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Waste Biomass Valor

DOI 10.1007/s12649-017-9862-8

ORIGINAL PAPER

Current Treatment Technologies of Cheese Whey and Wastewater


by Greek Cheese Manufacturing Units and Potential Valorisation
Opportunities
K. Valta1 · P. Damala1 · E. Angeli1 · G. Antonopoulou2 · D. Malamis1 ·
K. J. Haralambous1

Received: 15 June 2016 / Accepted: 13 February 2017


© Springer Science+Business Media Dordrecht 2017

Abstract In the present study, recording and evaluation sustainable energy alternatives to fossil fuels, such as etha-
of the current practices applied for the treatment of waste- nol, hydrogen and biogas. Among them, biogas produc-
water and cheese whey, derived from ten cheese manufac- tion through anaerobic digestion could be a viable solution
turing units in Greece, was performed. Wastewater from since relevant economic analysis revealed that this technol-
cheese manufacturing includes milk losses, wastewater ogy is a profitable and sustainable investment for a Greek
generated by the staff and by the washing of equipment, cheese whey factory.
floors and milk transferring vehicles. Based on the study,
cheese whey is separately collected from the cheese man- Keywords Cheese manufacturing wastewater · Cheese
ufacturing wastewater in almost all the Greek units under whey · Valorisation · Treatment · Greece · Economic
study. Wastewater generated by Greek medium size units evaluation
is mainly treated through the extended aeration activated
sludge process, while wastewater derived from small size
units is either disposed in the sewage system or it is stored Introduction
until its transportation for further treatment. Moreover,
aiming at revealing the potential exploitation opportunities, Globally, the dairy industry is one of the most important
a comprehensive literature review on cheese whey valorisa- processing sectors of the food and beverage industry. In
tion technologies was also conducted. The literature review 2010, Europe was the largest exporter of dairy products in
revealed that cheese whey and whey components can be the world, accounting for approximately 13% of the food
used in a wide range of applications, mainly in the food and drink sector turnover in the EU [1]. The dairy sector
and nutraceutical industry, as they contain several benefi- constitutes one of the most important players of the Greek
cial compounds that can be exploited. In this context, the food and beverage industry. In 2012, 6% of the Greek food
increasing consumer concerns related to health and well- and beverages companies were engaged in the dairy indus-
being have enhanced the acceptability and demand for try [2]. Moreover, the dairy industry sector employed 12%
whey products, such as the whey protein concentrates and of the total number of employees contributing with 17 and
isolates, the whey powder, the reduced lactose whey, etc. 15% to the total turnover and value added of the food and
Moreover, cheese whey can be used for the production of beverage sector respectively [2].
Dairy industry is related to the processing of the raw
milk into products such as fresh liquid milk, pasteurised,
* K. Valta sterilised, homogenised and/or ultraheat treated milk;
katvalta@gmail.com milk-based drinks; cream from milk; dried or concen-
1 trated milk whether or not sweetened; milk or cream in
School of Chemical Engineering, National Technical
University of Athens, 9 Iroon Polytechniou Str., Zographou solid form; butter; yoghurt; cheese and curd; whey; and
Campus, 15780 Athens, Greece casein or lactose. In 2014, across the EU-28, the farms
2
Institute of Chemical Engineering Sciences (ICE-HT/ produced approximately 1.648 billion tonnes of milk,
FORTH), Stadiou, Platani, 26504 Patras, Greece 68.8 million tonnes of which were utilised to produce

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Waste Biomass Valor

5.5 million tonnes of cheese [3]. More than 300 different Methodology
kinds of cheese and other dairy products count millions
of fans all over the world and are officially registered and In the present survey the term ‘wastewater’ is used to
protected as geographical indications or traditional spe- describe the stream that is mainly derived from the clean-
cialties in EU-28 [4]. ing of the equipment, the washing of the plant floor and of
The basic principles of cheese making process are vehicles for the transport of milk and from the staff. CW
common. However, many variations exist in all stages of is considered as a process by-product which is not treated
the process, resulting in the production of many differ- together with the wastewater a priori. The term ‘cheese
ent varieties, often from the same factory [1]. Cheese is whey’ is mainly used to describe the primary whey gener-
produced by coagulation of the milk protein, casein, in a ated during the production of cheese from raw milk while
way that traps milk solids and fat into a curd matrix [1]. the term ‘secondary whey’ refers to whey produced after
Milk is mixed with a starter culture of bacteria and the white cheese production. In order to shed light on oppor-
enzyme rennet, which catalyses casein coagulation [1]. tunities by wastewater and cheese whey management in
In the sequel, the curd is cut into cubes and the mixture Greece, the study was initially focused on recording waste-
is stirred slowly so as to collect as much protein as pos- water treatment applied to the Greek cheese manufacturing
sible into the curd [1]. The cheese yield is approximately sector. Following, international practices related to waste-
10%, with the remaining 90% being a liquid by-product water and cheese whey treatment and valorisation were
called “whey” [1]. The liquid whey is separated and reviewed aiming at revealing potential valorisation technol-
drained from the curd. The curd is salted, pressed, cured, ogies that are unknown in the Greek context. Hence, both
and packaged as cheese [1]. current treatment practices in Greece and trends proposed
In particular, according to Decision 97/80/EC: ‘whey by the scientific community were studied and evaluated.
is a by-product obtained during the manufacture of The same methodology has been also applied for explor-
cheese or casein’. In the liquid phase, whey contains nat- ing waste and wastewater valorisation opportunities by the
ural constituents (on average 4.8% lactose, 0.8% protein Greek meat processing industry [6] and by the Greek olive
and 0.2% fats by weight of the product) which remain oil processing industry [7]. For the needs of the present
when the casein and the majority of the fat have been study, targeted questionnaires were distributed and face-to-
removed from the milk [5]. Fifty years ago, cheese whey face interviews were conducted while further information
(CW) was considered as wastewater from the processing was taken from the Approvals of Environmental Impact
of cheese and it was mainly disposed along with waste- Assessment, officially issued by the Greek Ministry of
water generated by the washing of equipment and floors Environment and Energy. Collected data were related to
of the cheese manufacturing units. In many cases, this both the production process and the wastewater generation
stream was inappropriately disposed to the environment and treatment. In total, ten small and medium cheese man-
without any prior treatment. As a result due to the high ufacturing units operating in Greece were studied. They
organic load of CW serious environmental problems were codified from 10.5–1 to 10.5–10; since numerical
were caused. However, it was later observed that whey code 10.5 characterizes the manufacture of dairy products
can be utilised for the production of white cheese e.g. for under the Statistical classification of economic activities in
“manouri”, “anthotyro”, “mizithra”, “giza”; and also uti- the European Community (NACE Rev.2). Half of the units
lised as animal feed or for protein production. This new are processing less than 15 tonnes of raw milk per day and
direction in whey valorisation resulted in the opening of the rest are treating from 30 to 100 tonnes of raw milk per
a new market opportunity. Thus, nowadays food manu- day for the production of various types of hard, semi-hard,
facturers use whey as a functional ingredient in food and white cheese, etc. Next, mapping, interpretation and assess-
pharmaceutical applications, and as nutrient in dietetic ment of the collected information was implemented.
and health foods [3]. At the same time, a thorough literature review was con-
Although there are various studies and scientific pub- ducted. Both original research papers and review articles
lications related to the valorisation of CW worldwide, a related to the treatment and valorisation of cheese whey
comprehensive study revealing opportunities by cheese were analyzed. In total, more than 300 abstracts’ publica-
manufacturing wastewater and CW management for tions were initially screened, out of which 55 were selected
Greece does not exist. The present study aims at explor- for further study. From the selected papers, 42 were related
ing potential valorisation opportunities from wastewater to the production of energy (biogas, hydrogen, ethanol,
and/or CW generated by Greek cheese manufacturing butanol, electricity) and 13 to the valorisation of cheese
units by taking into account the currently applied meth- whey for the manufacture of valuable products. Addition-
ods for the treatment of both waste streams. ally, methods for the treatment of cheese whey are also
included, which mainly concern the anaerobic digestion

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Waste Biomass Valor

process that results in the production of biogas. Results and goats per day. The cheese-making unit produces some
obtained from the application of the methodology are pre- traditional Greek cheeses i.e. “metsovone”, “metsovella”,
sented in detail below. “graviera” and cheese made from goat milk. The installed
power is equal to 44 kW. For the needs of the process
approximately 20,670 m3 of water are consumed yearly.
Results and Discussion Wastewater includes the wastewater generated by the staff;
water from the washing of the equipment, the floors and the
Present Situation Related to Cheese Whey vehicles that transfer the milk; and milk losses from the
and Wastewater Treatment and Valorisation production process. Whey is separated and transferred
in the Greek Cheese Producing Industries either to pig farms to be used as feed or as substrate of
anaerobic digesters, while the remaining wastewater is dis-
Industrial unit 10.5-1 is a small cheese manufacturing posed to the municipal sewage system. The anaerobic
unit with a capacity of 0.8 tonnes of milk per day which digestion treatment is executed by an independent company
operates 260 days per year. The installed power is equal operating anaerobic digesters close to the industrial unit.
to 15.7 kW motor power and 15 kW thermal power. It is Wastewater other than whey is disposed to the municipal
estimated that 0.2 tonnes of cheese are produced, in a daily sewage system. Industrial unit 10.5-5 is a cheese manufac-
basis. During the production process the milk is stored turing unit with a daily capacity of 4.65 tonnes of milk per
in milk cooling tanks and is then transferred for filtering day for the production of 1 tonne of cheese. The total
purposes to a centrifugal separator. Filtered milk is mildly installed power is equal to 80 kW. The raw materials used
heat-treated while stirring and is then cooled. After cool- in the plant include milk from cows, sheep and goats; salt;
ing, the milk is transferred to tanks where rennet is added and rennet. In total 14 m3 of wastewater is produced in a
and curd is produced. The curd is then separated from daily basis. Moreover, 3.57 tonnes of CW is generated in
whey and ripening of curd takes place and finally cheese is each day, from which 3% is utilised for “mizithra” produc-
maintained in a cooling chamber. Wastewater stream gen- tion while the remainder is provided to a farm as a feed for
erated by the entire process includes whey and wastewater pigs. For the treatment of wastewater, activated sludge pro-
produced after washing of the equipment and floors. Whey cess is applied through sequencing batch reactors (SBR).
is collected in separate tanks and is provided to a nearby The treated effluent is chlorinated and is disposed under-
pig farm as feed while wastewater from the equipment and ground. Industrial unit 10.5-6 is processing up to 15 tonnes
floor washing, is directed to the sewage system. of raw milk per day with an installed power of the plant
Industrial unit 10.5-2 is a small cheese manufacturing being 135.48 kW. Cheese whey is co-treated with wastewa-
unit with a daily capacity of 1 tonne of milk per day, for the ter from the cleaning of the equipment and floors through
production of “feta”, “mizithra”, yogurt and “kefalotiri”. an attached growth aerobic process with trickling filters.
The installed power of the plant is 17.05 kW. In brief, the Treated effluent is disposed to the sewerage system. Indus-
production process includes the delivery and storage of the trial unit 10.5-7 has a daily capacity of treating 30 tonnes
milk; its pasteurisation and standardising processes; pro- of milk from sheep and goats. In total, 10,000 m3 of water
duction of feta cheese; and production of other dairy prod- are consumed to cover the needs of the unit. Thus, high
ucts such as “mizithra”, yogurt and “kefalotiri”. Wastewa- volumes of wastewater are generated including the washing
ter which is generated from the whole production process, water (of the equipment, the floors and the vehicles that
equipment and floors washing are stored to tanks for a short transfer the milk); wastewater generated by the staff and
period and are then led to the wastewater treatment plant milk losses from the production process. Wastewater is
(WWTP) of the municipality. Part from CW is used for the treated in a WWTP which operates at the premises of the
production of “mizithra”. Finally, primary and secondary industrial unit, where preliminary, primary, secondary and
cheese whey (700 kg per day) are delivered to a big farm as tertiary treatment is conducted. More particularly, the treat-
feed. Industrial unit 10.5-3 is also a small cheese manufac- ment process includes screening, flow equalisation, coagu-
turing unit with a daily capacity of 2 tonnes of milk for the lation, air flotation, biological treatment with extended aer-
production of 0.5 tonnes white cheese per day. The power ation activated sludge process and finally, chlorination. A
is equal to 31 kW motor power and 6 kW thermal power. portion of the biological sludge is recycled to the aeration
Wastewater is generated by the washing of the equipment tank to maintain a high mixed-liquor suspended solids
and floors; and from the staff. Whey is collected in separate level, while the remainder is removed from the process and
tanks and is provided to a pig farm as feed, while wastewa- is sent to sludge processing where stabilisation and then
ter is directed to a separate tank from where it is forwarded dewatering of the sludge in drying beds is carried out. CW
for further treatment. Industrial unit 10.5-4 has a daily is collected and provided as animal feed, in a daily basis
capacity of processing 4.6 tonnes of milk from cows, sheep while in the case that whey transportation cannot be

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Waste Biomass Valor

achieved in the same day, CW is kept to refrigerators. Wastewater is mainly generated by washing and cleaning of
Industrial unit 10.5-8 is a large cheese manufacturing unit the production and the packaging processes, as well as by
with a daily capacity of 40 tonnes of milk per day and a the cleaning of the vehicles that transfer the raw material
total installed power of 292.75 kW (motor) and of 39 kW (milk).Wastewater is treated in a WWTP at the premises of
(thermal). The water consumption is approximately the unit. During its treatment process, screening of the
15,000 m3 per year. The raw materials used in the plant are wastewater initially takes place and then it is directed into a
mainly the milk, salt and rennet. The main end-products are flow equalization tank. In the sequel, coagulation and dis-
cream and the traditional Greek cheeses “kasseri” and solved air flotation (DAF) take place and finally, biological
“mizithra”. The milk is received by local producers and treatment by extended aeration of the activated sludge is
after quality control is transferred into tanks. In the sequel, carried out. Secondary treated effluent is subjected to a
milk is cooled at temperature below 6 °C with the aid of a chlorination tank and is then disposed to a stream which
cooling device (chiller), to be used in the production pro- ends to a river. Sludge, generated by the biological treat-
cess of “kasseri” or whey or “mizithra”. The milk from ment process, is treated in drying beds (180 m2). Dewa-
these tanks is pre-heated in a temperature range of 32 °C to tered sludge has a total solids content of approximately
37 °C and then is directed to a cream separator machine. 80%. Industrial unit 10.5-9 is a large cheese manufacturing
The centrifugation process is applied in order to remove unit with a daily capacity of 62 tonnes of milk per day. The
any impurities such as plant fibers, soil, etc, from the milk. motor power of the plant is 710.66 kW which also includes
The fat, which is also separated, is then mixed again with power needs of the WWTP. Additional 193.63 kW power
the skimmed milk. For the production of “kasseri” cheese, for the auxiliary equipment is needed. The products that are
the milk is introduced in tanks and rennet is also added to manufactured are: feta cheese, “mizithra”, “giza”, butter,
cause milk coagulation. The mixture stays in the tanks for “anthotyros”, semi hard cheese and yogurt. Wastewater is
10–20 min in temperatures between 32 to 37 °C. Following, separately treated in a WWTP including DAF, anaerobic
the curd is cut into small pieces and then is heated digestion in an upflow anaerobic sludge blanket (UASB)
(32–37 °C) while is agitated and the mixture stays for reactor and aerobic treatment through extended aeration of
10–15 min. The heating step helps to separate the whey the activated sludge. The excess of sludge is separately
from the curd. Following, the curd is extracted and is then treated in a filter press. Part of produced biogas is utilised
pressed in order to obtain the desired shape. Afterwards the to cover the needs of the unit, while the remainder is burnt.
products are left for ripening for 24–48 h at 14–18 °C in a Whey (6486 tonnes/y) is collected and given to third par-
slightly acidic aqueous environment (pH 5.1–5.4). After- ties for protein production. Industrial unit 10.5–10 is a
wards cutting to the desired dimensions is implemented large cheese manufacturing unit with a daily capacity of
and the curd enters the machine for making the “kasseri”. 100 tonnes of milk per day for the production of “feta”,
There, the cheese mass is heated to 72 °C up 78 °C and salt hard cheese and different types of “mizithra”. The installed
(about 2% by weight) is added. At the final stage inside the power of the plant is 733.11 kW. Water consumption is
“kasseri” machine, moulding is implemented at ambient approximately 75.600 m3 per year. Wastewater generated
temperature. Then the first ripening, which lasts for 7 days, by the washing of the equipment along with the respective
is executed. The products after ripening are rinsed with produced by the staff is co-treated to the WWTP of the
water, dried and covered with paraffin. In the last step, the unit. The WWTP has been designed for treating310 m3 per
“kasseri” is cut into pieces and is stored in coolers (2–4 °C) day and includes screening, flow equalisation, biological
for the final ripening for 3 months. As in the case of “kas- treatment with extended aeration activated sludge process,
seri”, for the production of “mizithra” cheese, the milk, settling and chlorination. In addition, sludge dewatering is
which is kept in cooling conditions, is entering the cream carried out, through sludge filter press. From the other side,
separator in order to remove the cream from skimmed milk. there is no treatment process for CW, which is collected
The cream is then packed and is given for sale. Then the and provided as animal feed. Currently applied wastewater
milk enters the tanks to be heat- treated at 85–90 °C, for treatment methods and ways for disposal of the treated
5 min. The formation of the curd takes place and after effluent of the Greek dairy industrial units under study, are
10 min the curd is removed and is placed to cheesecloths summarised in Table 1.
where salt is added. CW is also removed. Drain takes place As it is noted above, CW is separately collected in
twice and cheesecloth is removed. Then crushing and pack- almost all units studied. Only wastewater and CW gener-
ing into containers is implemented and the final product is ated in industrial unit 10.5–6 are co-treated as a single
refrigerated to 4 °C, until the placement of the product to wastewater stream. CW is used either for the production of
the market for sale. From the operation of the unit, waste- white cheeses by many of the industrial units studied or it
water (100 m3/d) and whey (30 m3/d) are produced. CW is is directly provided as animal feed for pigs. The use of CW
separately collected and is provided as feed in big farms. as animal feed seems to be the most economically feasible

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Table 1  Currently applied wastewater treatment methods and ways of disposal of the treated effluent of the Greek dairy industrial units under
study
Code 10.5 Capacity, Products Wastewater (other than whey) treatment Whey treatment & valorisation
tonnes of milk method applied & disposal of the treated
per day effluent

1 0.8 Cheese Treatment: collection and disposal to septic Valorisation: collection and provision as
tanks animal feed for pigs
Disposal: to the sewerage system
2 1 Feta cheese Treatment: collection to tanks and then led Valorisation (0.7 t/d): production of mizithra
Mizithra to the municipal WWTP and the excess is provided as animal feed
Yogurt Disposal: na*
Kefalotiri
3 2 Cheese Treatment: collection to tanks and then led Valorisation: collection and provision as
for further treatment animal feed for pigs
Disposal: na*
4 4.6 Metsovone Treatment:- Valorisation: collection and provision as
Metsovella Disposal: to the municipal sewerage animal feed for pigs and as feedstock to an
Graviera system anaerobic digestion treatment plant outside
Cheese from goat milk the premises of the unit
5 4.65 Cheese Treatment (14 m3/d): SBR Valorisation (3.57 t/d): 3% used for the
Disposal: underground production of mizithra and the excess is
provided as animal feed for pigs
6 15 Cheese Treatment:- Cheese whey is co-treated with wastewater from the cleaning of the equip-
ment and floors through trickling filters
Disposal: to the municipal sewerage system
7 30 Cheese Treatment Valorisation: collection and provision as
Screening animal feed
Flow equalisation
Oil and grease removal
Biological treatment by extended aeration
activated sludge process
Chlorination of the treated effluent
Collection of the sludge to the stabilisa-
tion tank where sludge stabilisation
under continuous aeration takes place
Disposal: Surface water recipient (river)
8 40 Kasseri Treatment (100 m3/d) Valorisation (30 t/d): collection and provi-
Cream Biological treatment sion as animal feed for pigs
Mizithra The sludge is treated in drying beds
Disposal: Surface water recipient (river)
9 62 Feta cheese Treatment Valorisation (6486 t/year): collection and
Mizithra Flow equalisation provision for protein production
Giza pH control
Butter Anaerobic process through the use of
Anthotyro UASB reactors
Semi hard cheese Biological treatment with extended aera-
Yogurt tion activated sludge process
Settling
10 100 Feta cheese Treatment (310 m3/d) Valorisation: collection and provision as
Hard cheese Screening animal feed
Mizithra Flow equalisation
Biological treatment with extended aera-
tion activated sludge process
Settling
Chlorination

*na not available

option, since pig farms are located close to the cheese man- production of proteins was also recorded, as the currently
ufacturing units which in turns makes daily whey trans- applied method by industrial unit 10.5–10. This unit is a
port easy, even in small quantities. CW valorisation for the medium size unit resulting in the generation of large CW

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Waste Biomass Valor

volumes, which might explain the specific CW use. Finally, the generated wastewater is treated in an UASB reactor,
industrial unit 10.5–4 provides the excess of CW either for followed by an extended aeration activated sludge process.
animal feeding purposes or as a feedstock in an anaero- Finally in industrial unit 10.5–6, the wastewater and CW
bic treatment unit. Different valorisation routes for cheese are co-treated through the attached growth aerobic process
whey in the Greek units studied are presented in Fig. 1. with the application of trickling filters. The applied man-
Apart from CW, wastewater is also generated by the agement for wastewater produced by the operation of the
staff; the washing of the equipment, the floors and the vehi- Greek units studied are presented in Fig. 2.
cles that transfer the milk; including also milk due to milk
losses from the production process. From the Table 1, it Potential Valorisation and Treatment Opportunities
was observed that the existence of more technologically for Wastewater and CW Coming from Greek Cheese
advanced wastewater treatment systems was related to the Producing Industries
capacity of the cheese manufacturing unit. For instance
wastewater generated by the industrial units 10.5–1 (0.8 Anaerobic Digestion Treatment
tpd) and 10.5–4 (4.6 tpd) is directed to sewerage system.
Moreover, wastewater resulting for the manufacturing of Based on the literature review concerning whey and waste-
cheese by industrial units 10.5–2 (1 tpd) and 10.5–3 (2 water treatment and valorisation systems, the anaerobic
tpd) is stored to tanks for a short period and is then led to digestion (AD) process seems to be the most studied tech-
central WWTP. Industrial units 10.5–5, 10.5–6, 10.5–7, nology. Thus, Saddoud et al. [8] applied two-stage anaero-
10.5–8, 10.5–9 and 10.5–10 operate their own WWTP at bic digestion of CW consisting of a stirred tank acidogenic
their premises. The activated sludge process is applied for reactor followed by a CSTR methanogenic reactor. The
the treatment of the generated wastewater at the majority of second reactor was coupled to a membrane filtration sys-
the industrial units 10.5–5 use an SBR 10.5–7, 10.5–8 and tem, in order to remove the soluble solids from the effluent.
10.5–10 use extended aeration. At industrial unit 10.5–9, According to the results of that study, quality characteristics

Fig. 1  Cheese whey manage-


ment in the studied Greek
cheese manufacturing units

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Waste Biomass Valor

Fig. 2  Applied management for wastewater produced by the operation of the studied Greek cheese manufacturing units

of the permeate were satisfactory and below the acceptable The pretreated feedstock was then introduced into the UAF
standards for the disposal through public drains in Tunisia in which the average COD removal achieved was 80–90%.
(chemical oxygen demand (COD) < 90 mg/L, biochemi- The valorisation of different types of agroindustrial
cal oxygen demand (BOD) < 30 mg/L and total suspended wastes through anaerobic co-digestion has been addressed
solids (TSS) < 90 mg/L). Through the two-stage anaero- by many authors as a promising method for achieving both
bic digestion process, high removal efficiency values were waste treatment and renewable energy production. In par-
observed i.e. 98.5, 99 and 100% for COD, ­BOD5 and TSS, ticular, Rico et al. [11] applied co-digestion process using
respectively. Moreover, the daily biogas production rate one-stage UASB reactor with an external settler and efflu-
exceeded 10 times the reactor volume and the methane con- ent recycling for alkalinity supplementation. The process
tent in the biogas was greater than 70%, showing the high demonstrated stable operation when fed with a CW frac-
performance of the process. Diamantis et al. [9] studied the tion of 75% and operated with an applied OLR of 19.4 kg
anaerobic digestion of original CW which was diluted with COD ­m− 3 ­d− 1, achieving 94.7% efficiency removal and a
wastewater, either in an UASB reactor or in a two phase methane production rate of 6.4 m3 ­CH4 ­m− 3 ­d− 1. Critical
AD system, consisting of an acidogenic CSTR followed by biomass washout was observed when the CW fraction in
a UASB reactor, with and without biomass recirculation. the feed increased to 85%. In the same study was found that
Results clearly indicated that the two-stage configuration the use of lower CW fractions e.g. 60%, under high OLR
was superior in terms of process efficiency and methane (28.7 kg COD ­m− 3 ­d− 1) and low HRT values (1.3 d) a sta-
recovery when compared to the single-stage system, while ble operation was also observed achieving a removal effi-
the enhanced acidification process resulted in optimum ciency of 95.1% and the highest methane production rate
operational and performance features, achieving up to 90% of 9.5 m3 ­CH4 ­m− 3 ­d− 1. Based on the authors this method
COD removal and high methane yields [9].Gannoun et al. constitutes an interesting alternative for the co-management
[10] investigated the effect of biological pretreatment on of CW and manure.
the AD of CW through an upflow anaerobic filter (UAF) Bertin et al. [12] also studied the co-digestion of CW
operating at various organic loading rates (OLR) and with cattle manure but using a two-stage configuration pro-
hydraulic retention times (HRT). The pretreatment step was cess. The results showed that the addition of cattle manure
conducted with Lactobacillus paracasei which was growth improved the anaerobic digestion process performance,
on CW, conducting lactose fermentation into lactic acid. while the application of a two stage process exhibited
The organic matter was also precipitated with lime which higher methane yields, compared to the respective of the
resulted in 50% COD reduction and 60% TSS reduction. one stage system. Comino et al. [13] studied the feasibility

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of co-digestion of CW with cattle slurry in a dairy farm. the different alternative schemes tested, FO/RO with NaCl
The results of that study showed that production of methane draw solution, exhibited the most satisfactory results, pre-
from a mix of 50:50 (v/v) of both feedstocks, without pH senting the highest water recovery (77.4%) and whey pow-
adjustment through chemicals, was possible exhibiting a der production (98.9 entity/year), along with a net present
methane yield of 343.43 L ­ CH4/kgVS for OLR of 2.65 gVS/ value (NPV) of $12,347,000 and an inevitable result of
L/d. In the same line, Kavacik et al. [14] explored the pos- 0.8 years payback lower than that of UF/RO.
sibility of biogas production from the co-digestion of CW
with dairy manure either at 25 or 34 °C. The experimen- Other Cheese Whey Wastewater Treatment Process
tal results obtained verified that a co-treatment of different
waste types like manure and CW gives the possibility of Finally, Prazeres et al. [18] utilized a Fenton-like oxida-
treating a waste which cannot be successfully treated sepa- tion system for the treatment of CW wastewater, which
rately. Dareioti and Kornaros [15] had also investigated the had been previously processed either through a coagula-
potential of mesophilic (37 °C) anaerobic co-digestion of a tion-flocculation step with F
­ eCl3, or through a sedimenta-
pretreated mixture of ensiled sorghum, CW and liquid cow tion step with Ca(OH)2 and then an aerobic digestion step.
manure (55:40:5, v/v/v) in a two-stage CSTR system. The In the first case, a COD removal efficiency of 80% was
study was focused on the investigation of the HRT effect on achieved and—depending on the initial concentration of
two different processes where at the first acidogenic step, the reagent—the low retention times may result in almost
biohydrogen production is carried out, while at the sec- complete COD conversion efficiency, within few minutes.
ond stage methane production is conducted. According to Moreover, Ca(OH)2 addition enhanced the removal of
the authors, the highest H­ 2 production rate and yield were Fe(III) from the oxidation treatment, while an increase in
observed at an HRT of 0.5 d during acidogenic stage, while pH from 4.5 to 7.5 led to satisfactory settling properties.
in methanogenic stage, the highest ­CH4 productivity was
observed at the HRT of 16 d. At an HRT of 12 d instability Production of Valuable Products and Compounds
of the methanogenic reactor occurred [15].
Anaerobic treatment may also be combined with aero- From a valorisation point of view, apart from energy pro-
bic processes. Thus, in the study of Frigon et al. [16] whey duction, cheese whey can also result in the production of
wastewater was treated through an anaerobic digestion valuable products and compounds. In particular, based
step, followed by a sequential aerobic treatment step, under on the literature, CW can be considered as a valuable by-
low oxygen concentration. Both processes were conducted product that can be valorized in the food and pharmaceuti-
sequentially in the same vessel, by changing the cycle cal industry, as it contains more than half of the solids pre-
times in the same digester. An increase in either OLR or of sent in the original whole milk, including whey proteins,
the total cycle time (days) resulted in an increase in COD lactose, water-soluble vitamins and minerals [18]. Accord-
removal efficiency, reaching its maximum value of 98% at ing to Mollea et al. [19], cheese whey management can be
0.78 g COD/L/d and a cycle time of 4 d. A second set of accomplished via two main options: either by the recovery
experiments in the frames of the same study showed that of valuable compounds (e.g. proteins and lactose) with the
an improvement in the compartmentalization of the reac- application of suitable technologies, or by the application of
tor where the anaerobic and aerobic biomasses are con- fermentation processes in order to obtain value added prod-
tained, is necessary, in order to enhance the degradation of ucts, such as organic acids, single cell proteins and oils,
whey wastewater through sequential anaerobic and aerobic biopolymers (enzymes, polyhydroxyalkanoates, etc.) and
processes. bacteriocins [20]. In addition to this, when whey perme-
ate (obtained from the ultrafiltration step) is used as a fer-
Membrane Technologies mentation medium, both management options are applied.
Thus, depending on the processing technique that is used,
Another technology system that has been utilized for the many types of whey products can be produced, namely, the
prevention of environmental pollution caused from whey sweet and acid whey powder, the reduced lactose whey,
streams, could be the recovery of water and whey powder the demineralized whey, the whey protein concentrate
from whey. This technique was investigated by Aydiner (WPC) (with varying protein contents), the whey protein
et al. [17], who performed a techno-economical evalua- isolate (WPI), the mineral-concentrated whey (reduced
tion of a CW treatment and valorization process, consist- lactose whey), as well as lactoferrin, lactoperoxidase, gly-
ing of alternative steps such as ultrafiltration (UF), reverse comacropeptide and dairy minerals, such as calcium [21].
osmosis (RO), forward osmosis (FO) and thermolysis (T). Palatnik et al. [22] used microfiltration and tangential ultra-
In this context, three case studies were examined, includ- filtration in order to purify and concentrate caprine cheese
ing UF/RO, FO/RO and FO/T/RO processes steps. Among whey, reaching a protein concentration of 91.4/100 g.

13
Waste Biomass Valor

The concentrate, which was freeze-dried and character- soybean oil on the production of an enzyme (PaE) with
ized, showed good emulsifying properties, and high water plastic-degrading activity by P. antarctica growing on
and oil holding capacity. The functional properties of the lactose or CW. Hence, when soybean oil was used as the
caprine whey proteins were pH-dependent and their rheo- sole carbon sourcethe PaE activity was very low (0.03 U/
logical behavior indicated that the whey concentrate can mL) but increased at 1.79 U/mL when a limited amount of
be used in formulations that require gelation. In general, soybean oil (under 0.5%) was combined with a relatively
the product developed presented similar physicochemical high concentration of lactose (6%). Besides, fermentation
characteristics to commercial dressings with regard to the with lactose fed-batch cultivation combined with periodic
pH, ashes, viscosity, texture and color. The functionality of soybean oil addition resulted in 14.6 U/mL of PaE, after
caprine WPC was also investigated by Sanmartin et al. [23] a 5-days cultivation, while when the lactose was replaced
through the following consecutive processing methods: with CW, PaE production was 10.8 U/mL after a 3-day cul-
thermocalcic precipitation, ultrafiltration/diafiltration and tivation period. Galvão et al. [28] examined different con-
lyophilisation of the retentate. Among the functional prop- ditions of sequential hydrolyses of whey proteins in order
erties examined, only the solubility, emulsifying stability to produce protein hydrolysates with low Phenylalanine
and emulsifying capacity of the concentrates were higher (Phe) contents. For this purpose, trypsin, chymotrypsin and
than those in commercial bovine WPC. Galanakis et al. carboxypeptidase A (CPA) were immobilized/stabilized on
[24] investigated the separation and recovery of compounds special gel matrices and Phe was removed from the hydro-
rich in proteins and sugars from whey substrates, which lysates by the action of CPA, thus providing an adequate
were obtained during the processing of “Halloumi” cheese. source of proteins for phenylketonuria (PKU) patients. In
Experiments of ultrafiltration were conducted under con- this context, proteins were sequentially hydrolyzed to dif-
stant temperature, circulation flux and several transmem- ferent degrees of hydrolysis with trypsin and chymotrypsin
brane pressures. Two approaches were examined, the first employing different enzyme/substrate ratios. The best
using a 100 kDa-polysulphone barrier and the second by results were obtained using chymotrypsin directly to hydro-
combining 20 kDa-polysulphone and 2 kDa-polyethersul- lyze whey proteins and, based on the findings, a kinetic
phone membranes. Based on their findings, the combined model for the hydrolysis of CW proteins with immobilized
treatment optimizes protein recovery (87–90%) in the con- chymotrypsin was proposed, for high-load derivatives.
centrate stream—despite the weaker separation with sug- Sugai et al. [29] investigated yeast strains from several iso-
ars (39–32%)—and the recovered materials could be used lates obtained from raw milk and milk products in terms
as valuable ingredients in yogurt, dairy desserts and meat of their ability to produce glucosylceramide from CW.
products. Folmer Corrêa et al. [25] examined the process The majority of strains that had accumulated a detectable
of enzymatic proteolysis for the release of bioactive pep- amount of glucosylceramide were identified as Kluyvero-
tides. More specifically, a protease preparation from Bacil- myces lactis var. lactis. Depending on the origin of K. lac-
lus sp. was utilised for the hydrolysis of sheep CW and the tis var. lactis strains, variations in the quantity of gluco-
hydrolysates were evaluated for their antioxidant and angi- sylceramide and steryl glucoside produced, were detected
otensin I-converting enzyme (ACE)-inhibitory activities. [29].
During hydrolysis, soluble protein and free amino acids Following, two studies regarding the valorization of CW
increased for up to 4 h. Similarly, the antioxidant activity for the production of other cheese products, will be ana-
of hydrolysates increased 3.2-fold, from 0 (15.9%) to 6 h lysed. Dimitrellou et al. [30] evaluated the performance of
of hydrolysis (51.3%). As previously mentioned, whey can free and immobilized Lactobacillus casei ATCC 393 on
also serve as a food-grade fermentation medium, for the whey protein as starter cultures for the production of pro-
cultivation of producer strains and the production of bacte- biotic of the Feta-type cheese. This was achieved, firstly, by
riocins, which can be used for food bio-preservation. In this ensuring that the probiotic strains can provide health bene-
context, Kumari Garsa et al. [26] examined several pedi- fits at the time of consumption, secondly, by improving the
ocin producing strains, in terms of their capability to pro- quality characteristics of the new products, and, finally, by
duce b-galactosidase, which can be used for the hydrolysis extending the products’ life by suppressing growth of spoil-
of lactose. The authors conducted their experiments using age and pathogenic bacteria. Thus, based on the authors,
response surface methodology experimental design, which whey protein can be used for the production of probiotic
was found to be a powerful tool in optimizing pediocin foods as well as other highly added-value products. Finally,
PA-1 production. Their results indicated that pediocin PA-1 Di Cagno et al. [31] produced low-fat Caciotta-type
production is strongly affected by fermentation conditions cheeses testing the performance of several ingredients (par-
and CW can be used -at industrial scale- as a fermentation tially skim milk, microparticulated WPC, exopolysaccha-
medium for the production of food-grade biopreservatives. rides (EPS)-producing Streptococcus thermophilus ST446,
Moreover, Watanabe et al. [27] investigated the effects of as well as Lactobacillus plantarum (LP) and Lactobacillus

13
Waste Biomass Valor

rhamnosus (LRA) as adjunct cultures) which were used ­H2 production, but it is not sufficient to control and sup-
alone or in combination with each other. The experiments press methane production. Moreover it was found that the
revealed that microparticulated WPC increased the yield biomass appeared to acclimatize to the low pH value, as
of low-fat cheese under increased moisture content, while methanogenesis was restored even at pH 5. Venetsaneas
EPS exhibited satisfactory results, especially in regard to et al. [36] investigated the possibility of biological hydro-
the enhancement of texture characteristics. Moreover, the gen production from CW and subsequent methane genera-
adjunct cultures increased the content in volatile compo- tion from the effluent of the hydrogenogenic process. Mes-
nents (e.g. diacetyl and acetic acid) thus strengthening the ophilic fermentative hydrogen production from undiluted
market acceptance of the low-fat Caciotta-type cheese. CW was investigated at an HRT of 24 h. pH culture was
maintained at a constant value of 5.2 either through alkalin-
Energy Production ity addition or through an automatic pH controller. With
alkalinity addition, hydrogen production rate was
Due to its high content in biodegradable carbohydrates, 2.9 ± 0.2 L/ Lreactor/ d, while the yield of hydrogen pro-
CW may also constitute a promising feedstock for fer- duced was approximately 0.78 ± 0.05 mol H ­ 2/mol glucose
mentative hydrogen [32–48], ethanol [49–58] and butanol consumed. This yield corresponded to the production of
[59] production, as well as for the production of electricity 2.9 L of ­ H2/L CW. At pH controlling experiment, the
through microbial cells [60–62]. All of these options can be hydrogen production rate was 1.9 ± 0.1 L Lreactor/d, while
considered as sustainable energy alternatives to fossil fuels, the yield of hydrogen was 0.61 ± 0.04 mol ­H2/mol glucose
hence, a great number of studies found in the literature is consumed, corresponding to the production of 1.9 L of
focused on this direction. ­H2/L CW. Further conversion of the effluent of the hydrog-
enogenic reactor to methane was conducted in a continuous
Hydrogen Production anaerobic digester, operating at an HRT of 20 d in meso-
philic conditions. Approximately 1 L ­CH4/d was produced,
More specifically, Reyes et al. [32] studied the effect of pH, corresponding to a yield of 6.7 L ­CH4/L of influent. Taking
OLR and HRT οn inhibition of the methanogenic activity into account that a high COD removal was reported (>95%)
in a hydrogenogenic UASB reactor treating CW. This work it was showed that CW could be efficiently used for hydro-
demonstrated that it was possible to control the methane gen and methane production, in a two-stage process. In the
activity in a hydrogen producing reactor using operational same line, Antonopoulou et al. [37] studied the combined
strategies such as reduction of pH and HRT, organic shock hydrogen and methane production from undiluted CW in a
loads and repeated biomass heat treatment. Gomez-Romero two-stage process using a CSTR acidogenic reactor at the
et al. [33] studied the production of biohydrogen by co- first stage and a high-rate periodic anaerobic baffled reactor
digestion of CW with vegetables fruit waste. Results dem- (PABR) at the second methanogenic stage. It was shown
onstrated that the co-digestion of both substrates improves that continuous fermentative hydrogen production from
biohydrogen production process, due to a better nutrient CW at an HRT of 24 h led to a hydrogen yield of 0.9 mol /
balance and improvement of the system’s buffering capac- mol of glucose, corresponding to 2.49 L ­ H2/L of CW.
ity. Vazquez et al. [34] investigated the production of con- Regarding the second stage, the higher methane production
tinuous biohydrogen using powder solution CW, under dif- rate was obtained at an HRT of 4.4 days being 7.06 ± 0.29 L
ferent HRTs (10, 6 and 4 h) and OLRs (92.4, 115.5, 138.6 L/day [37]. Fernández et al. [38] studied the application of
and 184.4 g lactose /L/d− 1) values. The experimental a packed bed reactor (polyurethane foam was applied as
results showed that the highest volumetric hydrogen pro- support material) for the production of hydrogen from CW
duction rate (VHPR) was achieved at the HRT of 6 h, at all permeate, focusing on the effect of OLR. Based on the
OLRs which were tested. The highest VHPR (46.61 mmol results, the decrease in OLR from 18.8 to 6.3 g COD/ L/ d
­H2/ L/ ­h− 1) and hydrogen molar yield of 2.8 mol ­H2/mol resulted in a significant drop in hydrogen production. The
lactose were found at an OLR of 138.6 g lactose/L/d, while obtained results revealed the presence of non-H2 producers,
the lowest VHPR occurred at an OLR of 184.4 g lactose/ L/ Sporolactobacillus sp. and Prevotella, that might have
d. Castello et al. [35] examined the applicability of dark competed for substrate consumption and thus negatively
fermentation for hydrogen production in a UASB reactor affected the prevalence of ­H2 producers microorganisms.
fed with raw and unsterilized CW, and the effect of OLR Despite that, hydrogen generation has been detected during
increase, in hydrogen production performance. The results the entire experiment. In particular, hydrogen production
showed that hydrogen can be produced but in low amounts. was favoured when feeding was interrupted. Moreover, H ­2
For the highest loading rate tested (20 g COD / L/ d), production was increased when higher OLR was applied,
hydrogen production was 122 mL ­H2 / L/ d. It was reported while also maintenance of the pH of the feeding solution at
that operational pH value, is crucial parameter to promote a value of 7.5 was beneficial for the process. Based on the

13
Waste Biomass Valor

specific research, operational conditions and possible pre- production from cheese whey powder (CWP) solution
treatment methods should be further studied so as to focusing on comparison of thermophilic and mesophilic
increase hydrogen production. Seo et al. [39] developed a dark fermentation. The study showed that the thermophilic
pretreatment method for enhancing hydrogen production dark fermentation of CWP solution is a promising approach
from CW through a simple hydrodynamic cavitation (HC) for biohydrogen production provided that the production
system under alkaline conditions. The proposed system rates and yields were improved by simultaneous removal of
provided both the sonication effect but also an increase in products (such as VFAs), using more effective bacterial
the temperature of the solution. Applying the hydrody- culture and optimum operating conditions. Kargi andUzun-
namic cavitation pretreatment for 15 min, a higher hydro- car [45] conducted experiments with diluted CW solution
gen yield (1.89 mol ­H2/mol lactose) was achieved comper- in order to produce hydrogen by electrohydrolysis using
ing to that achieved with other conventional pretreatment photo-voltaic cells (PVC) as source of electricity. Effects of
methods (e.g. heating and sonication). The efficiency of the initial COD concentration on the rate and yield of hydrogen
method was improved when combined with alkaline condi- gas production were investigated using a completely mixed
tions. In this way, the amount of solubilised nutrient was and sealed reactor with aluminum electrodes. The use of
greatly increased and methanogens were completely PVC panels as source of electricity was found to be an
removed, leading to H ­ 2 gas of higher purity (48%) and a effective method for hydrogen gas production by electro-
yield of 3.30 mol ­H2/mol lactose. The authors claimed that hydrolysis of CW. Further improvements in ­H2 gas produc-
the HC pretreatment under alkaline conditions can be used tion might be accomplished by using sequential fermenta-
to efficiently pretreat organic-rich wastewaters, including tion and electro-hydrolysis of high strength CW solution
CW, without any scale-up problem since is an excellent and operating the system under more intensive sunlight.
pretreatment option for ­H2 production. Moreno et al. [40] Perna et al. [46] tested an upflow anaerobic packed bed
explored the potential of a two-stage process (fermentative reactor configuration at different organic loading rates to
and biocatalyzed electrolysis) to reduce the organic load of produce hydrogen using CW.. Results showed that this pro-
CW in parallel with hydrogen production. Overall, the cess could be a feasible and low-cost alternative for real-
combined process resulted in the reduction of COD of the scale applications that should be further studied to improve
effluent, while producing hydrogen at a maximum yield of the efficiency of hydrogen production. Rosales-Colunga
94.2 L ­H2/ kgVS. Rai et al. [41], investigated the optimum et al. [47] studied the fermentative hydrogen production by
concentration of selected trace elements (­Ni+2, ­Fe+2, and E. coli using CW. This was the first work on biohydrogen
­Mg+2) for photo-biohydrogen production by Rhodopseu- production by a genetically engineered E. coli strain, using
domonas BHU 01 strain from the nutrient-poo and VFAs CW as substrate. Azbar et al. [48] investigated continuous
rich spent medium resulting from dark-fermentation of CW anaerobic fermentation processes for ­H2 production from
wastewater by Enterobacter aerogenes MTCC 2822. The CW, under thermophilic conditions and different HRT val-
study showed that CW could be adopted as the effective ues. The experimental results demonstrated that lower HRT
fermentation feedstock employing the dark-fermenting E. values (e.g. 1 day) caused an increase in hydrogen produc-
aerogenes MTCC 2822. Moreover, Alvarado-Cuevas et al. tion rate. The hydrogen percentage in the headspace was
[42] reported through their study that nitrogen sources have not affected by any operational parameters studied.
impact on hydrogen production by Escherichia coli using
CW as substrate. The research revealed that CW is an inex- Alcohols Production
pensive potential raw material for hydrogen production by
fermentative processes, considering its high content of lac- Apart from the production of methane and hydrogen, eth-
tose and lactalbumin; however, this complex protein is not anol production from CW has been also studied by many
accessible for E. coli, and thus additional approaches are authors. Sansonetti et al. [49] studied the feasibility of
needed. Dębowski et al. [43] determined the possibility of bioethanol generation by batch fermentation of ricotta
applying psychrophilic bacteria for hydrogen production in cheese whey (“Scotta”). This substrate was characterised
whey biofermentation process. In this study the effective- by lactose ion of lactose between 4.5 and 5.0% (w/w) and
ness of biohydrogen production from whey powder using lower protein content compared to the traditional CW.
different groups of psychrophilic anaerobic bacteria (Gam- Traditional CW as well as deproteinized whey were also
maproteobacteria class—Rahnella aquatilis (9 strains) and tested in comparison to “scotta”. The microorganism used
Firmicutes phylum: Carnobacterium maltaromaticum, for the fermentation process was the yeast Kluyveromyces
Trichococcus collinsii and Clostridium algidixylanolyticum marxianu and the experiments conducted under anaerobic
which had been earlier isolated from underground water conditions. Based on the results, the scotta is an excel-
(3.7–5 m) and demersal lake water (17 m)), was investi- lent substrate for fermentation achieving complete lactose
gated. Kargi et al. [44] investigated the bio-hydrogen consumption in 13 h and great ethanol yield (97% of the

13
Waste Biomass Valor

theoretical value). Joshi et al. [50] also studied the produc- ­ 3) obtained when using an initial lactose concentration
m
tion of bioethanol from CW fermentation using Kluyvero- of 200 kg/m3. This value is about 4 times higher than that
myces marxianus biofilm. The study showed, that fuel etha- achieved during the fermentation of non-concentrated CW
nol production by fermentation of CW (lactose) can be a and represents thus an interesting alternative to decrease
sustainable route for its valorization, solving the environ- the distillation costs for ethanol production. Silveira et al.
mental pollution problems caused due to its high BOD and [58] studied the production of ethanol from CWP by K.
COD values. Another study using Kluyveromycess marxi- marxianus UFV-3 focusing on a flux analysis of oxido-
anus for fermentative production of bioethanol from CW reductive metabolism as a function of lactose concentra-
was performed by Hadiyanto et al. [51] who examined the tion and oxygen levels. In particular, the study focused on
effect of various temperatures (30, 35, 40 °C) to the ethanol the lactose concentration and the oxygen level that would
yields through fed-batch fermentation experiments. Results maximize ethanol yield. Raganati et al. [59] studied the
showed that the highest biomass and ethanol concentrations feasibility of bio-butanol production by continuous by
were achieved at 30 °C, with μ (0.186/h), Yp/s (0.21 g/g), bioconversion of CW in a continuous packed bed reactor.
and Yx/s (0.32 g/g). Moreover, Diniz et al. [52] studied The CW conversion process was characterized in terms of
the production of ethanol from CWP using Kluyveromy- metabolites production (butanol included), lactose conver-
ces marxianus UFV-3. The results indicated that using K. sion and biofilm mass. The study showed that under opti-
marxianus UFV-3 to convert lactose from CWP into etha- mized conditions, the performances were: butanol produc-
nol is promising since yields close to the theoretical values, tivity 2.66 g/L/h, butanol concentration 4.93 g/L, butanol
were achieved, at wide range of temperatures, pH values, yield 0.26 g/g, butanol selectivity of the overall solvents
and lactose concentrations, all of which are considered production 82 wt%.
crucial to the economic feasibility of using the perme-
ate as a raw material for ethanol production. Akbas et al. Electricity Production Through Microbial Fuel Cells
[53] investigated the improvement of ethanol production by
engineered ethanologenic E. coli to express the hemoglobin Apart from the above Tremouli et al. [60] studied the opera-
from the bacterium Vitreoscilla (VHb) providing evidences tion and characterization of a microbial fuel cell (MFC) fed
that “VHb technology” may be useful for improving the with pretreated (filter sterilized) CW at different organic
production of ethanol from waste and byproducts of vari- loads (0.35, 0.7, 1.5, 2.7 and 6.7 g COD/L respectively)
ous sources. Kadar et al. [54] implemented a method for using n a two-chamber MFC. The best performance of the
bioethanol production from rye and wheat grain by uti- cell was observed at the highest concentration of the CW
lizing the inherent amylase activity from germination of (6.7 g COD/L) corresponding to a maximum power den-
the seed. Simultaneous saccharification and fermentation sity of approximately 46 mW/m2 Antonopoulou et al. [61]
(SSF) was performed to reduce end-product inhibition of investigated the possibility of electricity generation from
the amylases during ethanol fermentation. The results of diluted cheese whey in a two-chamber mediator-less MFC
the study showed that using organic CW as a cheap nutrient without any pretreatment.. In that study was shown that
source, the use of water and chemicals is minimized aiming power generation is possible by using diluted cheese whey
at reduced process costs. Another study was performed by wastewater as energy source with a maximum power den-
Guedes et al. [55] who evaluated the feasibility of bioetha- sity obtained of 18.4 mW/m2 (normalized to the geomet-
nol production from Azorean whey permeate. The study ric area of the anodic electrode, which was 13.8 cm2), cor-
revealed that from a dairy plant that rejected 36,000,000 L responding to a current density of 80 mA/m2 and a MFC
of whey, it is possible to obtain 620,000 L of bioethanol voltage of 0.23 V.. The results showed that pretreatment of
which represents a financial advantage to Azorean econ- CW was necessary in order to minimize the competitive
omy and particularly for the dairy industry. Ozmihci and activity of indigenous microbial cultures contained in CW
Kargi [56] investigated the production of ethanol from and to increase MFC performance [61].
CW powder solution in a packed column bioreactor at dif-
ferent HRTs. The PCBR was found to be a compact and Single Cell Protein Production
effective reactor for ethanol production from CWP solution
with high ethanol yields as compared to the continuous sus- Ghaly et al. [62] studied a mathematical model which
pended cell bioreactors. Dragone et al. [57] examined the described the kinetics of continuous production of single
optimal fermentation conditions for maximizing the etha- cell protein (SCP) from CW using Kluyveromyces fragilis
nol production by Kluyveromyces fragilis from CWP. The which was developed from the basic principles of mass bal-
initial lactose concentration in deproteinized CWP solu- ances. The model takes into account the substrate utiliza-
tion exerted great influence on ethanol production by K. tion for growth and maintenance and the effect of substrate
fragilis, being the maximum product formation (80.95 kg/ concentration and cell death rate on the net cell growth

13
Waste Biomass Valor

and substrate utilization during the fermentation process. regarding bioethanol production using CW, it has been
Results showed that the viable cell mass and lactose con- shown that an initial lactose concentration of 200 g/L in the
sumption ranged from 1.3 to 34.3 g/L and from 74.31 to whey permeate, leads to the maximum ethanol yield pro-
99.02%, respectively. viding the economic viability of the process [66]. However,
the supply chain of CW for bioethanol production is not
Economic Aspects well defined, making effectiveness and implementation of
ethanol production from this substrate limited.
Despite the relative high investment costs, AD is consid-
ered to be one of the most promising and economically
viable processes for treatment and valorization of various
wastes and wastewaters. The payback period ranges from 5 Conclusions
to 16 years, for operation under optimum or not optimized
conditions, respectively, a period that could be signifi- In conclusion, on the basis of the evaluation of data, the
cantly decreased through government financial incentives prevailing CW valorisation practice by the Greek manu-
[63]. Based on the above, AD could be a viable solution facturing units is its provision as feed for pigs. Apart from
for the valorization of wastewaters coming from Greek CW, wastewater is also generated, which is mainly treated
cheese whey factories. For example, Diamantis et al. [9] in wastewater treatment plants in the case of medium scale
reported that for a small-to-medium size cheese produc- cheese manufacturing units. The most commonly applied
tion plant, the application of a two-stage anaerobic diges- method was the extended aeration activated sludge pro-
tion process consisting of an acidogenic CSTR followed cess. Cheese manufacturing units of smaller capacities
by a UASB reactor, could result in a net profit of 0.94 €/ either dispose wastewater directly in the sewerage system
m3 CW. In this line, Spachos and Stamatis [64] conducted or they store it until it is transported for further treatment.
an exergetic and economic analysis of an anaerobic treat- In international level, CW is currently highly utilised either
ment system of whey, installed in one of the biggest dairy for the industrial production of other kind of cheese (e.g.
industries in Greece (producing 150 m3/day of whey). The white cheese) or for the commercial manufacturing of other
produced biogas was subsequently burned and the energy whey derived products (e.g. sweet and acid whey powder,
released was used for steam production for covering the reduced lactose whey, demineralized whey, whey pro-
factory thermal needs. The Net Present Value (NPV) was tein concentrate, whey protein isolate). Apart from those
calculated based on the assumption that the whole capital well-established practices, CW can be processed for the
cost of the investment would be covered by a bank loan production of valuable products and compounds that can
received by the company. The results of the economic anal- be valorised in the food and pharmaceutical industry; and
ysis revealed that the anaerobic treatment of whey is a prof- energy. So far, the anaerobic digestion process that leads
itable and sustainable investment for the company, although to the production of biogas has been extensively studied in
the exergetic efficiency of the system is rather low. Similar scientific publications and applied in large treatment plants.
results were also obtained by Chatzipaschali and Stamatis Excepting methane production, CW has been studied as a
[63] who performed an exergetic and economic analysis for promising feedstock for fermentative hydrogen, ethanol and
the same anaerobic treatment system for which however the butanol production, as well as for the production of elec-
existing steam production was considered to be used for tricity through MFC. Those alternatives need to be further
covering both thermal and electrical needs of the factory. It studied in terms of process feasibility in order to be applied
was shown by the economic analysis that this investment is in industrial scale. However, whey products industrial pro-
profitable for the company, with high savings and incomes duction, whey derived products manufacturing and applica-
even from the first year of its operation. Another economi- tion of anaerobic digestion for CW utilisation can be con-
cally profitable solution for the factory could be the direct sidered as valorisation opportunities which could potential
conversion of the produced biogas to electricity solely, due add valued to the Greek cheese manufacturing sector.
to the current high selling price of electricity to the net-
work. In this case, the electricity production is calculated Acknowledgements The authors would like to thank the European
Social Fund and the Hellenic Ministry of Education and Religious
approximately to 1.5 MW. In all cases though, the scale is a Affairs, Cultures and Sports (Managing Authority) for funding the
significant factor when evaluating the economic feasibility project: FOODINBIO/2915 entitled “Development of an innovative,
of AD systems [65]. compact system that combines biological treatment technologies for
Regarding the other proposed processes for CW valori- the sustainable and environmental management of organic waste
streams that are produced from different types of food processing
sation, it seems that there are a lot of limitations and bar- industries”, in the framework of the Operational Programme Educa-
riers to be overcome in order for the proposed technolo- tional and Lifelong Learning (NSRF 2007–2013).
gies to be applicable in practice. Based on existing studies

13
Waste Biomass Valor

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