Ingredient
|
Attribute
|
Application
|
a
-lactalbumin
|
Tryptophan
content
Essential
amino acids
Branched
chain amino acids
|
Humanized
baby food
Nutritional
products
Sports
drink formulations
|
Lactoferrin
|
Sequesters
iron
Antimicrobial
agent in body
Immunostimulating
effect
|
Infant
formula
Nutritional
bars
Sports
& performance products
Medical
products
|
Lactoperoxidase
|
Antibacterial
agent in body
|
Shampoo
Toothpaste
Acne
preparation
|
Glycomicropeptides
|
Body
weight management
Appetite
suppressant
Management
of phenylketonuria
|
Sports
performance products
Medical
products
|
The Process
The process for producing WPI, alpha-enriched WPI, beta-enriched WPI, lactoferrin, lactoperoxidase and glycomicropeptides is shown in the figure below:
In order to capture the proteins on the resin, the pH of the whey is adjusted to a low pH. This will give all the proteins a positive charge, which will bind it to the negatively charged SepraPrep-S resin.
The pretreated and pH-adjusted whey is loaded on the column after the column has been equilibrated. Then the column is washed with water and the proteins are eluted by means of patented 'Opposing Salt and pH' gradients.
The process fractions are processed in an ultra- and diafiltration plant, where the protein is concentrated to 25-27% total solids, while the permeate containing the buffer salt solution is processed in a reverse osmosis plant, concentrating it to 2-3% solids for re-use.
The protein concentrate is dried in a spray dyer, which can be of the tall-form type using an inlet air temperature of 180°C.
Sepralac® Process Economics
Assumptions:
Volume: 250,000 liters of whey per day
Whey type: Sweet cheese whey,
pre-treated, past., normal comp.
Processing time: 24 hours per day, 300
days a year
|
Products
Permeate
Whey
Protein Isolate
a
–enriched WPI
ß-enriched
WPI
Lactoferrin
Lactoperoxidase
|
Market
Price US
D/Kg
0.18
7.5
15
9
250
300
|
Annual
Prod. (Kg)
WPI
a
–enriched WPI
ß-enriched
WPI
Lactoferrin
Lactoperoxidase
Permeate
Annual
Prod. (USD)
WPI
a–enriched
WPI
ß-enriched
WPI
Lactoferrin
Lactoperoxidase
Total
Permeate*
|
Case
1
364,500
4,110,000
Case 1
2,773,750
2,773,750
739,800
|
Case
2
362,800
1,200
500
4,110,000
Case 2
2,721,000
300,000
150,000
3,171,000
739,800
|
Case
3
145,120
217,680
1,200
500
4,110,000
Case 3
2,176,800
1,959,120
300,000
150,000
4,585,920
739,800
|
Investment
3* 500
L RFC columns
Tanks,
pumps, piping
Automation
and valves
Membrane
systems
Total
Annual
Prod. Costs
Depreciation
Resin
costs
Membrane
system OP
costs
Chemicals
Water
Energy
Waste
treatment
Cost of
whey (.5 c/L)
Labor
Drying
costs
Total
|
USD
675,000
200,000
350,000
300,000
1,525,000
USD
190,625
150,000
80,000
120,000
30,000
110,000
25,000
375,000
288,000
91,125
1,469,750
|
Annual
Gross
Margin, USD
Revenue
Production
costs
Gross
margin
|
Case
1
Process
A
2,773,750
1,469,750
1,264,000
|
Case
2
Process
B
3,171,000
1,690,210
1,480,790
|
Case
3
Process
C
4,585,920
1,763,700
2,822,220
|
|