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Optimize Production of Whey Protein Concentrate (WPC80)

Optimize Production of Whey Protein Concentrate (WPC80)
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Optimize Production of Whey Protein Concentrate (WPC80) - 1

APPLICATION NOTE OPTIMIZE PRODUCTION OF WHEY PROTEIN CONCENTRATE (WPC80) In-line analysis of total solids and protein in whey protein concentrate (WPC80) production allows for real time, closer to target control resulting in best consistency and quality. Introduction Whey, being a by-product of the cheese manufacturing process, is further processed because of its protein content. WPC80 is the product of concentrating the cheese whey to a protein content of 80% on a dry basis. Membrane filtration is the process used to concentrate the total solids and protein by removing the water. The control is in maintaining a Protein Total Solids ratio of 0.80 in the liquid in order to achieve the level of 80% Protein on a dry basis (PDB) once the product is dried to a powder i.e. 80% protein in powder corrected to 0% moisture. This PDB requirement is a minimum of 80%. In many cases, the protein is higher i.e. 82-85% in order to ensure the minimum specification is met. ProSpect real time in-line analysis The production manager is responsible for the overall production and sets procedures for the operators to control the process ensuring the products are within specification. The desire is to optimize the levels of constituents in the product to avoid rework or giving away product. Challenge Typically, samples are collected and taken to a central or satellite lab for analysis. This can take some time, especially during the solids building phase resulting longer start-up time and possible off-specification product being produced for longer than desired. While waiting for results, production may be stopped/put in recirculation or continued and risking making off-spec product..

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Optimize Production of Whey Protein Concentrate (WPC80) - 2

APPLICATION NOTE PROSPECT IN-LINE PROCESS BENEFITS Solution The ProSpect In-line NIR offers real time in-line analysis of the WPC for total solids and protein provides immediate control of the process. Total Solids This rapid continuous analysis of the process makes for better, closer to target closed loop control, less product “give away” while maintaining the Protein on Dry basis within specification. • R2 = The correlation between the lab reference value and the ProSpect predicted value • ECV = Standard Error of Cross Validation. Error of differences between S ProSpect Predicted and Lab...

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Optimize Production of Whey Protein Concentrate (WPC80) - 3

APPLICATION NOTE PROSPECT FULLY INTEGRATED SYSTEM The ProSpect is a fully integrated system with: • Built-in process computer with touch screen interface • Built-in PLC which includes bi-lateral communication to the plant PLC. ProSpect In-line Process NIR for measurement of fat and protein in cheese milk. - Output of analytical results to the plant PLC via ethernet or analogue - Input of production signal from the plant PLC to automatically select the product that is in production • Built-in power conditioning • Built-in air-conditioned temperature control • Insensitive to vibration •...

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