PROCESS FOR OBTAINING A DRY MILK FORMULA, A COMPOSITION THAT CAN BE OBTAINED BY THE PROCESS, DRY MIL

专利摘要:
process for obtaining a dry milk formula, composition that can be obtained by the process, dry milk formula and modular system. the present invention relates to a process and system for obtaining a dry milk formula, comprising the steps of (ai) ultrafiltration of an animal skimmed milk composition comprising 70-90% by weight of casein and 10-30% in weight of whey proteins, based on total protein, and (a-ii) ultrafiltration of an animal whey composition comprising 0-25% by weight of casein and 75-100% by weight of whey proteins, based on total protein; or (a-iii) ultrafiltration of a mixture of the compositions of (ai) and (a-ii), (b) preferably, combining the uf retentate originating from step (ai) with the uf retentate originating from step (a-ii); (c) removing polyvalent ions from the uf permeate arising from step (a-i) and/or (a-ii) or (a-iii) to obtain at least one smoothed uf permeate; (d) combination of the at least one smoothed uf permeate originating from step (c) with a uf retentate originating from step (ai) and/or (a-ii), or (a-iii) or ( b) to obtain a combined product; and (ei) drying the combined product originating from step (d) to obtain a dry milk formula, and/or (e-ii) drying any uf retentate originating from step (ai) and/or ( a-ii) or (a-iii) or (b) that is not combined in step (d), and drying any of the smoothed uf permeates that originate from step (c) that are not combined in step (d) , followed by combining dry uf retentate with dry smoothed uf permeate to obtain a dry milk formula.
公开号:BR112015025219B1
申请号:R112015025219-2
申请日:2014-04-03
公开日:2021-08-17
发明作者:John Tobin；Jitti CHIARANAIPANICH；Rudolph Eduardus Maria Verdurmen；Antonius Hendricus Janssen；Olivier Bertrand Rabartin；Raoul Charles Johan Moonen；Martijn Johannes Van Der Hoeven
申请人:N.V. Nutricia；
IPC主号:

专利说明:

[001] The present invention relates to an advanced process for treating skimmed animal milk and animal whey, preferably for the manufacture of dry milk formulas, such as infant formula and other nutritional products for infants, as well as a system designed to implement the process according to the invention. HISTORY OF THE INVENTION
[002] Human milk is considered the 'gold standard' for infant nutrition. The processing of animal milk, eg cow's milk, as it more closely resembles the composition of human milk, is known in the art. Such processing is known in the art as 'humanization' of animal milk. The animal milk humanization process involves changing the casein:whey protein ratio as found in animal milk (eg approximately 80:20 for cow's milk) to the desired ratio for infant nutrition as found in human milk (preferably between 75:25 and 30:70). Furthermore, the mineral content of animal milk is typically higher than that found in human milk. Thus, the humanization of animal milk also involves the reduction of mineral content.
[003] The preparation of products suitable for use in infant nutrition typically involves mixing several individually purified components in the proper proportions, whether wet or dry. Current manufacturing processes require multiple dairy ingredients from intermediate suppliers, including skim milk or a concentrate thereof (including skim milk powder), demineralized whey or a concentrate thereof (including demineralized whey powder), whey protein concentrates or isolates (usually as powders), and pure grade lactose (typically in powder form) to formulate a nutritionally balanced infant formula.
[004] WO 96/08155 describes a process for treating skimmed milk for the manufacture of cheese or milk powders, wherein whey proteins are removed from the skimmed milk by microfiltration and further treatment includes ultrafiltration.
[005] US 5,503,865 discloses a process for treating skimmed milk, comprising microfiltration or ultrafiltration. Its permeate can be demineralized, for example, by ion exchange and/or electrodialysis, in order to make it suitable for use in baby products.
[006] The document US 4497836 discloses a process in which serum is subjected to ultrafiltration, and its permeate is subjected to electrodialysis or ion exchange.
[007] WO 2001/93689 discloses a process in which whey is subjected to ultrafiltration, and its permeate is subjected to diafiltration. The retentate from ultrafiltration is combined with the retentate from diafiltration in the production of infant milk formulas by mixing the combined product with milk powder.
[008] EP 1133238 describes a process in which animal milk is subjected to microfiltration through a membrane having a porosity of 0.1-0.2 micrometers, after which the microfiltration permeate comprising whey proteins is demineralized by electrodialysis. The mineral content of microfiltration permeate passed in electrodialysis is very low, and subsequent fortification with minerals and trace elements is necessary to obtain an infant formula. SUMMARY OF THE INVENTION
[009] It is an objective of the present invention to provide an improved process to prepare or obtain a dry milk formula in which the amount of filtration and separation steps is reduced compared to existing methods, problems related to membrane clogging are reduced and the production in obtaining lactose or milk proteins is improved. This objective, in whole or in part, is solved by the present invention according to the appended claims.
[010] In general, the present invention refers to a process for obtaining a dry milk formula in which the most ideal use is made by filtration and separation technologies. In a preferred embodiment, the present invention relates to a process for obtaining a dry milk formula, preferably for obtaining a dry milk formula which can be further processed into an infant milk formula or a dry milk formula for infant (for human infants). Preferably, the process of the present invention involves ultrafiltration of animal skimmed milk and ultrafiltration of animal whey followed by mixing the ultrafiltration retentates, which are rich in milk proteins and whey proteins respectively. The addition of animal whey to skimmed animal milk alters the protein composition of the skimmed milk, thereby humanizing the skimmed milk to more closely resemble the protein composition of human milk. Both animal skimmed milk and animal whey contain polyvalent ions, fouling contents are reduced in order to make the combination of animal skimmed milk and animal whey suitable as a dry milk formulation for human consumption or as a nutritional formulation for feeding infants humans. In a preferred embodiment, also, monovalent ions are removed from the UF permeate and/or the UF retentate at sufficiently low levels so that the dry milk formula is adapted to feed human infants. Thus, broadly expressed, the present invention relates to a process for obtaining a dry milk formula comprising the steps of ultrafiltration of skimmed animal milk and animal serum, removal of polyvalent ions from at least one UF permeate, and combination of the UF permeate smoothed with the UF retentate, followed by a drying step to obtain the dry milk formula.
[011] The process, according to the invention, employs ultrafiltration for fractionation of casein and animal skim whey proteins and lower molecular weight animal whey constituents (for example, soluble salts, lactose, non-protein nitrogen ( NPN), organic acids). As such, neither animal skimmed milk nor whey need further softening or removal of monovalent ions in the medium which is commonly done in the art, in order to reduce the soluble salt content to a desirably low level, preferably, low enough for infant nutrition preparation. The process according to the invention circumvents the need for the inclusion of extensively softened or demineralized whey proteins from liquid whey protein streams, or the need for external addition of large amounts of dry crystallized lactose for the manufacture of milk powder dry suitable for the preparation of infant nutrition, by employing ultrafiltration of skimmed animal milk and animal whey which are combined in a preferred ratio to humanize the skimmed animal milk.
[012] Lactose that is removed from both animal skim milk and animal whey as an ultrafiltration permeate is subjected to polyvalent ion removal, and preferably monovalent ion removal, and used in the resulting dry milk formula. As such, the mineral content of the resulting formulation can be adapted to levels low enough to allow for the preparation of infant nutrition in accordance with regulatory bodies (eg EU directive 2006/141/EC, North Food and Drug Administration -American 21 CFR Chap. 1 part 107).
[013] Consequently, the present invention relates to a process for obtaining a dry milk formula, comprising the steps of: (ai) ultrafiltration (UF) of an animal skimmed milk composition comprising 70-90% by weight of casein and 10-30% by weight of whey proteins, based on total protein, and(a-ii) ultrafiltration of an animal whey composition comprising 0-25% by weight of casein and 75-100% by weight of whey proteins, based on total protein; or (a-iii) ultrafiltration of a mixture of the compositions of (ai) and (a-ii), (b) preferably, combining the UF retentate originating from step (ai) with the UF retentate originating from step (a-ii); (c) removing polyvalent ions from the UF permeate originating from step (ai) and/or (a-ii) or (a-iii) to obtain at least one smoothed UF permeate; (d) combination of the at least one smoothed UF permeate originating from step (c) with a UF retentate originating from step (ai) and/or (a-ii), or (a-iii) or ( b) to obtain a combined product; and (ei) drying the combined product originating from step (d) to obtain a dry milk formula, and/or (e-ii) drying any UF retentate originating from step (ai) and/or ( a-ii) or (a-iii) or (b) that is not combined in step (d), and drying any of the smoothed UF permeates that originate from step (c) that are not combined in step (d) , followed by combining dry UF retentate with dry smoothed UF permeate to obtain a dry milk formula.
[014] In another aspect, the present invention relates to a modular system for carrying out the process, according to the invention, comprising: (1) an ultrafiltration module, comprising (1a) an inlet to receive a first liquid composition as meant herein and/or a second liquid composition as meant herein, or a mixture thereof, to a first side of an ultrafiltration membrane, (1b) the ultrafiltration membrane,(1c) i, the first outlet for discharging a retentate from the ultrafiltration (UFR) from the first side of the ultrafiltration membrane, and(1d) a second outlet for discharging an ultrafiltration permeate (UFP) from the second side of the ultrafiltration membrane; (2) a polyvalent ion removal module, comprising (2a ) an input for receiving the UFP originating from the ultrafiltration module (1), (2b) means for removing polyvalent ions, and (2c) an output for discharging a smoothed UFP; (3) at least one mixing module, comprising (3a) a first entry a to receive the smoothed UFP originating from the polyvalent ion removal module (2),(3b1) a second inlet for receiving the first liquid composition or a UFR of the first liquid composition and a third inlet for receiving the second liquid composition or a UFR of the second liquid, or (3b2) a second inlet for receiving the mixture of the first liquid composition and the second liquid composition or a UFR of the first liquid composition and a UFR of the second liquid composition, and (3c) an outlet for discharging a recombined product; and (4) a drying module, comprising(4a1) a first input for receiving the UFR originating from the ultrafiltration module (1) and a second input for receiving the smoothed UFP originating from the polyvalent ion removal module ( 2), or (4a2) an inlet for receiving the recombined product originating from the mixing module (3), (4b) drying means, and (4c) an outlet for discharging the dry composition, wherein the first liquid composition is an animal skimmed milk composition comprising 70-90% by weight casein and 10-30% by weight whey proteins, based on total protein, and wherein the second liquid composition is an animal whey composition comprising 0-25% by weight casein and 75-100% by weight whey proteins, based on total protein. LIST OF PREFERRED ACHIEVEMENTS
[015] The invention particularly relates to:1. A process for obtaining a dry milk formula, comprising the following steps: (ai) ultrafiltration (UF) of an animal skimmed milk composition comprising 70-90% by weight of casein and 10-30% by weight of casein proteins. whey, based on total protein, and(a-ii) ultrafiltration of an animal serum composition comprising 0-25% by weight of casein and 75-100% by weight of whey proteins, based on total protein; or (a-iii) ultrafiltration of a mixture of the compositions of (ai) and (a-ii), (b) preferably, combining the UF retentate originating from step (ai) with the UF retentate originating from step (a-ii); (c) removing polyvalent ions from the UF permeate originating from step (ai) and/or (a-ii) or (a-iii) to obtain at least one smoothed UF permeate; (d) combination of the at least one smoothed UF permeate originating from step (c) with a UF retentate originating from step (ai) and/or (a-ii), or (a-iii) or ( b) to obtain a combined product; and (ei) drying the combined product originating from step (d) to obtain a dry milk formula, and/or (e-ii) drying any UF retentate originating from step (ai) and/or ( a-ii) or (a-iii) or (b) that is not combined in step (d), and drying any of the smoothed UF permeates that originate from step (c) that are not combined in step (d), followed by combining the dry UF retentate with the dry smoothed UF permeate to obtain a dry milk formula.2. The process according to 1, wherein the skimmed animal milk comprises 75-85% by weight of casein and 15-25% by weight of whey proteins, based on total protein, preferably about 80% by weight of casein and about 20% by weight whey protein or the skim animal milk composition comprises or is selected from skimmed animal milk, diluted animal skimmed milk, concentrated animal skimmed milk, skimmed milk concentrate powder or reconstituted skimmed milk (optionally diluted).3. The process according to 1, wherein the animal whey composition comprises 0-20% by weight of casein and 80-100% by weight of whey proteins, based on total protein, preferably 0-10% by weight of casein and 90-100% by weight of whey proteins, more preferably 0-5% by weight of casein and 95-100% by weight of whey proteins or the animal whey composition comprises or is selected from animal whey , diluted animal serum, concentrated animal serum, animal serum concentrate powder and reconstituted animal serum powder (optionally diluted). Preferably, the animal serum is or comprises sweet serum and/or acid serum, preferably the animal serum is sweet serum. The process, according to any one of 1 to 3, wherein a UF permeate originating from step (ai) and a UF permeate originating from step (a-ii) are combined prior to said ion removal polyvalents from step (c).5. The process, according to any one of 1 to 4, in which a UF retentate originating from step (ai) and/or (a-ii) is/are concentrated/s prior to the combination of step (b), (d) or drying step (ei) and/or (e-ii); and/or a UF retentate originating from step (a-iii) and/or (b) is/are concentrated/s prior to combining step (d) or drying step (ei) and/or (e- ii), preferably by nanofiltration.6. The process, according to any one of 1 to 5, wherein the UF permeate originating from step (ai) is combined with a permeate originating from (a-ii) prior to removal of polyvalent ion from step (c ), and preferably concentrated after removing the polyvalent ion from step (c).7. The process, according to any one of 1 to 6, in which the smoothed UF permeate originating from step (c) and/or the combined product from step (d) is/are concentrated/s, prior to the combination of step (d) or the drying of step (ei) and/or (e-ii).8. The process, according to any one of 5 to 7, in which the concentration occurs by reverse osmosis and/or nanofiltration.9. The process, according to any one of 1 to 8, wherein polyvalent ion removal from step (c) occurs by electrodialysis, ion exchange, lactose crystallization and/or salt precipitation, most preferably by a combination of nanofiltration , salt precipitation, ultrafiltration and electrodialysis, more preferably, following the sequence of nanofiltration, salt precipitation, ultrafiltration and electrodialysis.10. The process, according to any one of 1 to 9, wherein the smoothed UF permeate from step (c) and/or the UF retentate originating from step (ai) and/or (a-ii) or ( a-iii) or (b) is/are subject to monovalent ion removal, preferably by electrodialysis, nanofiltration, lactose crystallization and/or salt precipitation.11. The process, according to any one of 1 to 10, in which a UF retentate that originates from step (ai) and/or (a-ii), or (a-iii) or (b) and/or a UF permeate originating from step (ai) and/or (a-ii) or (a-iii), and/or smoothed UF permeate originating from step (c) or the combined product from step (d ) is/are heat treated, preferably heat sterilized by DSI, before drying in step (ei) and/or (e-ii); preferably, the combined product from step (d) is heat treated, preferably by DSI, before drying from step (e-i); or preferably any of the UF retentates from step (e-ii) and/or any of the smoothed UF permeates from step (e-ii) are heat treated, preferably by DSI, before drying in step (e-ii) .12. The process according to any one of 1 to 11, wherein the drying of step (e-i) and/or (e-ii) is by spray drying.13. The process, according to any one of 1 to 12, wherein the combined product originating from step (d), the dry combined product from (ei), and/or the dry UF retentate from (e-ii) which is combined with the dry smoothed UF permeate from (e-ii) in step (e-ii) is further processed into a nutritional product to provide nutrition to infants. Preferably, to the combined product originating from step (d) is/are added the appropriate amount/s of fat or oils, edible fiber, optionally lactose, additional vitamins and, optionally, additional minerals.14. The process, according to any one of 1 to 13, wherein the animal skimmed milk composition and animal whey composition from step (a-iii) or the UF retentates that originate from step (ai) and ( a-ii) are combined in a ratio so that a product is obtained having a casein:whey protein weight ratio of between 75:25 to 30:70, preferably between 64:36 to 36:64, more preferably, 60:40 to 40:60 or about 50:50.15. The process, according to any one of 1 to 13, wherein mixing the animal skim milk composition and animal whey composition from step (a-iii) or the combined UF retentate from step (b), or the combined product of step (d), the dry milk formula of (ei) or the dry milk formula of (e-ii) has a casein:whey protein weight ratio of between 75:25 and 30:70, more preferably between 70:30 and 35:65, more preferably between 64:36 and 36:64 or about 50:50.16. The process, according to any one of 1 to 15, wherein the at least one smoothed UF permeate from step (c) is obtained in a single step or polyvalent ion removal treatment.17. The process, according to any one of 1 to 16, in which any UF retentate that originates from step (ai) and/or (a-ii), or step (a-iii) or step (b) is subject to a maximum of two or preferably only one monovalent ion concentration and/or removal step and preferably to one or no polyvalent ion removal step before being subjected to the drying step (ei) or (e-ii) .18. The process, according to any one of 1 to 7, wherein a UF permeate originating from step (ai) and a UF permeate originating from step (a-ii) are combined prior to said combination in step (d), or preferably combined before removing polyvalent ions from step (c).19. The process, according to any one of 1 to 18, in which the UF permeate originating from step (ai) and the UF permeate originating from step (a-ii) are combined in a volume ratio between 10:1 and 1:20, preferably 5:1 and 1:15, more preferably 1:1 and 1:10, most preferably between 1:2 and 1:6.20. The process, according to any one of 1 to 19, wherein the mixture of step (a-iii) is obtained by combining the animal skimmed milk composition and the animal whey composition in a volume ratio between 10: 1 and 1:10, preferably 6:1 and 1:6, more preferably 3:1 and 1:3 or wherein the combination in step (b) comprises the combination of the UF permeate originating from step (ai ) with the UF permeate originating from step (a-ii) in a volume ratio between 10:1 and 1:10, preferably 6:1 and 1:6, more preferably 3:1 and 1:3.21 . The process, according to any one of 1 to 20, in which the UF retentate originating from step (ai), (a-ii), (a-iii) and (b) are rich in casein and proteins of whey compared to the first animal skim milk and second animal whey compositions, and/or the UF permeate that originates from step (ai), (a-ii) and (a-iii) is rich in lactose compared to first compositions of animal skimmed milk and second of animal serum.22. The process, according to any one of 1 to 21, wherein the ultrafiltration, polyvalent ion removal step, monovalent ion removal step, any concentration step and/or any combination step is carried out at a temperature below 40 °C, more preferably between 3 °C and 30 °C, even more preferably between 5 °C and 20 °C, most preferably between 8 and 12 °C. Higher temperatures can increase the risk of wasting dairy products, and lower temperatures can give rise to freezing liquid flows, both of which are undesirable.23. The process, according to any one of 1 to 22, wherein the process operates with 500-2500 kg, more preferably 800-1800 kg, most preferably 1000-1400 kg of dry matter of the skimmed milk composition of a farm animal. entry per hour.24. The process according to any one of 1 to 23, wherein the process according to the invention operates with 1500-5000 kg, more preferably 2200-4000 kg, most preferably 2600-3000 kg of dry matter of composition of animal serum, input per hour.25. The process according to any one of 1 to 24, wherein the process according to the invention preferably operates with 750-4000 kg, more preferably 1000-3000 kg, more preferably 1500-2000 kg of UF retentate obtained per hour of the ultrafiltration of (ai) and (a-ii) or (a-iii). 26. The process according to any one of 1 to 25, wherein the process according to the invention preferably operates with 1000-5000 kg, more preferably 1500-4000 kg, more preferably 2000-2500 kg of permeate of UF obtained per hour from the ultrafiltration of (ai) and (a-ii) or (a-iii).27. The process according to any one of 1 to 26, wherein the ultrafiltration of step (ai) is operated using a volume concentration factor of 1.5-6, preferably 1.7 to 4, more preferably 1 .8 to 3, more preferably about 2, and the ultrafiltration of step (a-ii) is operated using a volume concentration factor of 2 to 15, preferably 3 to 10, more preferably 4 to 7, more preferably about 5 and the ultrafiltration of step (aii-i) is operated using a volume concentration factor of 1.5 to 10, preferably between 2 and 8, more preferably between 3 and 6, most preferably about of 4.28. The process, according to any one of 1 to 27, wherein at least 10 or 20% by weight of the polyvalent ions that are present in said UF permeate (based on its dry weight) is removed, preferably at least 50 % by weight, 60% by weight, more preferably 70% by weight or at least 80% by weight, more preferably at least 90% by weight.29. The process according to any one of 1 to 28, wherein removing the monovalent ion comprises removing at least 10 or 20% by weight (based on dry weight) of the monovalent ions from the composition that has been subjected to a step of monovalent ion removal, more preferably at least 35% by weight or 50% by weight, more preferably at least 60% by weight.30. The process according to any one of 1 to 29, wherein the mixture of (a-iii) comprises a casein:whey protein ratio between 75:25 and 30:70, more preferably between 70:30 and 35 :65, more preferably between 64:36 and 36:64 or about 50:50. DETAILED DESCRIPTION OF THE INVENTION
[016] Today's manufacturers of dry milk (infant) nutritional compositions rely heavily on providing the use of highly purified ingredients, such as purified lactose, whey proteins and demineralized minerals, to produce said compositions by mixing these ingredients source. The present inventors have designed a process for treating non-fat animal milk and animal whey for the manufacture of dry dairy products, in particular dry milk formulations, which largely circumvent the purchase of these high-grade pure ingredients from third parties.
[017] The process of the present invention has several advantages over existing methods of producing dry milk formulas, for example, the loss in production of lactose and whey during processing of skim milk and whey is reduced (for example, during demineralization conventional whey and lactose crystallization), complications related to clogging of membranes and deposition of protein material are reduced, the use of chemicals (externally added) is reduced and the waste water can be recycled in the process to a wide extent. As such, an amount of waste and waste streams is reduced compared to the conventional process. In addition, the need for energy-consuming drying, softening and demineralizing steps is reduced. More in particular, while the production of lactose in the conventional purification methods for producing dairy products is at about 83-85%, the production of lactose can be improved to more than 90% in the process of the present invention. Thus, the process according to the invention has a lower environmental impact compared to the conventional process for the production of dairy products, such as dry formulas or milk powders, in particular nutritional products for feeding infants.
[018] The process, according to the invention, employs two liquid input compositions (ie, step (a-i) and (a-ii)); a first of these is an animal skimmed milk composition comprising 70-90% by weight of casein and 10-30% by weight of whey proteins, based on total protein, and the second of this is an animal whey composition comprising 0-25% by weight casein and 75-100% by weight whey proteins, based on total protein. At one point in the process, the first and second liquid compositions are combined or mixed. Such combination or mixing may take place prior to ultrafiltration, so that the ultrafiltration of step (a-iii) is carried out on a mixture of the first and second liquid composition. Alternatively, blending or mixing may take place after ultrafiltration, so that ultrafiltration is carried out on the first liquid composition in step (a-i) and the second liquid composition in step (a-ii).
[019] In a first advantageous embodiment, the present invention relates to a process for obtaining a dry milk formula, in which preferably a single ultrafiltration step is conducted, comprising the following steps: (a-iii) ultrafiltration of a mixing an animal skim milk composition comprising 70-90% by weight casein and 10-30% by weight whey proteins, based on total protein, and an animal whey composition comprising 0-25% by weight of casein and 75-100% by weight of whey proteins, based on total protein, (c) removal of polyvalent ions from the UF permeate originating from step (a-iii) to obtain a smoothed UF permeate;( d) combining the smoothed UF permeate originating from step (c) with a UF retentate originating from step (a-iii) to obtain a combined product; and (e-i) drying the combined product originating from step (d) to obtain a dry milk formula.
[020] In this first advantageous embodiment, the ratio of casein to whey protein can be influenced by selecting the volume ratio of the animal skim milk composition to the animal whey composition to be ultrafiltered. Thus, in that embodiment, preferably, the animal skim milk composition and animal whey composition from step (a-iii) are combined in such a ratio that a UF retentate product is obtained having a casein:protein weight ratio of serum between 75:25 to 30:70, preferably between 64:36 to 36:64, more preferably 60:40 to 40:60 or about 50:50. Preferably, a volume ratio between 10:1 and 1:10, preferably 6:1 and 1:6, more preferably 3:1 and 1:3 of the animal skim milk composition to the animal whey composition is used for achieve that end. Such UF retentate product is preferably subjected to a monovalent ion concentration and/or removal step before being combined with the smoothed permeate in step (d). Preferably, this UF retentate product is subjected to a single concentration step (e.g., reverse osmosis and/or nanofiltration) during which, also, monovalent ions are removed before being combined with the smoothed permeate in step (d) .
[021] In addition, in this first advantageous embodiment, the removal of polyvalent ions in step (c) to obtain a smoothed UF permeate is followed by a monovalent ion removal step (preferably, by a nanofiltration step and/or diafiltration) before the combination in step (d) takes place. This is especially preferred when ion exchange over monovalent ions is used for smoothing. Smoothed lactose rich UF permeate can be subjected to one, two or three steps of nanofiltration and/or reverse osmosis to remove sufficient amounts of monovalent ion when preparing a dry milk formulation usable to feed a human infant.
[022] In addition, in this first advantageous embodiment, the ultrafiltration of step (aii-i) is operated using a volume concentration factor of 1.5-10, preferably between 2 and 8, more preferably between 3 and 6 , more preferably about 4.
[023] In a second advantageous embodiment, the invention relates to a process for obtaining a dry milk formula, comprising the following steps: (ai) ultrafiltration (UF) of an animal skimmed milk composition comprising 70-90% by weight of casein and 10-30% by weight of whey proteins, based on total protein, and (a-ii) ultrafiltration of an animal whey composition comprising 0-25% by weight of casein and 75-100% by weight of whey proteins, based on total protein; (b) preferably, combination of the UF retentate originating from step (ai) with the UF retentate originating from step (a-ii); (c) removal of polyvalent ions from the UF permeate originating from step (ai) and/or (a-ii) to obtain at least one smoothed UF permeate; (d) combination of the at least one smoothed UF permeate originating from step (c) with at least one UF retentate originating from step (ai) and/or (a-ii), or (b) to obtain a combined product; and (ei) drying the combined product originating from step (d) to obtain a dry milk formula, and/or (e-ii) drying any UF retentate originating from step (ai) and/or ( a-ii) or (b) that is not combined in step (d), and drying any of the smoothed UF permeates originating from step (c) that are not combined in step (d), followed by the combination of the retentate of dry UF with dry smoothed UF permeate to obtain a dry milk formula.
[024] In this second advantageous embodiment, the casein to whey protein ratio can be influenced by selecting the UF retentate volume ratio that originates from (ai) and (a-ii), in step (b) or in step (d) or (e-ii). Thus, in this embodiment, preferably the UF retentates originating from step (ai) and (a-ii) are combined in a ratio such that a UF retentate product is obtained having a casein:protein weight ratio of serum between 75:25 to 30:70, preferably between 64:36 to 36:64, more preferably 60:40 to 40:60 or about 50:50. Preferably, a volume ratio between 10:1 and 1:10, preferably 6:1 and 1:6, more preferably 3:1 and 1:3 of the UF retentates originating from step (ai) and (a-ii ) is used to achieve this goal. The UF retentates originating from (ai) and/or (a-ii) or (b) are preferably subjected to a monovalent ion concentration and/or removal step before being combined with the smoothed permeate in step (d ). Preferably, any or all of these UF retentates are subjected to a single concentration step (for example, reverse osmosis and/or nanofiltration) during which, also, the monovalent ions are removed before being combined with the smoothed permeate in step ( d).
[025] In addition, in this second advantageous embodiment, the removal of polyvalent ions in step (c) to obtain a smoothed UF permeate is followed by a monovalent ion removal step (preferably by a nanofiltration and/or diafiltration step) before the combination in step (d) occurs. This is especially preferred when ion exchange over monovalent ions is used for smoothing. The smoothed lactose rich UF permeate can be subjected to one, two or three steps of nanofiltration and/or reverse osmosis to remove sufficient amounts of monovalent ion when preparing a dry milk formulation usable to feed a human infant.
[026] In a preferred version of this second advantageous realization, the UF retentates originating from (ai) and (a-ii) are (individually or separately) subjected to a monovalent ion concentration and/or removal step prior to combination in step (b). Then, the UF retentate thus treated and combined is combined in step (d) with a smoothed permeate originating from (c). Preferably, smoothing in this step (c) involves removing polyvalent ions from a single UF permeate originating from the combination of the permeates originating from (a-i) and (a-ii) to obtain a smoothed UF permeate.
[027] In an alternative aspect, a process for treating skimmed animal milk and animal whey is mentioned herein, comprising: (a) ultrafiltration (UF) of a mixture of skimmed animal milk and animal whey (sweet whey and/or or acid) on an ultrafiltration membrane having a molecular weight limit of 2.5-25 kDa using a volume concentration factor of 1.5-10, preferably between 2 and 8, more preferably between 3 and 6, more preferably about 4, and obtaining a retentate and a permeate. Optionally, polyvalent ions are removed from the UF permeate originating from step (a), after which the smoothed UF permeate is preferably subjected to a monovalent ion concentration and/or removal step. Optionally, too, the UF retentate is subjected to a monovalent ion concentration and/or removal step. Preferably, the smoothed UF permeate, which also preferably underwent monovalent ion removal, is mixed with the UF retentate that originates from step (a), this UF retentate may or may not have undergone concentration and/or monovalent ion removal to obtain a mixture. Said mixture is preferably dried into a dry milk formula. Preferably, the mixture of animal skimmed milk and animal whey comprises a casein:whey protein ratio of between 75:25 and 30:70, more preferably between 70:30 and 35:65, more preferably between 64:36 and 36 :64 or about 50:50. DEFINITIONS
[028] The term "animal serum" here refers to the liquid by-product obtained from the cheese making industry. The term "whey protein" refers to proteins that are present in said animal whey, such as sweet whey or acid whey. Typically, whey proteins include, but are not limited to, beta-lactoglobulin, alpha-lactalbumin, bovine serum albumin, immunoglobulins, lactoferrin, lactoperoxidase and/or glycomacroprotein.
[029] The term "sweet whey" here refers to the liquid by-product (containing whey protein) of the cheese making industry that makes use of enzymatic cheese curd formation (for example, based on casein precipitation using rennet), this material is readily accessible on the commercial market. Typically, whey proteins present in sweet whey include, but are not limited to, beta-lactoglobulin, alpha-lactalbumin, bovine serum albumin, immunoglobulins, lactoferrin, lactoperoxidase, and glycomacroprotein.
[030] Conversely, the term "acid whey" here refers to the liquid by-product (containing whey protein) of the cheese-making industry that makes use of (edible) acids for cheese curd formation (by example, based on precipitation of casein using acids such as citric acid), this material is readily accessible on the commercial market. Typically, whey proteins present in acid whey include, but are not limited to, beta-lactoglobulin, alpha-lactalbumin, bovine serum albumin, immunoglobulins, lactoferrin, and lactoperoxidase
[031] The term "casein" here refers to casein or caseinate proteins as found in animal skimmed milk such as bovine skimmed milk, more in particular, cow skimmed milk. Preferably, casein or caseinate is in substantially intact, unhydrolyzed form.
[032] By a “retentate of the UF that originates is meant the composition of liquid retentate that is (directly) obtained from the ultrafiltration steps (a-i), (a-ii) and (a-iii). The term also refers to the UF retentates that are transported as (liquid) compositions from the ultrafiltration step to the optional combination step (b) or the combination with a smoothed UF permeate in step (d) to obtain the permeate product /combined retentate or drying in step (e-ii). Regardless of whether it is between obtaining the UF retentate in step (ai), (a-ii) or (a-iii) and the combination in step (d) or drying in step (e-ii), the UF retentate is subject to a concentration step such as reverse osmosis or nanofiltration, the UF retentate term still applies to that UF fraction. Thus, the term UF retentate shall mean to denote the (protein-rich) fraction that is processed according to the steps of the invention from the ultrafiltration step to the point at which it is (re)combined with a UF permeate.
[033] Similarly, the term "UF permeate originating from", here, means the liquid permeate composition that is (directly) obtained from the ultrafiltration steps (ai), (a-ii) and (a- iii). The term also refers to UF permeates that are transported as (liquid) compositions from the ultrafiltration step to the polyvalent ion removal module, means to remove optional monovalent ions and/or optional concentration modulus to eventually obtain the permeate product /retentate combined from (d) or to the drying module for drying in step (e-ii). Regardless of whether, between obtaining the UF permeate from step (ai), (a-ii) or (a-iii) and the combination in step (d) or drying in step (e-ii), the UF permeate is subject to a processing step (eg, a polyvalent ion removal step, a concentration step, reverse osmosis and/or nanofiltration), within the context of the present invention, the term UF permeate still applies to this fraction of UF. Thus, the term UF permeate shall mean to denote the fraction (rich in lactose) that is processed according to the steps of the invention from the ultrafiltration step to the point at which it is (re)combined with a UF retentate.
[034] As used herein, the term "polyvalent ions" refers to ions having a positive or negative charge of two or more. More, in particular, this term refers to Mg2+, Ca2+ and polyvalent phosphate anions (eg, HPO42-, PO43-). The term “monovalent ions” refers to ions having a positive or negative charge of one, in particular, Na+, K+, Cl-.
[035] The term "polyvalent ion removal" means that said polyvalent ions are removed from the permeate of the UF composition that is subjected to the polyvalent ion removal step (step (c)). Preferably, the term "polyvalent ion removal" indicates that at least 10 or 20% by weight of the polyvalent ions that are present in said UF permeate (based on its dry weight) is preferably removed at least 50% by weight , 60% by weight, more preferably 70% by weight or at least 80% by weight, more preferably at least 90% by weight. The percentage by weight (% by weight) of polyvalent ion removal is determined by comparing the total weight of polyvalent ions present after step (c) to the total weight of polyvalent ions present before step (c). Likewise, the term “smoothing” is used to denote the removal of polyvalent ions. Thus, here, “smoothing” and “removal of polyvalent ions” are used interchangeably. Similarly, the term "smoothed" is used to refer to a composition from which polyvalent ions have been removed. Preferably, the term "smoothed" means that at least 10 or 20% by weight (based on dry weight) of the polyvalent ions is removed from the composition by polyvalent ion removal, preferably at least 50% by weight or 60% by weight more preferably 70% by weight or 80% by weight, more preferably at least 90% by weight. "Significant polyvalent ion removal" denotes the removal of at least 70% by weight of the polyvalent ions, preferably at least 85% by weight, more preferably at least 95% by weight or even at least 99% by weight of the polyvalent ions . Polyvalent ion removal or smoothing can be accompanied by monovalent ion removal, either in the same step or in a separate step. Preferably, polyvalent ion removal refers to the removal of at least or all of the calcium, magnesium and/or phosphate species to the extent as defined in that paragraph.
[036] The term “monovalent ion removal” means that said monovalent ions are removed from the composition that is subjected to the monovalent ion removal step (preferably a smoothed UF permeate and/or any UF retentate). In the case not otherwise indicated, preferably at least 10 or 20% by weight (based on dry weight) of the monovalent ions is removed from the composition which has been subjected to a monovalent ion removal step, more preferably at least 35 % by weight or 50% by weight, more preferably at least 60% by weight. Removal of monovalent ions is particularly preferred where the process according to the invention is aimed at manufacturing dry powder formulations intended for use as infant nutrition. "Significant monovalent ion removal" denotes the removal of at least 70% by weight of the monovalent ions, preferably at least 85% by weight, more preferably at least 95% by weight or even at least 99% by weight of the monovalent ions . Preferably, monovalent ion removal refers to the removal of at least or all of the sodium, potassium and/or chlorine to the extent as defined in that paragraph.
[037] The "total solids content" of a liquid composition denotes the percentage by weight of solids present in the composition, based on the total weight of the composition. Solids include all non-volatile, typically everything except water.
[038] The term "rich in" here refers to the situation where an amount of a particular constituent in a (liquid) composition (as % by weight based on dry weight) is greater after a process step, when compared to the content of the same ingredient in the (liquid) composition before said process step. Preferably, the dry weight percentage of an ingredient that is enriched has a content in a flow discharged from the process step of at least 110%, more preferably at least 125%, more preferably at least 150%, based on the percentage by dry weight of said ingredient in the inflow of said process step. An example is the ultrafiltration of skimmed animal milk, in which milk proteins are retained in the retentate, while water and small solutes permeate through the ultrafiltration membrane. As such, the UF retentate is rich in milk proteins, as the milk protein content in the retentate, as % by weight based on the dry weight of the composition, is increased compared to the % by weight of milk proteins in skimmed milk. . Likewise, the UF permeate is rich in small solutes (preferably lactose), as an amount of protein is significantly reduced in the permeate, and lactose makes up by far the largest part of the dry weight of the permeate.
[039] The term "dry milk formula" refers to a dry powder that at least comprises milk proteins, in particular casein and whey, and minerals that are obtained by drying skimmed animal milk and animal whey and are intended for for human consumption. As such, the milk formula is dry and has a water content between 0.5 and 5% by weight, based on the total weight of the formula, preferably between 1 and 4% by weight or 1.5 and 3.5. % by weight. The term "infant dry milk formula" here refers to a dry milk formula that is adapted to feed human infants.
[040] The term "volume concentration factor" or "VCF" is the factor in which a liquid composition is concentrated by filtration, that is, the total volume of the inflow before filtration, divided by the total volume of retentate after filtration, regardless of the total solid content. Thus, when 5 L of a liquid composition is fractionated over an ultrafiltration membrane into a 4 L permeate and a 1 L retentate, this UF process operates with a VCF of 5/1 = 5.
[041] The term "about" indicates a variation (plus and minus) of 10% of the given value, more preferably, 5%. First liquid composition (skimmed animal milk) and second liquid composition (animal serum)
[042] The process, according to the invention, uses at least two sources of milk protein, lactose and minerals, the first being a (liquid) composition of skimmed animal milk comprising 70-90% by weight of casein and 10 -30% by weight whey proteins, based on total protein and the second being an animal whey (liquid) composition comprising 0-25% by weight casein and 75-100% by weight whey proteins, based on total protein.
[043] The first liquid composition is an animal skimmed milk composition comprising milk proteins and lactose. It comprises amounts of minerals that are typical for skimmed animal milk (in the form of monovalent and polyvalent ions). The protein fraction of the first liquid composition comprises 70-90% by weight of casein and 10-30% by weight of whey proteins, preferably 75-85% by weight of casein and 15-25% by weight of whey protein more preferably 80:20% by weight casein to whey protein, based on the total dry weight of the protein fraction. Preferably, the first liquid composition comprises 20-60% by weight protein, more preferably 25-50% by weight protein based on the total dry weight of the first liquid composition. Preferably, the first liquid composition comprises 25-75% by weight lactose, more preferably 40-60% by weight lactose, based on the total dry weight of the first liquid composition. Preferably, the first liquid composition comprises 3-15% by weight minerals, more preferably 5-10% by weight minerals, based on the total dry weight of the first liquid composition. Preferably, the first liquid composition comprises 25-75% by weight of monovalent ions, more preferably 40-70% by weight of monovalent ions, and 25-75% by weight of polyvalent ions, more preferably 30-60% by weight of polyvalent ions, based on the total dry weight of the minerals. Preferably, the first liquid composition has a total solid content between 3 and 15%, more preferably between 6 and 11%, most preferably between 7.5 and 10%. The fat content of skimmed animal milk is typical for skimmed animal milk and is well below non-skimmed milk. In particular, the fat content is below 3% by weight (g/100g of skimmed animal milk), preferably below 2% by weight, more preferably below 1% by weight, most preferably below 0 .5% by weight.
[044] In an especially preferred embodiment, the first liquid composition comprises skimmed animal milk or is skimmed animal milk. Animal skimmed milk (ie non-human skimmed milk), preferably from bovine animals, and can be used as, in diluted or concentrated form, as skimmed milk concentrate or as reconstituted skimmed milk powder (optionally diluted). Most preferably, the first liquid composition is non-fat cow's milk. Animal skimmed milk can be pre-treated before being subjected to the process according to the invention. This pre-treatment comprises or consists of a heat treatment step (eg pasteurization) and/or a filtration step to reduce the bacterial load of the skimmed animal milk. Preferably, skimmed animal milk is not pre-treated with the aim of altering the mineral content or its profile. In particular, skimmed animal milk is preferably not (significantly) softened or subjected to monovalent ion removal prior to entering the present ultrafiltration process.
[045] The second liquid is an animal serum composition comprising protein, lactose and amounts of minerals that are typical for animal serum (in the form of monovalent and polyvalent ions). The protein fraction of the liquid animal whey composition comprises 0-25% by weight of casein and 75-100% by weight of whey proteins, preferably 0-10% by weight of casein and 90-100% by weight of protein of whey, more preferably 0-5% by weight of casein and 95-100% by weight of whey protein, based on the total dry weight of the protein fraction. Preferably, the animal serum composition comprises 5-40% by weight protein, more preferably 7-17% by weight protein based on the total dry weight of the second liquid composition. Preferably, the animal serum composition comprises 40-90% by weight lactose, more preferably 60-80% by weight lactose, based on the total dry weight of the second liquid composition. Preferably, the animal serum composition comprises 3-15% by weight minerals, more preferably 6-12% by weight minerals, based on the total dry weight of the second liquid composition. Preferably, the animal serum composition comprises 40-90% by weight of monovalent ions, more preferably 60-85% by weight of monovalent ions, and 10-60% by weight of polyvalent ions, more preferably 15-40% by weight of of polyvalent ions, based on the total dry weight of the minerals. Preferably, the animal serum composition has a total solid content between 1 and 15%, more preferably between 3 and 10%, most preferably between 4 and 8%.
[046] Animal whey is derived from constitution cheese in which any non-human (skimmed) milk is used, preferably, from skimmed bovine milk, more preferably, cow's milk. Animal serum can be used as such, in diluted or concentrated form, as animal serum concentrate or as animal serum reconstituted (optionally diluted) from a powder. Both sweet whey and acid whey are suitable as a liquid animal whey composition for use in the invention. Most preferably, the second liquid composition is sweet whey. Animal serum, as used, can be pretreated before being subjected to an ultrafiltration step of the process in accordance with the invention. Pre-treatment of animal serum comprises or consists of heat treatment (preferably pasteurization) and/or filtration to reduce the bacterial load of the animal serum. Preferably, animal serum is not pretreated with the aim of altering the mineral content or its profile. In particular, animal serum is not (significantly) softened or subjected to monovalent ion removal prior to entering the present process.
[047] Any pre-treatment of animal skimmed milk or animal whey is not primarily preferred from a cost perspective: any step of this is likely to increase the price of these liquid compositions, while the process of the invention is designed to be capable of processing these liquid compositions without any costly pre-treatment steps in a dry milk formulation. Ultrafiltration step (UF) (a-i), (a-ii), (a-iii)
[048] In the process, according to the invention, the first composition of animal skimmed milk and the second composition of animal whey are subjected to a UF step: (ai) and (a-ii) or (a-iii ). Here, water and small solutes can permeate through the membrane to end up in the UF permeate (UFP), while the UF retentate (UFR) comprises substantially all of the protein, which can be declared to be protein-rich. Small molecules that are able to permeate through the UF membrane include lactose, NPN, monovalent ions and polyvalent ions. Thus, UFP can be declared as rich in lactose.
[049] The ultrafiltration of step (a) can employ any UF membrane known in the art, including ceramic membranes, tubular spiral wound membranes and organic, preferably, the UF membrane is an organic spiral wound membrane. The UF membrane has a molecular weight limit (MWCO) which allows proteins (eg, whey proteins and casein) to remain in the retentate, and allows small solutes (eg solutes having a molecular weight of n°). maximum 25 kDa, preferably maximum 10 kDa) to permeate through the membrane. Preferably, the molecular weight limit is at most 25 kDa, more preferably at most 10 kDa, and preferably at least 2.5 kDa, most preferably at least 5 kDa.
[050] In a preferred embodiment, ultrafiltration involves steps (ai) and (a-ii), which are carried out separately in the first liquid composition and the second liquid composition respectively, and preferably followed by the combination of the UF retentates that are originate from it in step (b). Said combination or mixture in step (b) provides a UF retentate (combined) of which the protein composition is changed in the sense that the weight ratio of casein to whey protein is reduced. The proportion (by weight or volume) in which the UF retentates originating from steps (ai) and (a-ii) are combined is dependent on the exact protein composition of the first input liquid composition, but is primarily determined by the composition of desired protein in the resulting UF retentate and/or the resulting dry milk formula. The person skilled in the art is able to determine the protein composition and concentration of the first input liquid composition or its UF retentate by methods known in the art, for example, by the method according to FT001/IDF 20-3 (for total protein , N*6.38), IDF29-1/ISO17997-1:2004 (for casein) and FT003 (for serum, NCN, casein-free nitrogen *6.38). The exact protein composition of the first input liquid composition (skimmed animal milk), or its UF retentate, may vary between different animals, but even skimmed milk from the same animal (eg cow) may have limited periodic variations. In a particularly preferred embodiment, the dry milk formula is further processed into a nutritional product for human infants, such as infant formulas, weaning infant formulas, follow-on milk or formulas, growth milk or infant milk. In that regard, the resulting casein:whey protein weight ratio after mixing is preferably between 75:25 and 30:70, more preferably between 70:30 and 35:65, most preferably between 64:36 and 36: 64 or about 50:50.
[051] In case the ultrafiltration is by step (a-i) and (a-ii), the mixing of the UF retentate that originates from it can be carried out in liquid flow, thus, offering a liquid mixture. Alternatively, the UF retentate originating from step (ai) and (a-ii) is subjected to drying from step (ei) and (e-ii) before mixing, and a liquid composition and a solid composition are mixed (for example, by dissolving the solid in the liquid) to obtain a liquid mixture, or two solid compositions, preferably powders, are mixed (for example, by dry mixing) to obtain a dry mixture, preferably a powder. In case drying is carried out before mixing, it is preferred that both UF retentates originating from (ai) and (a-ii) are subjected to drying in step (ei) and (e-ii) before mixing, and the resulting solids are dry blended. Preferably, the dry compositions are powders. In an especially preferred embodiment, both streams are liquid during mixing and drying of step (ei) and (e-ii) are carried out in the liquid mixture, after mixing the UF retentate originating from step (ai) and (a-ii).
[052] In another preferred embodiment, the UF of step (a-iii) is performed in a mixture of the (first) liquid animal skim milk composition and the (second) liquid animal whey composition of the present invention. Mixing the first liquid composition with the second liquid composition, thus, is carried out prior to ultrafiltration. Such mixing of the first liquid composition with the second liquid composition allows for changing the protein composition of the first liquid composition, in particular, changing the protein composition of animal skimmed milk. The proportion (weight or volume) in which the second and first liquid composition are mixed is dependent on the exact protein composition of the first input liquid composition, but is primarily determined by the desired protein composition in the resulting UF retentate and, preferably, the resulting dry milk formula.
[053] In both the case that the first liquid composition and the second liquid composition are subjected to ultrafiltration in step (ai) and (a-ii) separately, or UF is by step (a-iii), the retentates of the UF that originating from step (ai), (a-ii) and/or (a-iii) may undergo additional processing steps, either before mixing the UF retentates originating from (ai) and/or (a -ii) or the UF's retentate originating from (a-iii). Such optional additional processing steps include, and are preferably limited to, concentration of the liquid composition (i.e., increasing the protein/water weight ratio, for example by means of (partial) evaporation or filtration techniques, such as nanofiltration or osmosis reverse), heat treatment (eg pasteurization (such as HTST, ESL or UHT) or sterilization (dry heat or moist heat)) and/or supplementation of additional water or other components. Preferably, the UF retentate originating from (ai) and/or (a-ii) is subjected to a concentration step, before or after mixing the UF retentates in step (b), preferably using nanofiltration, optionally , enhanced with diafiltration, and/or reverse osmosis. Carrying out the concentration step on the individual UF retentates has the advantage that more flexibility and fine-tuning is allowed in the process of the invention. Preferably, the UF retentate originating from (a-iii) or (b) is subjected to a concentration step, preferably using nanofiltration, optionally enhanced with diafiltration, and/or reverse osmosis. In an optional embodiment, the drying of step (e-i) or (e-ii) takes place in each of the UF retentates originating from UF of the first and second liquid composition separately, prior to mixing. In an especially preferred embodiment, the additional processing steps that can be performed on the UF retentates of (a-i) and (a-ii) before mixing them do not include any polyvalent ion removal step or any step that fractionates the proteins. Mixing (as in step (b))
[054] Mixing the first liquid composition with the second liquid composition before (a-iii), or combining the UF retentates originating from (ai) and (a-ii) in step (b) can be performed by any means known in the art, such as "in a tube" (i.e., by joining two tubes into a single outlet tube), in a tank or (balancing vessel), in an agitated vessel, or by any industrial mixer or melter. In case two liquid streams are mixed, dynamic mixing or static mixing can be employed. In case two dry streams (eg two powders) are mixed, a dry caster such as a rubber caster, a paddle caster, a drum caster and a vertical caster can be employed. Preferably, the mixing step is carried out in two liquid streams, preferably "in a tube" or in a balance tank. The proportion in which the first composition of animal skim milk is mixed with the second composition of animal whey before (a-iii), or mixture of the UF retentate originating from (ai) and (a-ii) in step (b) is conveniently influenced by controlling the flow of inlet compositions. Polyvalent ion removal (step (c))
[055] Ultrafiltration of the first composition of animal skimmed milk and the second composition of animal whey in (ai) and (a-ii), or their mixture (in step (a-iii)) yields at least one permeate of ultrafiltration (UFP) comprising (or rich in) lactose. At least one of the UF permeates originating from step (a) is smoothed in step (c) to obtain at least one smoothed UF permeate, which is subsequently combined in step (d) with any of the ultrafiltration retentates of step (The). In step (c) of the process, according to the invention, polyvalent ions are removed from any of the UF permeates that originate from step (a). In case the ultrafiltration is by step (ai) and (a-ii), two UF permeates are obtained. In case the ultrafiltration is by step (a-iii) in mixing the first liquid composition and the second liquid composition, a permeate of UF is obtained. Thus, at least one of the UF permeates originating from UF of the first liquid composition and the UF permeate originating from UF of the second liquid composition is subjected to polyvalent ion removal from step (c), or the UF permeate originating from (a-iii) is subject to polyvalent ion removal from step (c).
[056] In case two UF permeates are obtained in the ultrafiltration of step (ai) and (a-ii), the UF permeates that originate from it can be combined before step (c), or step (c) be performed on at least one of the UF permeates, that is, on only one of the UF permeates or on each of the UF permeates separately. In case two UF permeates are obtained from ultrafiltration in step (ai) and (a-ii), both UF permeates originating from it are subjected to polyvalent ion removal in step (c), preferably UFP1 and the UFP2 are combined before step (c) into a single UF permeate, so that one UF permeate is smoothed in (c).
[057] The removal of polyvalent ion from step (c) allows the removal of (significant) amounts of polyvalent ions. Preferably at least 10 or 20% by weight, or preferably 50% by weight, more preferably at least 70% by weight or at least 80% by weight, most preferably at least 90% by weight of the polyvalent ions are removed. Thus, the smoothed UF permeate comprises at least 50 wt% less polyvalent ions, preferably at least 70 wt% less, more preferably at least 80 wt% less, more preferably at least 90 wt% less polyvalent ions , when compared to the inlet UF permeate originating from step (a).
[058] The smoothing of at least one of the UF permeates that originates from the UF of step (a-i) and/or (a-ii) or (a-iii) is preferably accompanied by or followed by the removal of monovalent ions. Preferably, the monovalent ion removal step causes the removal of significant amounts of monovalent ions. Preferably at least 10 or 20% by weight of the monovalent ions is removed, more preferably at least 35% by weight or at least 50% by weight, most preferably at least 60% by weight of the monovalent ions is removed. Removal of monovalent ions (such as from at least one UF permeate originating from step (c) and/or at least one or all UF retentates originating from step (ai) and/or (a-ii) or (a-iii) or (b)) is especially preferred in case the dairy product obtained by the process according to the invention is further processed into a nutritional product suitable for infant nutrition.
[059] Polyvalent ion removal and optionally monovalent ion removal can be performed using any known technique, such as electrodialysis techniques, ion exchange, salt precipitation, lactose crystallization, membrane filtration, such as nanofiltration, optionally, enhanced with diafiltration, or combinations thereof. The preferred polyvalent ion removal technique is ion exchange. In the context of the present invention, polyvalent ion removal, optionally combined with monovalent ion removal, also includes the crystallization of lactose from a liquid UF permeate originating from step (ai) and/or (a-ii) or (a-iii) and simultaneously keeping (significant amounts of) the polyvalent ions and, preferably, (significant amounts of) the monovalent ions in the solution. The crystalline lactose obtained is considered to be a smoothed UF permeate in the context of the present invention, as it originates from the UF of step (a) and has (significant amounts of) the polyvalent ions removed.
[060] The process of the invention generates at least one or two UF permeates (from (a-i) and (a-ii)), or from (a-iii). In case two UF permeates are obtained, they are preferably combined before being subjected to polyvalent ion removal (ie smoothing), which may be followed by monovalent ion removal. In a more costly embodiment, the two UFP permeates of (a-i) and (a-ii) are separately subjected to polyvalent ion removal and optionally monovalent ion removal, to obtain two smoothed UF permeates which can subsequently be combined. Each of the smoothed UF permeates can then be used in the recombination of step (d), preferably the smoothed UF permeate originating from (ai) and the smoothed UF permeate originating from (a-ii) are mixed prior to combining in step (d) or are simultaneously blended during step (d). Each of the UF permeates originating from the UF of step (ai) and/or (a-ii) or (a-iii) may undergo additional processing steps before being subjected to step polyvalent ion removal ( ç). Such optional additional processing steps include, preferably, are limited to, concentration of the liquid flow (i.e., increasing the lactose/water weight ratio, for example, by means of evaporation or (partial) filtration techniques, such as nanofiltration or reverse osmosis), heat treatment (eg pasteurization (such as HTST, ESL or UHT) or sterilization (dry heat or moist heat)) and/or supplementation of additional water or other components. Concentration can also be carried out during smoothing in step (c) or during optional monovalent ion removal, eg during nanofiltration, optionally enhanced with diafiltration.
[061] It is preferred that the removal of polyvalent ions from at least one (or preferably all) of the UF permeates originating from step (ai) and/or (a-ii) or (a-iii) is performed by exchange of ion. Preferably, this step is followed by subjecting at least one or all of the smoothed UF permeates to nanofiltration (NF) in order to concentrate them and also remove (significant amounts of) monovalent ions from them. Using this sequence of steps, the smoothed UF permeate from which (significant amounts) monovalent ions are removed is then combined with any of the UF retentates in step (d) or dried and combined in step (e-ii) . During ion exchange, polyvalent ions (eg, Mg2+, Ca2+, PO43-) are replaced by monovalent ions (typically, Na+, K+, Cl-), and during nanofiltration, these monovalent ions permeate through the nanofiltration membrane, so that the separation of lactose and monovalent ions is carried out. Preferably, nanofiltration is enhanced with diafiltration, i.e., at least once an additional volume of water is added to the NF retentate, and the diluted NF retentate is subjected to NF again. Conveniently, NF permeate, comprising monovalent ions, can be used to regenerate the ion exchange column(s).
[062] It is especially preferred that the removal of polyvalent ions from at least one (or preferably all) of the UF permeates originating from step (ai) and/or (a-ii) is carried out by a combination of steps comprising nanofiltration , salt precipitation and precipitate removal. Preferably, this combination of steps also comprises electrodialysis. Most preferably, removal of polyvalent ions is carried out in the following order: nanofiltration, salt precipitation and precipitate removal. Preferably, precipitate removal is followed by an additional nanofiltration step (preferably enhanced with diafiltration) or by electrodialysis, more preferably it is followed by electrodialysis. The salt precipitation step is primarily aimed at removing polyvalent ions, in particular phosphate ions such as calcium phosphate and magnesium phosphate, and can be achieved by creating suitable conditions under which the calcium ions precipitate from the rich liquid in lactose. These conditions include adding a strong base such as sodium hydroxide, adjusting the pH to a neutral pH such as between 6 and 8, and raising the temperature to between 70 and 90 °C, followed by lowering the temperature to between 5 and 30°C. Also, calcium and magnesium levels will decrease under these precipitation conditions. Subsequently, precipitates can be removed by any technique known in the art (eg filtration, centrifugation). Especially suitable for removing precipitates is an ultrafiltration step. It is preferred that the resulting polyvalent ion depleted UF permeate(s) is further desalted in an additional nanofiltration step and/or an electrodialysis step, more preferably in a step of electrodialysis. Any type of electrodialysis, as known in the art, can be employed. The result is a smoothed lactose-rich UF permeate as mentioned in step (c), which can be combined in step (d) with a UF retentate originating from step (ai) and/or (a-ii ), or (a-iii) or (b) to obtain a combined product. Combination step (d)
[063] Any or all of the smoothed UF permeates originating from step (c) are combined in step (d) with any of the UF retentates originating from step (ai) and/or (a-ii) or ( a-iii) to obtain a combined product. Thus, (i) the smoothed UF permeate that originates from (ai) and/or (a-ii) (either separated or combined, preferably combined), or (ii) the smoothed UF permeate that originates from ( a-iii) is added to any of the UF retentates that originate from step (ai) and/or (a-ii) or (a-iii). Thus, the at least one smoothed UF permeate originating from step (c) is combined with the UF retentate originating from (ai) and/or (a-ii) or (a-iii) or step (b )..
[064] Each of the smoothed UF permeates comprises lactose. As the person skilled in the art will realize, an amount of any of the smoothed UF permeates that must be recombined with any of the UF retentates may depend on the desired amount of lactose in the final dairy product, the amount and purity of lactose in each of the smoothed UF permeates originating from step (c), which are subjected to the combination of step (d), and the amount of residual lactose present in any of the UF retentates originating from step (a). In a preferred embodiment, at least 70% by weight, preferably at least 80% by weight, more preferably at least 90% by weight or even at least 95% by weight, more preferably at least 98% by weight of the lactose that is obtained in the UF permeate(s) originating from step (a) it is combined in step (c) with the UF retentates originating from step (a). The lactose content in a liquid composition can be readily determined by one skilled in the art, for example, enzymatically or by HPLC.
[065] Each of the smoothed UF permeates and each of the UF retentates may undergo additional processing steps prior to the combination of step (d). UF retentate originating from (ai) and/or (a-ii) or (a-iii) or step (b) may be subject to additional processing steps before subjecting it to the combination of step (d) . These additional processing steps include, preferably are limited to, concentration of the liquid flow (i.e., increasing the protein/water weight ratio, for example, by means of (partial) evaporation or filtration techniques, such as nanofiltration or reverse osmosis ), heat treatment, eg pasteurization (such as HTST, ESL or UHT) or sterilization (dry heat or moist heat)) and/or supplementation of additional water or other components. Preferably, the UF retentate originating from (ai) and/or (a-ii) or (a-iii) or step (b) is subjected to a concentration step after the ultrafiltration of step (a) and before the combination of step (d), preferably using nanofiltration, optionally enhanced with diafiltration, and/or reverse osmosis.
[066] In an especially preferred embodiment, the UF retentate originating from (ai) and/or (a-ii) or (a-iii) or step (b) is not subject to any polyvalent ion removal step after the ultrafiltration of step (a). Preferably, the UF retentate originating from (a-i) and/or (a-ii) or (a-iii) or step (b) is not subject to electrodialysis, ion exchange and salt precipitation. In an optional embodiment, the drying of step (e-i) or (e-ii) occurs prior to the combination of step (d) and the drying of step (d). Prior to the combination of step (d), any of the smoothed UF permeates can undergo additional processing steps. Such optional additional processing steps include, preferably, are limited to, concentration of the liquid stream (i.e., increasing the lactose/water weight ratio, for example, by means of (partial) evaporation or filtration techniques, such as nanofiltration or reverse osmosis), heat treatment (eg pasteurization (such as HTST, ESL or UHT) or sterilization (dry heat or moist heat)) and/or supplementation of additional water or other components. Concentration can also be carried out during smoothing of step (c) or during monovalent ion removal, eg during nanofiltration, optionally enhanced with diafiltration. In an optional embodiment, the drying of step (e-i) or (e-ii) takes place prior to the combination of step (d). Drying step (e-i) or (e-ii)
[067] The process, according to the invention, involves a drying step (ei) or (e-ii) that is performed in one or more UF retentates that originate from step (ai) and/or (a- ii) or (a-iii) or step (b) and at least one of the smoothed UF permeates originating from step (c), or in the combined product originating from step (d), preferably, the drying of step (ei) is carried out on the combined product originating from step (d). Drying can take place before the combination of step (d) and/or after the combination of step (d). In case drying takes place after blending, the combined product originating from step (d) is preferably dried to a powder. In case the drying occurs before blending, the one or more UF retentates originating from step (a) and at least one of the smoothed UF permeates originating from step (c) are dried separately, all preferably into a powder . Alternatively, drying can also occur prior to the combination of step (d) in one of the one or more UF retentates originating from step (a) and at least one of the smoothed UF permeates originating from step (c ), preferably in a powder, and the dry composition, preferably in the form of a powder, is recombined with the remaining liquid composition. As such, an additional drying step is preferably carried out to dry the combined product originating from step (d) in order to obtain a dry formula.
[068] Drying can be performed by any means known in the art, for example, spray drying, bed drying (fluidized), drum drying, freeze drying, roller drying etc. In an especially preferred embodiment, drying is carried out using spray drying, optionally preceded by partial evaporation of the liquid (e.g. by nanofiltration, reverse osmosis, evaporation).
[069] In an especially preferred embodiment, the drying of step (e-i) occurs after the combination of step (d), since this order of steps needs less amount of drying steps to obtain a dry formula; only one in the combined product originating from step (d). As such, the UF retentate originating from (ai) and/or (a-ii) or (a-iii) or step (b), and the liquid smoothed UF permeate originating from step (c) is combined with the liquid UF retentate mixture in step (d), after which the combined product is dried in step (ei), preferably spray dried. Here, only one drying step is required in the manufacture of dry formula, preferably an infant formula base powder. Usually, more drying steps are needed, such as drying a composition containing casein or drying skim milk, drying a composition containing whey protein and drying lactose. Drying, like spray drying, is a costly procedure, which is typically performed at high temperatures, such as above 150 °C or even above 180 °C. Reducing an amount of drying (by spray) to a single step greatly improves process efficiency.
[070] The drying step (e-ii) involves drying any UF retentate that originates from step (ai) and/or (a-ii) or (a-iii) or (b) that is not combined in step (d), and drying any of the smoothed UF permeates originating from step (c) that is not combined in step (d), followed by combining the dry UF retentate with the dry smoothed UF permeate to obtain a dry milk formula. For example, if the UF retentate originating from (b) is combined in step (d), it is subsequently dried in step (e-i), and not dried and combined in step (e-ii).
[071] When the drying of step (e-i) or (e-ii) occurs after the combination of step (d), the combined product can undergo additional processing steps before drying. Such optional additional processing steps include, preferably are limited to, concentration of the liquid stream (i.e., increasing the protein/water weight ratio, for example, by means of (partial) evaporation or filtration techniques, such as nanofiltration or osmosis reverse), heat treatment (eg pasteurization (such as HTST, ESL or UHT) or sterilization (dry heat or moist heat)) and/or supplementation of additional water or other components. In an especially preferred embodiment, the additional processing steps that can be carried out on the combined product prior to drying in step (e-i) do not include any polyvalent ion removal step or any step that fractionates the proteins.
[072] The drying of step (e-i) or (e-ii) obtains a dry formula, preferably in the form of a powder. In the context of the present invention, the dry formula has a water content of at most 10% by weight, preferably 0-8% by weight, more preferably 2-4% by weight, based on the total weight of the composition. . The dry formula can be further processed into nutritional products, preferably products suitable for feeding infants.
[073] The process, according to the invention, produces a dry milk formula, preferably in the form of a powder. In a preferred embodiment, such dry milk product is further processed into a nutritional product suitable for providing nutrition to a human infant, in particular an infant between 0 and 36 months of age. Further processing typically comprises adding additional ingredients to the dairy product as known in the art, in particular one or more selected from vitamins, minerals, lipids, prebiotics, probiotics, lactose. Where appropriate, these ingredients may also be added to any of the UF retentates or UF permeates that originate from step (a), or (b) the smoothed UF permeate that originates from step (c) and the combined product that originates from step (d) before drying, or even from any of the first and second liquid input compositions. The person skilled in the art will be aware of the essential and beneficial ingredients for infant nutrition, and how they are best blended with the protein fraction. Further processing of the dry milk formula preferably comprises one or more of homogenization, heat treatment, wet and/or dry mixing of one of the ingredients mentioned above.
[074] Regardless of the combination of lactose in any of the smoothed UF permeates originating from step (c) with any of the UF retentates originating from step (a) or (b), additional lactose supplementation may be necessary to meet the requirements for infant nutrition.
[075] The process, according to the invention, provides sufficient removal of polyvalent ions and preferably monovalent ions, by virtue of the ultrafiltration of step (a) and the removal of polyvalent ion of step (c), so that all minerals are at or below their level needed for infant nutrition. In case the content of a particular mineral is below the required level, preferably that mineral is added because it is on target (eg EU directive 91/321/EEC, or EU directive 2006/141/EC, Administration Agency US Food and Drug Administration 21 CFR Ch. 1 part 107).
[076] The process, according to the invention, provides residual water at various points, for example, the drying step and optionally as nanofiltration permeate, as reverse osmosis permeate. In a preferred embodiment, such waste water, optionally after further purification, for example by reverse osmosis, is recycled into the process according to the invention, for example used to dilute or reconstitute the first liquid composition and/or the second liquid composition or as diafiltration water. INTERMEDIATE PRODUCTS
[077] The process of the present invention generates several intermediate products: 1) the combined UF retentates that originate from step (a-i) and (a-ii); 2) a combined product of the smoothed and retentate UF permeate from step (d); and 3) a dry blended product of step (ei) or (e-ii) in the case of a dry infant milk formula is meant to be obtained. Intermediate product 1)
[078] Intermediate product 1 is obtained by separately subjecting the UF retentates originating from (ai) and (a-ii) to a step of nanofiltration and combining their fraction (comprising protein) (i.e., the nanofiltration retentate which originates from it). UF retentates are preferably combined in a weight or volume ratio between 3:1 and 1:3.
[079] Intermediate Product 1 is characterized by (based on the total dry weight of the composition): a protein content between 40 and 52% by weight, wherein casein and whey are present in a proportion by weight that is between 70: 30 and 30:70, lactose in an amount between 35 and 50% by weight, and the presence of the following minerals: magnesium in an amount between 0.01 and 0.30% by weight, calcium in an amount between 0.80 and 1.70% by weight, phosphorus in an amount between 0.60 and 1.50% by weight, sodium in an amount between 0.10 and 0.60% by weight, chlorine in an amount between 0.05 and 0. 60% by weight and potassium in an amount between 0.60 and 1.50% by weight. Preferably, this product comprises NPN in an amount between 1.50 and 3.30% by weight, preferably between 1.90 and 3.0 and fat in an amount between 2.0 and 3.50, preferably between 2.30 and 3.30 and ash in an amount between 4.0 and 10.0% by weight. Preferably, intermediate product 1 is liquid.
[080] More preferably, intermediate product 1 is characterized by (based on the total dry weight of the composition): a protein content between 42 and 50% by weight, wherein casein and whey are present in a proportion by weight that is between 65:35 and 35:65, lactose in an amount between 37 and 46% by weight, and the presence of the following minerals: magnesium in an amount between 0.05 and 0.20% by weight, calcium in an amount between 0. 95 and 1.50% by weight, phosphorus in an amount between 0.60 and 1.30% by weight, sodium in an amount between 0.20 and 0.45% by weight, chlorine in an amount between 0.15 and 0.40% by weight and potassium in an amount between 0.70 and 1.20% by weight. Intermediate product 2)
[081] Intermediate Product 2 is obtained by separately subjecting the UF retentates originating from (ai) and (a-ii) to a concentration step (in this case, nanofiltration), combining the concentrated UF retentate (comprising protein ) (i.e., the nanofiltration retentate originating from it) and combining the liquid composition thus obtained with the smoothed and concentrated UF permeate (i.e., the UF permeates originating from (ai) and (a-ii) were combined after UF, subjected to ion exchange and concentrated by nanofiltration).
[082] Intermediate Product 2 is characterized by (based on the total dry weight of the composition): a protein content between 16 and 24% by weight, wherein casein and whey are present in a proportion by weight that is between 70: 30 and 30:70, lactose in an amount between 65 and 80% by weight, and the presence of the following minerals: magnesium in an amount between 0.01 and 0.25% by weight, calcium in an amount between 0.20 and 0.80% by weight, phosphorus in an amount between 0.40 and 0.80% by weight, sodium in an amount between 0.20 and 0.80% by weight, chlorine in an amount between 0.30 and 0. 90% by weight and potassium in an amount between 0.30 and 0.90% by weight. Preferably, this product comprises NPN in an amount between 1.30 and 2.80% by weight, preferably between 1.50 and 2.60 and fat in an amount between 0.5 and 2.0, preferably between 0.75 and 1.70 and ash in an amount between 2.0 and 8.0% by weight. Preferably, intermediate product 2 is liquid. Intermediate product 3)
[083] Intermediate Product 3 is a dry milk formula to feed a human infant aged 0 - 36 months, as a follow-on formula or infant formula, which is obtained by drying (spray) the intermediate product 2 to which adequate amounts of additional nutrients are added to reach their target levels. Said nutrients include dietary fiber (in particular, galacto-oligosaccharides and/or fructo-oligosaccharides), minerals (when necessary), lactose (when desired), vitamins, fats. The dry formula contains between 1.0 and 3.0% by weight of moisture. FIGURE
[084] The Figure depicts the preferred embodiments of the system, according to the invention. With reference to the included Figure, the system according to the invention is described as follows. SYSTEM
[085] The present invention also refers to an apparatus or system specifically designed to implement the process, according to the invention. The system according to the invention is preferably a modular system, in which at least three, preferably at least four modules are in fluid connection with each other, with the option that the fluid connection(s) ) can be closed when and where necessary. Here, each module can be a separate unit or two or more modules can be integrated as a single unit. Preferably, each module is a separate unit and is distinguishable as such in the system.
[086] The system, according to the invention, is arranged to receive two incoming liquid compositions (i.e., the skimmed animal milk composition and the animal whey composition, as defined herein) and to discharge a solid composition (eg a dry milk formula). Furthermore, additional liquid and/or solid compositions can be received by the system or discharged from the system.
[087] The system, according to the invention, comprises an ultrafiltration module (1), comprising an ultrafiltration membrane (1b). The first module is designed to receive the first liquid composition (i.e., the animal skimmed milk composition as defined herein), or a mixture of the first and second liquid compositions, via a first inlet (1a) to a first UF membrane side (1b). Furthermore, the ultrafiltration module (1) comprises a first outlet (1c) for discharging an ultrafiltration retentate (UFR) from the first side of the UF membrane (1b) and a second outlet (1d) for discharging an ultrafiltration permeate ( UFP) on the second side of the UF membrane (1b).
[088] The UF membrane has two sides, one for receiving the first liquid composition, or a mixture of the first and second liquid compositions, and discharging the UFR, and one for discharging the UFP. The retentate is discharged from the same side of the UF membrane (1b) as the first liquid composition, or a mixture of the first and second liquid compositions, is received, and the UF permeate is discharged from the other side of the UF membrane. The UFP thus comprises only the material that has permeated through the UF membrane (1b). The UF membrane (1b) employed in the ultrafiltration module (1) can be any UF membrane known in the art, including ceramic membranes and organic spiral wound membranes, preferably, UF membrane (1b) is a spiral wound membrane organic. The UF membrane (1b) has a molecular weight limit that allows proteins, such as whey proteins and casein, to remain in the retentate. Preferably, the molecular weight limit is at most 25 kDa, more preferably, at most 10 kDa, and preferably at least 2.5 kDa, most preferably at least 5 kDa.
[089] Optionally, the system, according to the invention, comprises a second ultrafiltration module (10), comprising a second ultrafiltration membrane (10b). The second ultrafiltration module (10) is designed to receive the second liquid composition (i.e. the animal serum composition as defined herein) via a first inlet (10a) to a first side of the second UF membrane (10b ). Furthermore, the second ultrafiltration module (10) comprises a first outlet (10c) for discharging a second ultrafiltration retentate (UFR) from the first side of the second UF membrane (10b) and a second outlet (10d) for discharging a second ultrafiltration permeate (UFP) from the second side of the second UF membrane (10b). The second UF membrane (10b) employed in the ultrafiltration module (10) can be any UF membrane known in the art, including ceramic membranes and organic spiral wound membranes, preferably UF membrane (10b) is a spiral wound membrane organic. The UF membrane (10b) has a molecular weight limit that allows proteins such as whey proteins and casein to remain in the retentate. Preferably, the molecular weight limit is at most 25 kDa, more preferably at most 10 kDa, and preferably at least 2.5 kDa, most preferably at least 5 kDa.
[090] The system, according to the invention, comprises a polyvalent ion removal module (2) to remove polyvalent ions from one or more ultrafiltration permeates (UFPs) originating from the ultrafiltration module (1) and optionally from the ultrafiltration module (10). The polyvalent ion removal module (2) comprises an inlet (2a) for receiving the one or more UFPs, means for removing polyvalent ions from the UFP (2b), and an outlet (2c) for discharging a smoothed UFP. The polyvalent ion removal module (2) removes (significant amounts of) polyvalent ions (ie, ions having a positive or negative charge of two or more) from the UFP, and can also remove (significant amounts of) monovalent ions from the UFP . Preferably, the polyvalent ion removal module (2) comprises means for removing (significant amounts of) polyvalent ions and means for removing (significant amounts of) monovalent ions. In case the means to remove (significant amounts of) polyvalent ions and the means to remove (significant amounts of) monovalent ions are both present, these means can be a single means, capable of removing polyvalent and monovalent ions, or preferably two means separated, one capable of removing polyvalent ions (2b) and one capable of removing monovalent ions (2f). The two means for removing separate ions can be present in two distinct units within the module (2), wherein an output (2d) of the first unit (2b), preferably for removing polyvalent ions, is in fluid connection with an input ( 2e) from the second unit (2f), preferably to remove monovalent ions, and the outlet (2c) is arranged to discharge a smoothed UFP from the second unit (2f).
[091] Any known technique to remove polyvalent and optionally monovalent ions can be used as a means to remove polyvalent ions (2b) and optionally a means to remove monovalent ions (2f). Conveniently, the ion removal unit(s) is(are) selected from an electrodialysis configuration (comprising ion exchange membranes and means for applying an electrical potential difference over said exchange membranes of ion), an ion exchange configuration (comprising at least one column filled with anionic and/or cationic resins), a salt precipitation configuration, a nanofiltration membrane, optionally with an additional inlet to receive diafiltration water, or combinations thereof. In a preferred embodiment, module (2) comprises at least one ion exchange column comprising anion and/or cation exchange resins as polyvalent ion removal unit (2b) and a nanofiltration membrane as ion removal unit monovalent (2f). In an especially preferred embodiment, module (2) comprises at least a nanofiltration membrane, a salt precipitation configuration and a means for precipitation removal (preferably an ultrafiltration membrane), more preferably module (2) further comprises an electrodialysis setup. More preferably, module (2) comprises, in the following order placed in series, at least a nanofiltration membrane, a salt precipitation configuration, a means for removing precipitation (preferably an ultrafiltration membrane) and a configuration of electrodialysis.
[092] In the system, according to the invention, the polyvalent ion removal module (2) is arranged between the ultrafiltration module(s) (1 and optionally 10) and the mixing module (3 ).
[093] The system, according to the invention, comprises a mixing module (3) to mix at least two liquid streams, at least two solid streams (for example, powders) or at least one liquid stream and at least one stream solid, preferably to mix at least two liquid streams. The mixing module (3) preferably allows mixing of the UF retentate originating from the ultrafiltration module (1), the UF retentate originating from the ultrafiltration module (10) and the smoothed UF permeate originating from the polyvalent ion removal module (2).
[094] In a first preferred embodiment, the mixing module (3) is designed to mix the UF retentate originating from the ultrafiltration module (1), the UF retentate originating from the ultrafiltration module (10) and the smoothed UF permeate originating from the polyvalent ion removal module (2). Thus, in the first preferred embodiment, the mixing module (3) is designed to receive a smoothed UF permeate that originates from the polyvalent ion removal module (2) (either as liquid or solid) via a first inlet ( 3a), the UF retentate originating from the ultrafiltration module (1) (either as a liquid or solid) through a second inlet (3b) and the UF retentate originating from the ultrafiltration module (10) (either as liquid or solid) via a third inlet (3d). The mixing module (3) further comprises an outlet (3c) for discharging a recombined product (whether as liquid or solid).
[095] In a second preferred embodiment, there are two mixing modules, a mixing module (30) for mixing the first liquid composition with the second liquid composition and for discharging the mixture of the first and second liquid compositions, and a mixing module (3) to mix the mixture of the UF retentate originating from the ultrafiltration module (1) and the UF retentate originating from the ultrafiltration module (10) with the smoothed UF permeate originating from the UF removal module polyvalent ion (2). In the second preferred embodiment, the first mixing module (30) is designed to receive the first liquid composition via a first inlet (30a) and the second liquid composition via a second inlet (30b), and to discharge the mixture. of the first and second liquid compositions via an outlet (30c). Thus, the first mixing module (30) comprises a first inlet (30a) and a second inlet (30b) for receiving liquid compositions and an outlet (30c) for discharging a mixed liquid composition. The second mixing module (3) is designed to receive the smoothed UF permeate originating from the polyvalent ion removal module (2) (either as a liquid or solid) via a first inlet (3a) and the mixing of the UF retentate originating from the ultrafiltration module (1) and the UF retentate originating from the ultrafiltration module (10) (either as liquid or solid) through a second inlet (3b), and to discharge the product recombined via an output (3c). Thus, the second mixing module (3) comprises a first inlet (3a) and a second inlet (3b) for receiving liquid and/or solid compositions and an outlet (3c) for discharging a recombined liquid or solid composition.
[096] In the mixing module(s) according to the invention, mixing can be carried out by any method known in the art. Mixing can be carried out merely by combining two or more compositions. The mixing module(s) may further comprise mixing means. The mixing means can be any means suitable for mixing two compositions known in the art, as "in a tube" (i.e., by joining two or more inlet tubes into a single outlet tube), in a tank or vessel ( equilibrium), in an agitated vessel, or by any industrial mixer or melter known in the art. Suitable mixing means include means for mixing two liquid compositions, for example dynamic mixing or static mixing, or for mixing two solid compositions (for example two powders), for example a dry melter, such as a rubber melter, a paddle caster, a drum caster and a vertical caster, or a liquid composition and a solid composition, preferably for mixing two liquid compositions. In an especially preferred embodiment, the mixing means is "in a tube" or in a balance tank.
[097] The mixing module (3) and optional mixing module (30) can be arranged in the system before the ultrafiltration module (1) or after the ultrafiltration module (1). In case the mixing module (30) is arranged before the ultrafiltration module (1), the first liquid composition and the second liquid composition are mixed before ultrafiltration. In case the mixing module (3) is arranged after the ultrafiltration modules (1) and (10), the first and second liquid compositions are each ultrafiltered separately before mixing the UF retentates originating from the modules of ultrafiltration (1) and (10).
[098] The system, according to the invention, preferably comprises a drying module (4), which is arranged for drying at least one liquid composition. The drying module (4) is designed to receive a liquid composition (eg the recombined product) via an inlet (4a) to the drying means (4b), and to discharge a solid composition via an outlet ( 4c) of the drying means (4b). The drying means (4b) may be any suitable means for drying a liquid composition known in the art, for example, a spray dryer, a (fluidized) bed dryer, a drum dryer, a freeze dryer, a dryer bearing etc. In an especially preferred embodiment, the drying means (4b) is a spray dryer.
[099] The drying module (4) can be arranged in the system before the mixing module (3) or after the mixing module (3), as long as it is arranged after the ultrafiltration module (1) and ultrafiltration module ( 10) optional. In case the drying module (4) is arranged between the ultrafiltration module (1) and the optional ultrafiltration module (10) and the mixing module (3), at least one of the ultrafiltration retentates originating from the ultrafiltration (1) and optionally (10) is dried before mixing. In case the drying module (4) is arranged after the mixing module (3), the ultrafiltration retentates are first mixed and then the UF retentate mixture originating from the ultrafiltration module (1) and the UF retentate originating from the ultrafiltration module (10) is dried.
[0100] Optionally, the system, according to the invention, comprises additional drying module(s), each for drying at least one liquid stream. Each drying module is designed to receive a liquid composition via an inlet to the drying means, and to discharge a solid composition via an outlet to the drying means. The drying means can be any suitable means for drying a liquid composition known in the art, for example, a spray dryer, a (fluidized) bed dryer, a drum dryer, a freezing dryer, a roller dryer etc. . In an especially preferred embodiment, the drying means is a spray dryer. An additional drying module can be arranged in the system before the mixing module (3) and after the second ultrafiltration module (10), preferably in case the first drying module (4) is arranged before the mixing module (3 ) and after the first ultrafiltration module (1). As such, the ultrafiltration retentates discharged from both the ultrafiltration modules (1) and (10) are dried prior to mixing in the mixing module (3).
[0101] In a first preferred embodiment, the system, according to the invention, comprises two ultrafiltration modules (1) and (10). The output (1c) of the first ultrafiltration module (1) is in fluid connectivity with the input (3b) of the mixing module (3), and the output (1d) is in fluid connectivity with the input (2a) of the mixing module. polyvalent ion removal (2). The output (10c) of the second ultrafiltration module (10) is in fluid connectivity with the input (3d) of the mixing module (3), and the output (10d) is in fluid connectivity with the input (2a) of the mixing module. polyvalent ion removal (2). The output (2c) is in fluid connectivity with the input (3a) of the mixing module (3), and the output (3c) is in fluid connectivity with the input (4a) of the drying module (4). The inlets (1a) and (10a) are arranged to receive liquid compositions into the system (e.g., skimmed animal milk and animal whey) and the outlet (4c) is arranged to discharge a solid composition from the system (e.g., a dry milk formula). Especially preferred is the module (2) comprising a polyvalent ion scavenger unit (2b), preferably at least one ion exchange column, and a monovalent ion scavenger unit (2f), preferably a nanofiltration membrane.
[0102] In a second preferred embodiment, the system, according to the invention, comprises two mixing modules (3) and (30). The outlet (30c) of the first mixing module (30) is in fluid connectivity with the inlet (1a) of the ultrafiltration module (1). The output (1c) is in fluid connectivity with the input (3b) of the second mixing module (3), and the output (1d) is in fluid connectivity with the input (2a) of the polyvalent ion removal module (2) . The output (2c) is in fluid connectivity with the input (3a) of the second mixing module (3), and the output (3c) is in fluid connectivity with the input (4a) of the drying module (4). The inlets (30a) and (30b) are arranged to receive liquid compositions into the system (e.g., skimmed animal milk and animal whey) and the outlet (4c) is arranged to discharge a solid composition from the system (e.g., a dry milk formula). Especially preferred is that module (2) comprises a polyvalent ion scavenger unit (2b), preferably at least one ion exchange column and a monovalent ion scavenger unit (2f), preferably a nanofiltration membrane.
[0103] The system, according to the invention, may comprise additional modules or additional aspects, as described here below.
[0104] In a further preferred embodiment, the system, according to the invention, comprises one or more concentration modules for concentration of (a) liquid stream(s). This concentration module comprises an inlet for receiving a liquid composition, a means for concentrating, a means for concentrating and an outlet for discharging a concentrated liquid composition. Any known concentration technique can be used as a means for concentration. Conveniently, the medium for concentration is selected from an evaporation configuration (for example, when increasing temperature and/or reducing pressure) or a membrane filtration configuration (for example, a reverse osmosis membrane or a membrane nanofiltration). A concentration module can also be combined with the polyvalent ion removal module (2) in order to carry out concentration during monovalent ion removal (eg using optionally enhanced nanofiltration with diafiltration).
[0105] In a further preferred embodiment, the system, according to the invention, comprises means for recycling (waste) water from outflows to inflows. Waste water can be obtained from the drying module (4), the polyvalent ion removal module (2) (eg as nanofiltration permeate) and each of the concentration modules (eg as reverse osmosis permeate) . Preferably, at least one of the drying module (4), the polyvalent ion removal module (2) and a concentration module further comprises an additional outlet for discharging water from the module, more preferably at least one of the concentration modules understands this additional output. More preferably, the drying module (4), the polyvalent ion removal module (2) and each of the concentration modules each comprise an output. The waste water can be used to dilute any of the incoming liquid compositions, for example, the first liquid composition and/or the second liquid composition, or it can be used as diafiltration water, for example, in the polyvalent ion removal module ( two). Preferably, the first ultrafiltration module (1) and/or the second ultrafiltration module (10) and/or the polyvalent ion removal module (2) further comprises an additional inlet for receiving waste water. The person skilled in the art appreciates that the outlets for discharging waste water are in fluid connectivity with the inlets for receiving waste water, preferably through a conduit, in which optionally one or more collection tanks or one or more additional purification means ( eg reverse osmosis membranes) are integrated.
[0106] In a further preferred embodiment, the system according to the invention comprises means for heat treating a liquid composition. Any of the liquid compositions which are carried through the system in accordance with the invention can be suitably heat treated using any heat treatment technique known in the art. Conveniently, the system according to the invention comprises at least one heat treatment module arranged to heat treat a liquid composition. Such a heat treatment module comprises an inlet for receiving a liquid composition and a means for heat treatment, a means for heat treatment and an outlet for discharging a liquid composition heat treated. Any heat treatment technique known in the art can be used as a means for heat treatment, such as a pasteurization or sterilization setting. Preferably, a plate heat exchanger (PHE) and/or a direct steam injection/infusion (DSI) is used as the heat treatment medium.
[0107] The system, according to the invention, may further comprise cooling means, preferably to allow the system to operate at a temperature below 15 °C, more preferably below 12 °C. The person skilled in the art will understand that freezing the liquid stream is highly undesirable, in that the temperature must be kept high enough for the different liquid streams to remain liquid. Typically, the cooling medium allows the system to operate at a temperature of at least 2 °C. Each module can have a separate cooling means, or a central cooling means can be installed to regulate temperature throughout the system. Preferably, the cooling means are selected from the cooling tower, heat exchanger (plate or tubular, preferably in connection with the PHE used for heat treatment), coolant cooling (heat transfer fluid), transferable ice.
[0108] In case a module comprises a nanofiltration membrane, nanofiltration can be optionally enhanced by diafiltration. To perform diafiltration, the module needs an additional inlet to receive water to the first side of the nanofiltration membrane, in order to allow for dilution and re-filtration of the nanofiltration retentate. In a preferred embodiment, the polyvalent ion removal module (2) comprises this additional input (2d).
[0109] All filtration modules preferably comprise means to facilitate permeations of solvent and optionally small solutes through the membrane. Any means known in the art can be used to effect easy permeation, such as using gravity or applying transmembrane pressure (TMP). TMP can be performed by pressurizing the first side of the membrane (ie, the retentate side) or by depressurizing the second side of the membrane (ie, the permeate side). Suitably, a pump using hydrostatic pressure to pressurize the first side of the membrane and/or a pump generating suction on the second side of the membrane is used. Suitable pumps include centrifugal pumps and positive displacement pumps, preferably centrifugal pumps are used.
[0110] In the system, according to the invention, the different modules are interconnected, that is, the output of one module is in fluid connectivity with the input of another module, preferably through a conduit. The different modules of the system, especially the ultrafiltration module (1), the mixing module (3) and the drying module (4), can be interconnected in different configurations, as long as the system is willing to implement the process, according to the invention.
[0111] The system, according to the invention, preferably operates with 500-2500 kg, more preferably 800-1800 kg, more preferably 1000-1400 kg of dry matter of the first liquid composition, preferably of skimmed animal milk , input per hour. The system according to the invention preferably operates with 1500-5000 kg, more preferably 2200-4000 kg, more preferably 2600-3000 kg dry matter of the second liquid composition, preferably animal serum, inlet per hour . The system according to the invention preferably operates with 750-4000 kg, more preferably 1000-3000 kg, most preferably 1500-2000 kg of UF retentate discharged from the ultrafiltration module(s) per hour of both input streams combined. The process according to the invention preferably operates with 1000-5000 kg, more preferably 1500-4000 kg, most preferably 2000-2500 kg of UF permeate discharged from the ultrafiltration module(s) per hour of both input streams combined.
[0112] The invention will now be illustrated by several examples which should not be understood to limit the invention in any way. EXAMPLES Example 1
[0113] 400 kg of pasteurized skim cow's milk with a casein to whey protein weight ratio of 80:20 was subjected to ultrafiltration by a membrane of UF Synder ST3838 having a MWCO of 10 kDa. The ultrafiltration was carried out at a temperature between 8 and 10 °C, with a transmembrane pressure of 2 bar and a VCF of about 2. The permeate was collected at a flow rate of up to 260 L/h. 208 kg of a UF permeate (UFP1) and 211 kg of a UF retentate (UFR1) were obtained. The compositions of the incoming skimmed milk and the ultrafiltration products are given in table 1. The slight increase in the total weight of the final products (UFR1 and UFP1) compared to the incoming skimmed milk can be attributed to the dilution of the seasonal dead volume during the transition from product to water during wash station. As can be seen from the data in Table 1, the UF retentate is rich in protein, while the UF permeate is rich in lactose. Table 1: Compositions from Example 1 (in % by weight based on total dry weight)

Example 2
[0114] 1000 kg of sweet whey pasteurized with whey proteins as the only protein source was subjected to ultrafiltration through a UF Synder ST3838 membrane having a MWCO of 10 kDa. Ultrafiltration was carried out at a temperature between 10 and 12 °C, and with a transmembrane pressure of 2 bar and a VCF of about 5. The permeate was collected at a flow rate of up to 400 L/h. 818 kg of a UF permeate (UFP2) and 195 kg of a UF retentate (UFR2) were obtained. The compositions of the incoming sweet whey and the ultrafiltration products are given in Table 2. The slight increase in the total weight of the final products (UFR1 and UFP1) compared to the incoming sweet whey can be attributed to the dilution of the station dead volume during the transition from product to water during wash station. Table 2: Compositions from Example 2 (in % by weight based on total dry weight)

Example 3
[0115] UFP1 from example 1 and UFP2 from example 2 were combined in a weight ratio of 20/80 to obtain 799 kg of a combined UFP. The combined UFP was subjected to ion exchange to produce a smoothed UFP and subsequently to enhanced nanofiltration with diafiltration. The ion exchange employed an anionic resin charged with chlorine ions and a cationic resin charged with sodium ions to exchange the polyvalent ions for sodium and chlorine. Ion exchange operated at a pH between 2.4 and 4.3 and a temperature between 5 and 10 °C. Nanofiltration employed an NF Synder NFX 3838 membrane having a MWCO of 150-300 Da, operated at a temperature between 8 and 22 °C, and with a transmembrane pressure of 2 bar. The permeate was collected at a flow rate of up to 400 L/h. Two diafiltration volumes of 200 L of water were added sequentially when the total solids content of the retentate reached 20%. The smoothed UFP was concentrated to a final total solids content of about 20%. 178 kg of a smoothed UFP concentrate was obtained as a nanofiltration retentate (NFR1), together with 1225 kg of a nanofiltration permeate (NFP1). The compositions of the input combined UFP and nanofiltration products are given in Table 3. The vast majority of polyvalent ions were removed during ion exchange and the vast majority of monovalent ions ended up in NFP1. The softened UFP concentrate (NFR1) contained almost exclusively lactose. Table 3: Compositions of example 3 (in % by weight based on total dry weight)
Example 4
[0116] The UFR1 of example 1 was concentrated and subjected to monovalent ion removal by nanofiltration over an NF Synder NFX 3838 membrane having a MWCO of 150-300 Da. Nanofiltration operated at a temperature between 8 and 20 °C, and with a transmembrane pressure of 2 bar and VCF of about 2. The permeate was collected at a flow rate of up to 220 L/h. 108 kg of a UFR1 concentrate as nanofiltration retentate (NFR2) were obtained, together with 149 kg of a nanofiltration permeate (NFP2). Using nanofiltration, UFR1 is concentrated to a total solids content of about 18%. The composition of the NFR2 product from the nanofiltration is given in table 4. Table 4: Composition of example 4 (in % by weight based on total dry weight)
Example 5
[0117] The UFR2 of example 2 was concentrated and subjected to monovalent ion removal by nanofiltration through an NF Synder NFX 3838 membrane having a MWCO of 150-300 Da. Nanofiltration operated at a temperature between 8 and 20 °C, and with a 2 bar transmembrane pressure. The permeate was collected at a flow rate of up to 400 L/h. 73 kg of a UFR2 concentrate as nanofiltration retentate (NFR3) were obtained, along with 148 kg of a nanofiltration permeate (NFP3). Using nanofiltration, UFR2 is concentrated to a total solids content of about 18%. The composition of the NFR3 product from the nanofiltration is given in table 5. Table 5: Example composition 5 (in % by weight based on total dry weight)

Example 6
[0118] The aim is to produce a mixture with a casein:whey ratio of 40:60. For this purpose, the UFR1 concentrate of example 4 (NFR2) is mixed with the UFR2 concentrate of example 5 (NFR3) in a weight ratio of 59 kg: 87.62 kg (based on a liquid composition) or in a weight ratio of 10.59 kg:16.45 kg (based on a dry composition) respectively, to produce a blend of UFR1 and UFR2. In addition to the constituents being mentioned in table 6, the NFR2/NFR3 mixture comprises NPN at 2.82 wt% and fat at 3.08 wt%. Table 6: Composition of example 6 (in % by weight based on weight total dry)

[0119] Combining the UFR1 concentrate of example 4 (NFR2) with the UFR2 concentrate of example 5 (NFR3) in another selected weight ratio allows to obtain a mixture comprising casein to whey proteins in a ratio that is within the range claimed. The addition of an optionally concentrated softened UF permeate (which is substantially protein free) allows you to increase an amount of lactose to a desired level. The obtained mixture can be spray dried into a dry milk formula. For example, adding the necessary adequate amounts of nutrients and minerals, when needed, allows a growth formula to be obtained with a 40:60 ratio of casein to whey protein. Alternative blends of UFR1 and UFR2 were made to produce other blends of UFR1 and UFR2 that comprised a 50:50 and 60:40 casein to serum ratio. Example 7
[0120] A smoothed UFP concentrate was recombined with the mixture of UFR1 and UFR2 to produce a composition with a 60:40 ratio of casein to whey protein. The softened UFP concentrate was combined with the blend of UFR1 and UFR2. The UFR1 concentrate of example 4 (NFR2), the UFR2 concentrate of example 5 (NFR3) and the concentrate and softened UFP (NFR1) of example 3 are blended in a weight ratio of 88.51 kg:43.81 kg :188.77 kg (based on a liquid composition) or a weight ratio of 15.88 kg:8.23 kg:38.57 kg (based on a dry composition) respectively, to produce a blend of UFR1 , UFR2 and UFP smoothed.
[0121] In addition to mentioning constituents in table 7, the mixture of NFR1/NFR2/NFR3 comprises NPN at 1.67% by weight and fat at 1.01% by weight. based on total dry weight)

[0122] The combination of the softened UFP concentrate with the mixture of UFR1 and UFR2 in other selected weight ratios allows to obtain a mixture comprising casein to whey proteins in a desired ratio that is within the claimed range. The addition of the softened and optionally concentrated UF permeate (which is substantially protein free) allows to increase an amount of lactose to higher levels as shown. The obtained mixture can be spray dried into a dry milk formula. For example, the addition of adequate amounts of necessary nutrients and minerals, where necessary, allows to obtain a growth formula with a 60:40 casein to whey protein ratio. Alternative blends were made in a similar manner to obtain compositions comprising a ratio of 50:50 and 40:60 casein to whey. Example 8
[0123] Fractionation of reconstituted skim milk powder (SMP) and reconstituted sweet whey powder (SWP), according to the invention, was performed using a combination of unit operations, to prepare three types of nutrition base products from infant. Reconstituted SMP and reconstituted SWP were each subjected to UF (step 1), retentates (UFRs) were subjected to NF (step 2) and permeates (UFPs) to poly and monovalent ion removal (step 3). Subsequently, the NF retentates (NFRs) from step 2 and the smoothed UFPs from step 3 are combined in step 4. The compositions of SMP and SWP are given in table 8. Each process step operated under steady-state conditions for 4- 10 h, during which an acceptable average flow was achieved completely throughout the production sequence. Concentration factors for membrane filtration steps are given in “mass concentration factor” (MCF), which are calculated in the same way as a VCF, but using weight instead of volume. It can be assumed that MCF = VCF, since all densities are close to those of water (1000 kg/m3) and all solids present in the inflow end up in the retentate and permeate flows. Over time, slight variations were observed for MCFs. Here below, the MCF variation is given or the deviation from the given value was less than 10% at all times.Table 8: Compositions of SMP and SWP (per 100 g of powder)

Step 1: Fractionation of reconstituted SMP and reconstituted SWP was performed using two 3838 10 kDa ultrafiltration membranes in series (Synder Filtration) to separate the feed materials into a protein-rich retentate and a lactose/milk salts-rich permeate a 10°C. The reconstituted skim milk feed material (~2800 kg) at a total solids content of 8.64% w/w solid, pH 6.9 at 5.8 °C, was fractionated using a concentration factor of mass concentration of 2, while the reconstituted sweet whey feed material (~3500 kg) at a total solids content of 6.1% w/w solid, pH 6.63 at 6.8 °C was fractionated using a mass concentration factor of 5.5. The macronutritional and mineral distribution of the liquid retentate and permeate fluxes of UF1 and UF2 are shown in table 9. The permeates were collected with an average flux of 10.54 kg/m2/h (for SM) and 20.21 kg/m2 /h (for SW). Table 9: Compositions of UFRs and UFPs (per 100 g)

Step 2: Post-ultrafiltration of the reconstituted skim milk powder and sweet whey streams, subsequent retentates UFR1 and UFR2 were concentrated and partially demineralized using a 3838 150-300 Da nanofiltration (NF) membrane (GEA Filtration, Denmark [Denmark] ). For concentration and demineralization of ~500 kg UFR1 (pH 6.82 at 6 °C) to 26% w/w solids content, NF1 used two NF membranes in series; while for the concentration and demineralization of ~640 kg UFR2 (pH 5.88 at 6.5 °C) for 28% w/w solids content as a single NF membrane was used in NF2. NF1 operated within a mass concentration factor range of 1.8-2.2, while NF2 operated within a mass concentration factor range of 2.6-3. Both NF1 and NF2 were operated within the temperature range of 13-14 °C. Permeates were collected with an average flux of 1.64 kg/m2/h (for UFR1) and 9.64 kg/m2/h (for UFR2). The macronutritional and mineral distribution of the NF1 and NF2 liquid retentate and permeate fluxes is shown in Table 10. The process produced for NFR1 and NFR2 milk protein concentrate powders (MPC50) and whey protein concentrate (WPC35) respectively. Table 10: Compositions of NFRs and NFPs (per 100 g)
Step 3: Milk and whey permeates from UF1 and UF2 respectively were separated and partially demineralized separately by NF3 using two series nanofiltration (NF) 3838 150-300 Da membranes (GEA Filtration, Denmark [Denmark]). For concentration and demineralization ~1000 kg of UFP1 (pH 5.9 to 6.9 °C) were concentrated to 22% w/w solids content. For concentration and demineralization ~1000 kg of UFP2 (pH 5.6 at 6 °C) were concentrated to 22% w/w solids content. For the concentration of both UFP1 and UFP2, NF3 operated within a mass concentration factor range of 3.5-4 at a temperature of 10 °C. The average permeate fluxes totaled 9.73 kg/m2/h (for UFP1) and 10.9 kg/m2/h (for UFP2). The macronutritional and mineral distribution of the NF3 liquid retentate and permeate fluxes are shown in table 11.
[0124] Post-concentration and demineralization of UFP1 and UFP2 by NF3, both retentates were subsequently heated indirectly to 82 °C using an indirect plate heat exchanger feeding a 250 L stainless steel lined vessel. Once the NF3 retentate was in the storage vessel, the pH was adjusted to 7.2 (at 82°C) using a 30% w/w NaOH solution, causing the precipitation of calcium salts, mainly phosphate and citrate. The precipitated solution was held at 82°C for 20 minutes to maximize the precipitation reaction followed by cooling to 20°C using an indirect plate heat exchanger feeding a second 250 L vessel lined with stainless steel. Precipitated material was removed from the NF3 retentate stream (post-precipitation) by UF3 using two 10 kDa 3838 ultrafiltration membranes in series (Synder Filtration). UF3 operated within a mass concentration factor of 10 at a temperature of 20 °C. The macronutritional and mineral distribution of the UF3 liquid retentate fluxes are shown in Table 12. The process, according to the invention, produced ~50% demineralization in the UF3 retentates compared to UFP1 and UFP2 by dry matter.
[0125] The UF3 liquid retentate streams were combined in a stainless steel vessel at 40 °C. The composite batch (65 kg of total mass) constituted the UFR3 of skimmed milk and the UFR3 of sweet whey in a mass ratio of 20:80 respectively. The batch was subsequently demineralized using a pilot electrodialysis station (P1 EDR-Y, MemBrain). The endpoint of demineralization was determined based on the relationship between the conductivity of the demineralized lactose and the ash content in it (endpoint: conductivity < 1 mS; ash content < 0.75% by weight based on dry matter). Once the endpoint of demineralization was reached, the demineralized lactose concentrate stream was cooled to 5 °C, followed by determination of the total solids content of the ED product as 16.62% w/w.Table 11: Compositions of NFR3s and NFP3s (per 100 g)
Table 12: Compositions of UFR3s and UFP3s (per 100 g)
Step 4: The final step in the process was the production of nutritionally balanced infant/child nutrition using the materials prepared in the previous steps (1 to 3). As such, the lactose concentrate solution produced in step 3 (ED product) was used as the liquid flow to which the NFR1 and NFR2 were added, offering the desired content (legally necessary) and protein ratio (casein/whey) and lactose for first-stage infant milk (IF), follow-up milk (FO) and growth milk (GUM). The fluxes were mixed in the proportions mentioned in table 13. At this stage, the flux of liquid concentrate comprising demineralized lactose (from the ED product), MPC (from NFR1) and WPC (from NFR2) was preheated to 50 °C, followed by dosage of oil and GOS to meet nutritional requirements. The liquid concentrated infant formula streams were then heated and treated at 85 °C for 5 min. in an indirect tubular heat exchanger (Mircothermics), homogenized downstream of the heat treatment at first and second stage pressures of 125 and 25 bar respectively (at 60 °C), followed by evaporation at 55% w/w of solids in a single drop-effect film evaporator operating at 55 °C; and spray drying using a single stage spray dryer equipped with 2 fluid nozzle atomization operating at an inlet and outlet temperature of 175 °C and 90 °C respectively. The nutritional composition of the IF, FO and GUM powders produced is outlined in table 14.
[0126] Note that all components mentioned in table 14, except for the fat and part of the carbohydrates (GOS) originated from the starting materials of skim milk and sweet whey. All components in table 14 are within acceptable ranges for that component, or are below those acceptable ranges. For components whose content is below acceptable, fortification would be necessary to increase their content to within acceptable ranges. It is important to note that none of the mentioned components, not even the polyvalent ions, are present above their acceptable range, which would be unacceptable since taking away is impossible, whereas the addition of one or a few components can happen directly. The possibility of preparing different nutritional products for infants, all in accordance with legal standards, demonstrates the versatility and flexibility of the process according to the invention. Table 13: Mixing Proportions, expressed in kg of liquid concentrate per 100 kg of dry powder
Table 14: Compositions of IF, FO and GUM powders (per 100 g)

权利要求:
Claims (19)
[0001]
1. PROCESS FOR OBTAINING A DRY MILK FORMULA, characterized in that it comprises: (ai) ultrafiltration (UF) of an animal skimmed milk composition comprising 70-90% by weight of casein and 10-30% by weight of protein from whey, based on total protein, and(a-ii) ultrafiltration of an animal serum composition comprising 0-25% by weight of casein and 75-100% by weight of whey proteins, based on total protein; or (a-iii) ultrafiltration of a mixture of the compositions of (ai) and (a-ii), (b) optionally, combining the UF retentate originating from step (ai) with the UF retentate originating from step (a-ii); (c) removing polyvalent ions from the UF permeate originating from step (ai) and/or (a-ii) or (a-iii) to obtain at least one smoothed UF permeate; (d) combination of the at least one smoothed UF permeate originating from step (c) with a UF retentate originating from step (ai) and/or (a-ii), or (a-iii) or ( b) to obtain a combined product; and (ei) drying the combined product originating from step (d) to obtain a dry milk formula, and/or (e-ii) drying any UF retentate originating from step (ai) and/or ( a-ii) or (a-iii) or (b) that is not combined in step (d), and drying any of the smoothed UF permeates originating from step (c) that is not combined in step (d) , followed by combining dry UF retentate with dry smoothed UF permeate to obtain a dry milk formula.
[0002]
Process according to claim 1, wherein the skimmed animal milk is characterized in that it comprises 75-85% by weight of casein and 15-25% by weight of whey proteins, based on total protein.
[0003]
Process according to claim 1, wherein the animal whey composition is characterized in that it comprises 0-20% by weight of casein and 80-100% by weight of whey proteins, based on total protein.
[0004]
4. A process according to claim 1, characterized in that a UF permeate originating from step (ai) and a UF permeate originating from step (a-ii) are combined before said removal of polyvalent ions from the step (c).
[0005]
5. PROCESS according to claim 1, characterized in that a UF retentate that originates from step (ai) and/or (a-ii) is/are concentrated before the combination of step (b), (d) ) or drying step (ei) and/or (e-ii); and/or a UF retentate originating from step (a-iii) and/or (b) to be/be concentrated/s prior to the combination of step (d) or drying step (ei) and/or (e- ii).
[0006]
6. Process according to claim 1, characterized in that the UF permeate originating from step (ai) is combined with a permeate originating from (a-ii) before removing the polyvalent ion from step (c).
[0007]
7. PROCESS according to claim 1, characterized by the smoothed UF permeate that originates from step (c) and/or the combined product from step (d) is/are concentrated/s, before the combination of step (d) ) or drying step (ei) and/or (e-ii).
[0008]
8. Process according to claim 5, characterized in that the concentration occurs by reverse osmosis and/or nanofiltration.
[0009]
9. PROCESS according to claim 1, characterized in that the removal of polyvalent ion from step (c) occurs by electrodialysis, ion exchange, lactose crystallization and/or salt precipitation.
[0010]
10. PROCESS according to claim 1, characterized by the smoothed UF permeate from step (c) and/or the UF retentate that originates from step (ai) and/or (a-ii) or (a-iii ) or (b) to be/are subject to monovalent ion removal.
[0011]
11. PROCESS, according to claim 1, characterized by a UF retentate that originates from step (ai) and/or (a-ii), or (a-iii) or (b) and/or a permeate of the UF originating from step (ai) and/or (a-ii) or (a-iii), and/or the smoothed UF permeate originating from step (c) or the combined product from step (d) be /be heat treated/s, by DSI, before drying step (ei) and/or (e-ii).
[0012]
Process according to claim 1, characterized in that the drying of step (e-i) and/or (e-ii) is by spray drying.
[0013]
Process according to claim 1, characterized in that the combined product that originates from step (d), the dry combined product of (ei), and/or the dry UF retentate from (e-ii) that is combined with the dry smoothed UF permeate from (e-ii) in step (e-ii) are further processed into a nutritional product to provide nutrition to infants.
[0014]
14. PROCESS according to claim 1, characterized by the composition of skimmed animal milk and composition of animal whey from step (a-iii) or from the UF retentates that originate from step (ai) and (a-ii ) are combined in a ratio such that a product having a casein:whey protein weight ratio of between 75:25 to 30:70 is obtained.
[0015]
15. Process according to claim 1, characterized by mixing the composition of skimmed animal milk and animal whey composition from step (a-iii) or the combined UF retentate from step (b), or the combined product from step (d), the dry milk formula of (ei) or the dry milk formula of (e-ii) has a casein:whey protein weight ratio of between 75:25 to 30:70.
[0016]
16. COMPOSITION THAT MAY BE OBTAINED BY THE PROCESS as defined in claim 1, characterized in that it comprises: a protein content between 40 and 52% by weight, in which casein and whey are present in a weight ratio that is between 70:30 and 30:70, lactose in an amount between 35 and 50% by weight; and the following minerals: magnesium in an amount between 0.01 and 0.30% by weight, calcium in an amount between 0.80 and 1.70% by weight, phosphorus in an amount between 0.60 and 1.50% by weight, sodium in an amount between 0.10 and 0.60% by weight, chlorine in an amount between 0.05 and 0.60% by weight and potassium in an amount between 0.60 and 1.50% by weight , all based on the dry weight of the intermediate product.
[0017]
17. COMPOSITION THAT CAN BE OBTAINED BY THE PROCESS, as defined in claim 1, characterized in that it comprises: a protein content between 16 and 24% by weight, in which casein and whey are present in a weight ratio that is between 70:30 and 30 :70, lactose in an amount between 65 and 80% by weight; and the following minerals: magnesium in an amount between 0.01 and 0.25% by weight, calcium in an amount between 0.20 and 0.80% by weight, phosphorus in an amount between 0.40 and 0.80% by weight, sodium in an amount between 0.20 and 0.80% by weight, chlorine in an amount between 0.30 and 0.90% by weight and potassium in an amount between 0.30 and 0.90% by weight.
[0018]
18. DRY MILK FORMULA, characterized in that it is obtained by drying a composition as defined in claim 16.
[0019]
19. MODULAR SYSTEM, characterized in that it comprises: (1) an ultrafiltration module, comprising (1a) an inlet for receiving a first liquid composition and/or a second liquid composition, or a mixture thereof, to a first side of a membrane of ultrafiltration,(1b) the ultrafiltration membrane,(1c) a first outlet for discharging an ultrafiltration retentate (UFR) from the first side of the ultrafiltration membrane, and(1d) a second outlet for discharging an ultrafiltration permeate (UFP) from the second side of the ultrafiltration membrane; (2) a polyvalent ion removal module, comprising (2a) an inlet for receiving the UFP originating from the ultrafiltration module (1), (2b) means for removing polyvalent ions, and( 2c) an output for discharging a smoothed UFP; (3) at least one mixing module, comprising(3a) a first input for receiving the smoothed UFP originating from the polyvalent ion removal module (2),(3b1) a second entry to receive the first the liquid composition or a UFR of the first liquid composition and a third inlet for receiving the second liquid composition or a UFR of the second liquid, or(3b2) a second inlet for receiving a mixture of the first liquid composition and the second liquid composition or a UFR of the first liquid composition and a UFR of the second liquid composition, and(3c) an outlet for discharging a recombined product; and (4) a drying module, comprising(4a1) a first input for receiving the UFR originating from the ultrafiltration module (1) and a second input for receiving the smoothed UFP originating from the polyvalent ion removal module ( 2), or (4a2) an inlet for receiving the recombined product originating from the mixing module (3), (4b) drying means, and (4c) an outlet for discharging a dry composition.

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同族专利:

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公开号 | 公开日

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AU2014250177A1|2015-10-22|

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BR112015025219A2|2017-07-18|

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RU2709173C2|2019-12-16|

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EP2986153A1|2016-02-24|

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NZ712773A|2021-02-26|

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AU2014250177B2|2017-07-20|

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CN105263341A|2016-01-20|

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US9993009B2|2018-06-12|

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ES2802885T3|2021-01-21|

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CN105263341B|2018-04-17|

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EP2986153B1|2020-04-01|

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RU2015146989A|2017-05-16|

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US20160044932A1|2016-02-18|

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WO2014163485A1|2014-10-09|

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WO2014163493A1|2014-10-09|

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PL2986153T3|2020-09-21|

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DK2986153T3|2020-07-13|

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法律状态:
2018-05-02| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-09-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-05-11| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-08-17| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 03/04/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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PCT/NL2013/050248|WO2014163485A1|2013-04-03|2013-04-03|Process and system for preparing dry milk formulae|

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NLPCT/NL2013/050248|2013-04-03|

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PCT/NL2014/050202|WO2014163493A1|2013-04-03|2014-04-03|Process and system for preparing dry milk formulae|

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