Food Pro Clean Line - Alan Fourie

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26 September 2014

Alan Fourie

Senior Application Specialist

DuPont Nutrition and Health SSA

Imagine trouble-free UHT processing for hours and hours!

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What is FoodPro® Cleanline?

9/25/2014

“The Modification of Milk Surface Properties by

Glycerophospholipid Cholesterol Acyltransferase (GCAT)”

Abstract:

The presentation will focus on the application of the FoodPro® Cleanline

enzyme Glycerophospholipid Cholesterol Acyltransferase (GCAT) in the milk,

which converts cholesterol to cholesterol esters and lysophospholipids.

Lysophospholipids are surface-active amphiphiles that will act as

biosurfactants and prevent protein aggregation and promote refolding of

proteins (chaperone-like properties), resulting in various processing

advantages and increased emulsion stability when used in the manufacture

of milk and dairy products. GCAT can reduce free cholesterol in milk by as

much as 65 to 85%, which could potentially be an important advantage from

a nutritional point of view when producing milk and dairy products.


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What is your UHT unit performance today?

How often is the UHT system being cleaned per day?

What is the cost of cleaning chemical for each

cleaning cycle?

How many hours/tons of production capacity is lost

per day due to production stop for CIP?

Any product quality issues like taste or creaming?

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What is an enzyme?

› An enzyme is a protein that catalyzes

a chemical reaction

› Works by selectively binding to

substrate

› Enzyme reactions are less energy

consuming and create much less

waste compared to reactions using

chemicals

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› Temperature

• Each enzyme has an optimum/ideal temperature which

leads to highest number of enzyme/substrate

interactions

› pH

• Each enzyme has an optimum/ideal pH which leads to

highest number of enzyme/substrate interactions

› Inhibitors and activators

• Enzyme inhibitors are molecules that bind to enzymes

and decrease their activity

› Enzyme concentration

› Substrate concentration

What influences enzyme activity

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Acyltransferase

FoodPro® Cleanline

O

O

CH3

O

P

OH

O

ON

+

CH3

CH3

CH3

OH+

Lyso-phospolipid (enzyme modified phospholipids)

Phospolipid

(phosphatidylcholin) Cholesterol

Cholesterolester

+

13

149

810

1712

11

15

16

75

6

20

CH318

CH3191

23

22

4

24

2

3

H

H

H

H

OH

CH3

CH3

CH3

+

Enzyme reaction with acyltransferase in milk

6

13

149

810

1712

11

15

16

75

6

20

CH318

CH3191

23

22

4

24

2

3

H

H

H

H

O

CH3

CH3

CH3

O

CH3

O

O

O

CH3

O

CH3

O

P

OH

OO N

+

CH3

CH3

CH3


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Why this new development?

During the production of UHT milk, the heating surface of the heating unit foul due to

build up of proteins and sugars and minerals from the milk

This results in pressure building in the system and reduced heat transfer. When the

pressure becomes too high and the heat transfer is reduced, the unit needs to be

cleaned

This can also result in burnt taste of the UHT milk

Cleaning and sterilisation takes time, up to 2 hours, and takes significant amounts of

cleaning compounds

This can lead to:

Not meeting overall performance on capacity, cost and quality

High costs for cleaning: hours spent and chemicals consumed

Product rejection due to taste

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Without FoodPro ® Cleanline,

After 11 hours run time

With FoodPro ® Cleanline,

Milk enzymation 15 ppm 6 – 8 hours

at 5°C ,

After 15 hours run time

Industrial scale trials in tubular heat equipement, plant capacity 13 000

L/hour

Effect of FoodPro® Cleanline on fouling

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Fouling of heat exchangers in the dairy industry is a quite severe problem, both

technically and economically.

During a normal working cycle, the heat exchanger is subject to undesired

material accumulation along its working surfaces, normally referred to as

Fouling.

Fouling formation causes increased pressure drop over plate heat exchangers,

and also leads to reduced heat transfer and thereby increased energy

consumption.

Result: loss of production capacity as well as increased costs for manpower,

energy and detergent consumption during processing and cleaning.

The enzymatic treatment of milk will greatly reduce fouling rates


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Development of pressure drop in commercial UHT plant

0

2

4

6

8

10

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Hours

Pre

ssure

dro

p (

bar)

Enzymated UHT r.milk Non Enzymated UHT r. milk

Pre-set CIP

limit

3 day average from full scale production run Recombined milk. Dosage 10 ppm, 45-100 minutes at 40°C.

Observed conversion rate of Cholesterol to Cholesterol-ester 82%

› Fouling can be expressed by an increase in backpressure over the heat exchanger

› Acyltransferase reduces the increase in pressure drop

› Production cycles are extended 4 to 6 hours before CIP is needed

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› Native phospholipids always form lamellar bi-layers and cholesterol is commonly found in biological membranes (native milk fat globules being a typical example)

› Cholesterol-esters are, like triglycerides, entirely hydrophobic and thus do not play a role in membrane formation like cholesterol normally does

› Lyso-phospholipids are less hydrophobic than phospholipids and, therefore, can more readily associate with hydrophobic amino acids in denaturated whey proteins, and have a better ability to bind proteins to the interphase between fat and water

› Lyso-phospholipids prevent protein aggregation and promote refolding of proteins* (chaperone-like properties)

› These functions will impact the accumulation of denatured proteins on hot surfaces (fouling)

* Biochemical and Biophysical Research Communications 289, 1268–1274 (2001)

The theory behind the anti-fouling effect

Plate heat exchanger

Fouling on heat exchanger

Clean heat exchanger

Fouling may vary depending on UHT Plants

Tubular heat exchanger

We expect FPCL will be more efficient in an indirect system where fouling

accumulates on the exchange surfaces (e.g. equipment where there is no direct

contact between the product and the heating media, such as plate or tubular

heat exchangers)

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Practical experience with FoodPro® Cleanline :

increased run-time

Dosage 10 ppm, 2-14 hours at 4°C.

Trials repeated 6 times

always with more than

doubling of possible run-

time.

Observed 40-45% reduction

of organic material in CIP

water after enzymated

product compared to

reference

Pilot scale trials with condensed milk (UHT) 13

0

2

4

6

8

10

12

14

16

Reference Enzymated

Run time (hours)

Run time


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Emulsion stability effect of FoodPro® Cleanline

Enzymation of milk with FoodPro ® Cleanline will decrease the surface tension

and thereby increase the efficiency of the homogeniser

Increased protein incorporation in the fat globule membrane will increase

resistance against coalescence, without increased tendency to flocculation

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Creaming of UHT-milk is reduced by FPCL treatment


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Enzyme addition recommendation

Enzyme dosage depends on process time and temperature.

2 main recommendations:

Addition to the retention tank, after

fat standardisation, at 5-10°C.

Enzyme reaction for 2 hours

minimum and up to 36 hours before

UHT treatment.

Enzyme dosage 10-12 ppm

For recombined milk: Enzyme addition

at 40-50°C in the recombination tank.

Enzyme reaction for 30 minutes

minimum and up to 4 hours, prior to

UHT treatment.

Enzyme dosage 4-6 ppm


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FoodPro® Cleanline potential benefits:

• Higher factory output

• Labor cost savings

• Lower cleaning chemical costs

• Less quality issues

• Higher sales because of a better tasting product

• Fewer complaints on creaming

• Easy to implement (no investment needed)

• Reduced environmental impact (water, CO2 and chemicals)

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What is your potential value? Example:

Example : Dairy working 300 days/year, 24 hours/day, production capacity 13000

liters/hour. 2 CIP/day of 2 hours each. Possibility to go down to 1 CIP/day when

using FoodPro® Cleanline 17

FoodPro® Cleanline

FEATURE

Modification of milk

phospholipids

POTENTIAL BENEFIT

Reduced fouling

Reduced consumption of energy,

water & chemicals

Reduced organic material in

waste water

Reduced creaming

POTENTIAL GAIN

Higher factory output, higher

profits

Reduced costs

(labour, chemicals, energy,

recycling)

Reduced environmental

impact

Increased market

share/customer satisfaction

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