID No.:
All buffering functions may not be illustrated. milk separation-V01
Copyright ©2021 GEA Process Engineering A/S. All rights reserved. This document contains confidential and proprietary information of GEA Process Engineering A/S. This document and its contents shall be safeguarded from unauthorized access, use
or disclosure; it is not permitted to copy, modify, disassemble, reverse engineer, use or disclose to others this document or any of its contents without express prior written authorization.
All rights reserved for patents, utility models and design rights (including related applications).

GEA INTERNAL
 Whole Milk Powder – Cold Milk Separation
Cold Milk Separated Milk, Fat and Protein Standardized Whole milk powder with or without vitamin and lecithin
addition.
A B
Raw Milk Reception Raw Milk Storage

C D
Cold separation Raw Cream Storage
@ 8-20ºC 40-42% Fat @< 6°C

H1
Milk Filtration
250 Micron
G E Cream Pasteurizer
Skim Milk Storage
@ <6°C Min 85°C, 15 sec.

J H RO pre-concentration F
Lactose Powder Tipping Pasteurized Cream Storage
Concentration depends on heat
from 25kg or Bulk Bags @< 6°C
treatment parameters

K I Excess Cream to further

Lactose Mixing & Storage Milk Standardization
Mixed to 18%TS, Cooled to <6°C Using Automated Inline control
Processing
e.g., Into butter or AMF

L M Standardized Milk
Milk Permeate
4 to 30%TS Storage
@ <6°C

R P Heat treatment
Additives Vitamin / Minerals
Time and temperature depend on
Reconstituted into batches of water
Evaporation
product characteristics

Q
Evaporation

S Concentrate Storage
Spray drying

T Dryer Feed System

Incl. pre-heating, homogenization
and high-pressure pump

V Lecithin Addition U
Drying
Liquid Lecithin
Rework

W Powder Transport
and Storage

X
Powder Pregassing

Y
Powder Packing
25kg or Bulk Bags

• RWMP
Whole Milk Powder • AWMP
• IWMP

Main process Storage End product Raw material Side product Processing aids Process flow Alternative(s)

GEA LPT Block Diagram & Process Description Approver: Date:

Creator: EM Date 2021-06-11

This document is only for presentation of conceptual layout of process/technical solution.
DP-MP-01-BDP-102-Whole milk powder – cold
This means that the contents may not be considered as part of any firm offer or estimate. ID No.:
All buffering functions may not be illustrated. milk separation-V01
Copyright ©2021 GEA Process Engineering A/S. All rights reserved. This document contains confidential and proprietary information of GEA Process Engineering A/S. This document and its contents shall be safeguarded from unauthorized access, use
or disclosure; it is not permitted to copy, modify, disassemble, reverse engineer, use or disclose to others this document or any of its contents without express prior written authorization.
All rights reserved for patents, utility models and design rights (including related applications).

GEA INTERNAL
 Whole Milk Powder – Cold Milk Separation
Cold Milk Separated Milk, Fat and Protein Standardized Whole milk powder with or without vitamin and lecithin
addition.

A
RAW MILK RECEPTION

The milking temperature at farm is approximately 35ºC, which is the optimal temperature for the multiplication of mesophilic
microorganisms. For this reason, milk should be chilled immediately below 4ºC to reduce the bacteria growth. Psychrotrophs have
optimal and maximum growth temperatures of >15 and 20ºC respectively, however, they can also grow at refrigeration
temperatures below 7ºC. During the transport of milk from farmers to dairies, a slight increase in temperature occurs and therefore
is important to reduce the temperature below 4ºC once the milk is discharged by a centrifugal pump through a plate exchanger.
For milk receptions with high capacities and where the temperature fluctuation of the incoming milk is relatively low, the milk can
alternatively be chilled by recirculation around the raw milk silo(s). This will reduce the instantaneous chilled water demand and
high shear impact on the milk. Several controls with samplings in the reception are carried out to check the microbiology and
composition of the milk. For raw milk with high amount of solids load or dirt content, a clarifier before cooling could be needed.

B
RAW MILK STORAGE

Raw milk storage time, at 4ºC, is limited due to the phycrotrophic bacteria growth. At this temperature, psychrotrophs (mainly
Pseudomonas) can produce thermostable enzymes with lipolytic and proteolytic activity which can affect the milk quality. In order
to avoid problems during shelf life of the final product, the maximum storage time for raw milk should not exceed 72 h. Lateral
agitators are recommended to avoid the separation between cream and milk (creaming). Insulation in tank is needed to keep the
right temperature.

C
COLD MILK SEPARATION

With cold milk separation either the whole or only part of the total milk stream is sent through the separator. When only a part of
the milk is cold skimmed the amount to be separated needs to be high enough to produce enough skim milk to fat standardize the
remaining unseparated raw milk. Milk sent for separation is pre-heated to 8-20°C to achieve the required skimming efficiency. The
skimming efficiency is lower compared to hot separation and depends on the separator capacity and temperature. Skim can be
regeneratively cooled against incoming milk, and then chilled to 4 to 8°C prior to further processing. The milk separation line is run
for >20hours before needing CIP cleaning, although sometimes a mid-run hot water rinse is employed to remove fat residues
accumulating in the separator.

D
RAW CREAM STORAGE

Cream storage tanks should be insulated, and cooling jackets are recommended to avoid a temperature increase due to
crystallization of fat globules (fusion of heat). An increase of temperature can trigger bacteria growth. The temperature should be
below 6°C. During agitation, it is important to avoid air-incorporation for the downstream process. Alternatively, the raw cream can
be heated to 65°C if the storage time before pasteurization is limited.

E
CREAM PASTEURIZATION

The aim of raw cream pasteurization is to inactivate organisms that may be pathogenic or cause spoilage and to inactivate
enzymes (lipolytic and proteolytic enzymes). Because fat protects bacteria the pasteurization temperature will depend on the fat
content. In general, cream of 18% fat is pasteurized at 75°C for 15 sec, cream of 35% fat is pasteurized at 80°C for 15 sec., and
standard cream at 38-42% fat is pasteurized at 85-90°C for 15-22 sec. The cream pasteurization can also run inline with the raw
milk pasteurizer. In this case the raw cream storage tanks can be omitted.

F
PASTEURIZED CREAM STORAGE

Cream storage tanks should be insulated, and cooling jackets are recommended to avoid a temperature increase due to
crystallization of fat globules (fusion of heat). An increase of temperature can trigger bacteria growth. The temperature should be
below 6°C. During agitation, it is important to avoid air-incorporation for the downstream process.
 Whole Milk Powder – Cold Milk Separation
Cold Milk Separated Milk, Fat and Protein Standardized Whole milk powder with or without vitamin and lecithin
addition.

G
SKIM MILK STORAGE

The pasteurized skim milk can optionally be stored before further processing. The storage tanks should be insulated to keep the
temperature (4ºC) and avoid any risk of bacteria growth.

H1
MILK FILTRATION

The raw milk not sent through the separator is filtered to 250micron to remove any particulate matter in the milk. Usually,
duplex wedgewire filters with automatic changeover are recommended.

H
REVERSE OSMOSIS (RO) PRE-CONCENTRATION

The skim milk can optionally be pre-concentrated by RO. The concentration degree must be considered for each specific project
as it depends on the subsequent heat treatment required and end-product characteristics. The process will run cold at 5-8 °C for
up to 20 hours between CIP.

I
MILK STANDARDIZATION

The skim milk is fat and protein standardized to reduce seasonal variations in the milk and to adjust the composition to limits set
by the end-product specification. The protein standardization is usually done with lactose or milk permeate. The standardization
can be done inline or batch-wise:
- Inline: For this method, an analytical NIR instrument is used. The instrument measure and control the addition rates of cream
and lactose/permeate to ensure the milk composition is fully optimized. Inline standardization can be performed using fully
chilled ingredients or it can be performed downstream the milk separator at 55 °C. Be aware that some NIR instruments can
only operate at cold conditions (depends on manufacturer).
- Batch: For this method, the skim milk is standardized in the standardized milk storage tanks with cream and/or
lactose/permeate based on analytical measurements performed in the laboratory. This is a discontinuous method that requires
frequent sampling of the raw or skim milk to detect the seasonal variations.

J
LACTOSE POWDER TIPPING

Lactose powder, is generally tipped from 25kg or 1 ton bulk bags. On larger plants lactose tipping is decoupled from lactose
mixing by adding some intermediate storage bins for dry lactose powder. Decoupling allows the ergonomics around tipping to be
better optimized and for wet and dry operations to be better segregated. When decoupled then Powder is conveyed to the bins
using a lean phase air system. Conveying air may be cooled and dehumidified depending on ambient conditions. For smaller and
lower cost plants then lactose can be tipped directly to a simple mixer where it is reconstituted directly into water or into the milk.

K
LACTOSE MIXING & STORAGE

Potable water is generally heated to around 85°C before lactose is added to make up an 18 %TS solution. This concentration is to
make sure that lactose does not crystallize when chilled. If the lactose solution is stored at higher temperatures the concentration
can be higher.
Lactose is usually added via a standard funnel mixer, after which the mix passes through a holding tube to allow it to be fully
dissolved, before it is regeneratively cooled, then chilled to <8°C, and sent to storage. Storage tanks are sized to achieve
decoupling of lactose tipping and dosing operations. Lactose powder can alternatively be dissolved directly into the milk at the
standardized milk storage tanks with a similar setup as when dissolved into water or inline using a vacuum mixer.

GEA INTERNAL
 Whole Milk Powder – Cold Milk Separation
Cold Milk Separated Milk, Fat and Protein Standardized Whole milk powder with or without vitamin and lecithin
addition.

L
MILK PERMEATE

Milk Permeate (Permeate produced from Ultrafiltration of Milk) may be imported and used for protein standardizing of milk in place
of, or in addition to, reconstituted lactose. Permeate is generally concentrated >14% using RO to reduce any dilution of milk, and
to reduce transport and storage costs.

M
STANDARDIZED MILK STORAGE

Standardized Milk Silos are required to decouple the milk standardization from the evaporator(s) operation. The number of silos
depends on the level of segregation needed , and whether milk is batch processed or silos are allowed to simultaneously fill and
empty. Silos are typically insulated to maintain milk at 4-6°C. Multiple silos are needed with multiple evaporators, or to decouple
CIP of standardized silos from CIP of the evaporator(s).

P
HEAT TREATMENT

Milk must be heated prior to evaporation. Whole Milk is usually heated to at least 90°C for 30-60 seconds to inactivate enzymes
that could lead to oxidative spoilage of the powder. Initial preheating to 40-45°C is typically done indirectly using a PHE or tubular
heat exchanger. It is recommended that further heating uses GEA's low thermophile direct contact heat treatment system. 3-step
heat treatment is generally sufficient for WMP unless high heat WMP also needs to be made in which case 5-step heating is
needed.

Q
EVAPORATION

A series of Falling Film calandria typically with 16m tubes are used to concentrate the milk under vacuum to 48-53%TS prior to
drying. Shorter tubes may be used if there are restrictions on building height. The size and number of calandria used is
dependent on the range of duties required, and a balance of capital and operating costs required by the customer. Separator
vessels are used to separate vapour from the concentrated liquid. Integrated wrap-around separators can be used on larger
calandria which reduces the plant footprint and building costs for the plant, otherwise external separators are used. The water
vapour produced by evaporation can be recompressed and reused using MVR and / or TVR technology depending on the
customers' specific payback requirements and the relative cost of power and steam. MVR's provide greater flexibility to handle a
wider range of duties and reduces the thermal energy requirement to the evaporator which for many customers provides a more
sustainable energy solution. Condensed vapour (cow water) from the shell side of the calandria is collected and can be used for
feed preheating. This water can be recovered and treated back to potable water standard if justified by payback calculations.
Indirect tubular condensors are used to condense the final vapour stream from the evaporator. Multiple evaporators can be used
to increase flexibility or to maintain a continuous feed and extended running of the dryer for multiple days.

R
VITAMIN/MINERALS MIXING & DOSING

A range of vitamin and minerals may be added to fortify the milk to meet final product requirements. Water soluble vitamin and
minerals are mixed in solution up to 10%TS in tanks using cold or warm water. Multiple tanks are needed to ensure a continuous
supply of these batched ingredients to the evaporators and to maintain segregation between any incompatible ingredients that will
need to be added separately. Tanks are generally sized to be emptied every 4hours, but this depends on the stability of the
ingredients. Insoluble minerals such as calcium are mixed into a slurry and dosed to the evaporator from recirculating ring main
circuits to prevent any settling of powder in the pipework. The vitamin and mineral solutions are generally dosed into the suction
side of the evaporator feed pump to ensure fast and thorough mixing, although other dosing locations are possible.
 Whole Milk Powder – Cold Milk Separation
Cold Milk Separated Milk, Fat and Protein Standardized Whole milk powder with or without vitamin and lecithin
addition.

S
CONCENTRATE STORAGE

Concentrate tank(s) provide a buffer between evaporation and drying. Dual tanks allow regular cycling and cleaning of tanks, ideally
every 4 hours. A third tank can be added to improve the recovery of low solids material during start up and shut down.Tanks can be run
under vacuum if required by the customer. Agitators designed for vigorous mixing even at low tank levels are needed to avoid age
thickening of the concentrate during storage.

T
DRYER FEED SYSTEM

The concentrate to be dried is heated using a HIPEX heater, a brand of indirect mono-tubular heater with fluted tubes. Heating reduces
the viscosity of the concentrate and therefore improves atomization. High pressure pumps with homogenizing valves are used to feed
pressure nozzles. Rotary atomizers can also be used, typically on Compact type Dryers. Dual feedlines when combined with multiple
evaporators can be used to provide continuous operation of the dryer for multiple days.

U
DRYING

Spray drying of milk powder involves atomizing concentrated milk into a hot air stream (180 – 230°C). The atomizer may be either a
pressure nozzle or a centrifugal disc. By controlling the size of the droplets, the air temperature, and the airflow, it is possible to
evaporate almost all the moisture while exposing the solids to relatively low temperatures. GEA can offer a range of different Dryer types
which depends on the requirements set by the customer. MSD's are generally preferred for making a higher value agglomerated
functional powder. Compact dryers are sometimes used for lower cost commodity powders, or to match powder being produced by
earlier Compact dryers owned by the customer. Tall form dryers are generally not used for making commodity milk powder.
Filtered air used for drying is indirectly heated using steam, thermal oil, or natural gas. Separate heaters can be used for each of the
separate air flows, or a single common heater provided and cold air mixed back in to control air temperatures at each part of the
process. The single heater concept reduces complexity of heater installation and steam piping networks and allows instantaneous
adjustment of secondary air temperatures. Dehumidification of the inlet air can be done to improve drying capacity but is generally only
justified for commodity powders in locations where ambient humidity is high (above 16g/kg) for much of the year. Exhaust air from the
dryer is passed through a CIPable SANICIP bag filter before discharge. Powder Fines recovered from the bagfilter are returned to the
process. In some cases where environmental discharge limits are less stringent than cyclones (type CEE) can be used in place of
bagfilter(s). Semi-dried powder from the dryer chamber passes through a series of fluidized beds (depending on the type of dryer) where
final drying and cooling of the powder occurs. The finished powder passes through a vibrating screen sifter with aperture size of 3-4mm
to remove lumps, before being conveyed to storage. The dryer must be protected against the risk of fires and explosions according to
local and international requirements. The dryer is typically cleaned using a dedicated CIP system due to the high flowrates, and to allow
gravity return of CIP flows. Generally, all powder contact areas of the dryer need to be CIPed up to the inlet of the sifter. Vapour barriers
are needed to isolated areas that are not being cleaned.

V
LECITHIN ADDITION

Lecithin can be applied to the powder during drying to create an Instant Whole Milk Powder. Lecithin is generally sprayed onto the
powder as it drops into the fluid bed. The front sections of the fluid bed are run hotter to ensure adequate coating of lecithin on the
powder particles. This requires the fluid bed to be slightly larger than normal.
 Whole Milk Powder – Cold Milk Separation
Cold Milk Separated Milk, Fat and Protein Standardized Whole milk powder with or without vitamin and lecithin
addition.

W
POWDER TRANSPORT AND STORAGE

Powder is conveyed from the outlet of the dryer sifter into powder silos for intermediate storage before being packed.
For agglomerated and instant powder, the powder conveying system needs to be designed to minimize any breakdown of the
powder which would otherwise negatively affect functional properties. Dense phase conveying (vacuum or pressure) can be used.
High Pressure Dense phase conveying is better for transfer over large distances but is generally is more expensive and higher
running costs when the cost of generating high quality compressed air is factored in. When making regular powder then powder
breakdown during conveying is desirable, and often a powder mill is included, or powder is lean phase transferred to ensure that
the bulk density is increased to the desired levels. The size and number of powder bins needed depends on the degree of
segregation of powder, management of powder from dryer start & stop powder, and level of decoupling needed with packing.
Packing is a labor-intensive operation, therefore often packing is limited to a single day shift and the size of storage bins must be
made larger to ensure that the dryer operation is not disrupted.

X
POWDER PREGASING

Because this powder contains fat it must have oxygen removed prior to packing to reduce oxidation of the powder and achieve an
acceptable shelf life. Generally, this is achieved using a vacuum pregassing system, where air is removed in vacuum receiving
vessels, before nitrogen gas is added to shield the powder from oxygen.

Y
POWDER PACKING

Finished Powder is generally packed into 25kg bags using GEA Avapac packing equipment, although it can also be packed into
consumer sachets or 1 tonne bulk bags.Low intervention (Li) packing lines are typically used which reduces the labour input
required. Larger and more sophisticated plants also have automated depalletizing and conveying systems for the empty bags.
The weight of the filled 25 bags are checked and then passed through a metal detector before being coded. Rejected bags are
automatically removed from the line. A system can be included for tipping rejected powder and transporting back into storage. The
finished bags are stacked onto pallets usually using robot palletizers and then stretch wrapped prior to dispatch to the warehouse.
Strechwrapping can be manual, semiautomated, or fully automatic.