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Ultrafiltration Feta Cheese Plant on Turnkey Basis

Ultrafiltration Feta Cheese Plant on Turnkey Basis

Advantages of UF over Traditionmal method:
-Better yield (Less whey protein loss)
-Continuous process
-Closed system (Good bacteriological control)
-Easy to control parameters and composition
-New cheese types easily obtainable
-High nutritional value (More whey protein)
-Saving in rennet
Disadvantages of UF over Traditionmal method:
-Slower ripening (Due to presence of whey proteins)
-Poor meltability (Due to presence of whey proteins)
-Generally softer consisterncy (Due to presence of whey proteins)
-Difficult to obtain controlled eye formation
Ultrafiltration Feta Cheese Plant on Turnkey Basis

Utilities

The required utilities for running the UF plant are as follows:

-Power supply: 3x400 V AC, 50 Hz (Other voltage and frequencies are also available upon request)
-CIP water supply: 2-3 bar(g) @ 10-50 °C
-Cooling water supply: 2-3 bar(g) @ 10-50 °C
-Ice water supply: 2-3 bar(g)@1-2 °C
-Shaft seal water supply: 2-3 bar(g) @ 10-50 °C
-Steam pressure: 2-3 bar(g)
-Air supply: 6 bar (g) Instrument air, oil-free
-Cleaning: Membrane cleaning detergent for manual or automatic dosing (Henkel or Diversey or Novadan)

Operation

Operation:
The UF plant is designed fully automatic and from HMI all of the operation parameters and program sequences can be controlled and monitored. Also, all of the necessary process alarms are already incorporated into the program. The operation presence is only required during operation as surveillance The following process sequences are realized automatically:
-Start up/ Recirculation/Ready for product
-Pre concentration
-Production
-Re circulation of product
-Emptying
-Rinse
-Cleaning in place (CIP)

Options :

UF plant can include the following options:
-Automatic CIP dosing unit
-Refractometer for online measurement/control of final product brix
-In line cartridge filters for soft water input
-In line filter for product with 10 micron filter
-Mix proof product manifold valve on feed, retentate and permeate inlet/outlet
-Conductivity transmitter for CIP dosing
-Automatic shut off (Isolation) of each loop to cut water consumption during CIP
-Flush water seal re circulation system. Reducing water
circulation
-UPS (Uninterrupted Power Supply)
-Air cooler for Control Panel

Components

UF Plant usually includes the following components:
-Closed balance tank including level transmitter, floater and CIP device
-Valve manifold including set of change over valves and automatic butterfly valves
-Feed pressure system including feed pump, flow transmitter and in line filter
-UF Modules and filters
-Re circulation loops each including circulation pump, tubular heat exchanger, pressure and temperature transmitters, flow indictors and sampling device
-Retentate/Permeate system including modulating valves, flow transmitter, permeate pump
-Equipment for flush water including shut off valves and adjustment valves
-Equipment for steam and cooling water including shut off valves and non-return valves
-Set of pipes and fittings and wiring
-Set of shut off valves for water balance tank
-Set of instruments such as temperature and pressure transmitters.
-Stainless steel control panel including PLC, HMI, power supply, solenoid valves, motor starters, MCC etc.
-All of the UF plants are tested in our factory before delivery
-The UF Plant Panel/Programme ensures the following are
realized:
1-Automatic temperature control in the loops
2-Automatioctotal solid ration control in the final retentate
3-Recording feed and retetnate flow and each loop temperature as long as long as the memory of HMI allows it

HMI Schematic Diagram

Ultrafiltration Feta Cheese HMI Schematic Diagram

Simplified Flowdiagram

Ultrafiltration Feta Cheese Simplified Flowdiagram

Simplified Processdiagram

Ultrafiltration Feta Cheese Simplified Processdiagram

Comparison of Whey and UF Permeate (Indicative)

Comparison of Whey and UF Permeate (Indicative):

>
Cheese Whey UF Permeate
True Protein (%) 0/60 0/01
(%) NPN 0/2 0/19
Lactose (%) 4/50 4/60
Fat (%) 0/06 0/00
Total Solids (%) 5/36 4/80