Protein concentration membranes that increase productivity in WPC80 manufacturing.
Making WPC80 requires ultrafiltration (UF) membrane systems that concentrate whey. The conventional polyethersuflone (PES) UF membranes used experience a natural build-up of organics as a gel layer on the membrane surface which impedes flux and cleanability. By using anti-fouling zwitterionic Evolution membranes, users can experience thinner gel layers than those on conventional membranes, resulting in a higher average sustainable flux and a simplified cleaning program that saves an hour or more of time each day.
Application Details
WPC80 is a whey protein concentrate that contains 80% protein and is commonly used as an egg or fat replacement, in dairy products like yogurt and ice cream, nutrition bars, bakery products, and more. UF membranes are featured at the heart of the WPC80 manufacturing process.
The process begins with blended skimmed whey that has been pasteurized, clarified, and separated. The pretreated whey is then fed to a UF system with multiple stages of membranes to concentrate the whey to the desired protein concentration. The process includes diafiltration at various stages to increase removal of smaller non-target components. Tighter membranes are typically used towards the back-end of the system to drive up protein concentration. The retentate stream from the membranes is ultimately dried to produce a final product of WPC80 powder.
Since the UF permeate stream contains high concentrations of lactose, it can be sent to downstream lactose concentration systems. Click here to read more about lactose concentration.
Membranes Used in WPC80 Manufacturing
Sanitary PES UF membranes have been used in WPC80 manufacturing for decades without a significant change in their performance. Now, with the novel zwitterionic anti-fouling membrane chemistry used in Evolution membranes, whey processors can experience a significant step-change in productivity and cleanability.
Evolution Protein Concentration Membrane (PCM) elements and Evolution Superfiltration (SF) elements are available as drop-in replacements for conventional membranes and provide distinct value.
Observed Higher Operating Flux
- Back-end of UF system in a WPI system at a large whey processor (comparable to the back-end of a WPC80 system)
- Field demonstration in operation more than 2 months
- Evolution SF running in parallel with conventional UF
- No noted difference in permeate
- Retentate total solids: 28-29%
Maximize productivity
By utilizing an anti-fouling membrane chemistry, Evolution PCM and SF membranes minimize gel layer formation at the membrane surface, allowing users to maximize productivity through the membrane.
Decrease cleaning costs by 50% or more
Evolution PCM and SF elements eliminate multiple steps from a cleaning program, saving money on chemicals, water use, and utilities—all while supporting more sustainable operations.
Minimize cleaning time
Evolution PCM and SF can reduce cleaning time by an hour or more per day—giving operators precious time back to focus on other critical tasks and producing more.
Simple implementation
Evolution PCM and SF elements are direct replacements for industry-standard products—no system modifications or new CAPEX required.
Podcast: ZwitterCo Unfiltered
ZwitterCo Unfiltered: Real Talk on Membrane Filtration is a candid, experience-driven podcast exploring real-world membrane applications across food processing, water, and wastewater treatment.
Mott Case Study
Speak with our engineers to discover ways that ZwitterCo can support positive changes at your plant. With our help, you can reduce your hauling and avoid heavy OPEX spend on plant expansion.
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Industrial Wastewater Reuse
ZwitterCo has only polymeric membranes that can filter high strength organic streams without rapid and irreversible fouling. More description here to describe the kind of solutions we offer for NMP.
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Challenging Surface Water Treatment
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High Value Protein & Co-Product Separation
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Remove Bulk Organics
Remove tough to fight organics, such as fats, oils, grease, and protein.
Fully Chlorine-Intolerant
Can endure aggressive cleaning without wear and tear
Runs at Low Pressure
Runs at low pressure by not removing salt, sugar, alcohol’s or other small molecules.
Replaces Biological Systems
Replace biological systems or coagulation/flocculation processes commonly used to treat organics.
Reduce your cleaning costs by 50%.
With Evolution membranes, your cleaning programs are easier and shorter, enabling more uptime for operators to focus on other important tasks. With easier cleanings and less chemicals, plants enjoy significantly reduced time and labor required for maintenance.
Minimize gel layer formation, maximize productivity.
Evolution membranes feature the highest resistance to organic fouling, which reduces gel layer formation at the membrane surface and leads to higher sustainable average flux. This leads to more output, more uptime, more time for maintenance, and protection against equipment failure for dairy processors.
Simplified & sustainable operations.
Evolution membranes simplify cleaning programs and require fewer chemicals, while also reducing freshwater demand, energy consumption, and amount of wastewater generated.
- Reduced pumping
- Less water
- Less heating of CIP solutions
- Decreased chemical usage
- Reduced energy requirements
Improve your OPEX.
In whey protein concentration applications, Evolution membranes significantly reduce freshwater demand through their simplified cleaning process.
Reduced Operating Costs
With lower cleaning costs, decreased water usage, less wastewater generated, and lower energy requirements, Evolution membranes offer a significant decrease in OPEX.
Increase in Uptime
Evolution membranes offer more uptime due to shorter cleaning programs, freeing operators to work on other priorities.