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Tetra Pak Ultra filtration UF

Ultrafiltration plant for fermented products

3 Main items:
1) Thermization unit
2) Ultrafiltration (UF) for fermented milk
3) Cooler and Silo.

The line is used to produce Quark/Skyr.
The thermization and ultrafiltration unit are also suitable for producing other fermented and concentrated dairy products such as: Skyr, Mascarpone, and Double Cream cheese.

Key data:
- Input: 3,500 - 5,000 liters per hour of fermented skim milk, full-fat milk, or enriched products.
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- Concentration factor: 1.8-2.5

1) Thermization unit
Complete skid-mounted thermization unit.
Flow rate: 3,500 up to 5,000 liters (depending on the product).
Manufacturer: Tetra Pak

Temperature cycle:
Input: 21-30 °C (incubation temperature) -> recuperation (permeate cooler) -> thermization at 55/60°C or pasteurization at 72/95 °C -> holding -> output to ultrafiltration at approx. 45 °C.

Complete unit including:
* Stainless steel frame in which everything is pre-assembled.
* Closed balance tank with spray bowl.
* Centrifugal product pump, stainless steel casing, flush seal, type: LKH.
* Plate heat exchanger, 4 stages, new, Tetra Pak, Clip6-SR Model.
* Control box with all connections for sensors and pneumatic valves.

* Holding tube for 5,000 liters per hour, adjustable by connecting more or fewer tubes: 30 seconds up to 180 seconds in 9 stages.

2) Ultrafiltration unit
Manufacturer: Tetra Pak
Type: Tetra Alcross US P&F
Serial number: T5845810096
Year: 2010
Capacity: Input up to 5,300 liters/hour

Description:
Concentrates yogurt or fermented milk to achieve the desired composition and texture.

The UF separates the product into retentate and permeate.
The retentate is the product, with proteins and fat (if included) concentrated.
The advantage of this design of UF (compared to spiral-wound UF and separators) is that it is suitable for fermented products with and without fat.
Also, all proteins are concentrated (even whey proteins).

This results in high pressures in the system; filtration can only be achieved with a plate and frame filtration system with flat FR60pp filters and rotary piston circulation pumps.

Some example products that can be made with this system:
Input: skim milk 9% TS -> output approx. 16% TS (Skyr).
Input: 20% TS including fat -> output: cream cheese or mascarpone.
Input: pre-concentrated fermented skim milk up to 12% TS -> output up to 18% TS (Quark).

The limiting factor is the permeate output.

Approximate permeate per stage:
Stage 1: 1100-1755 liters/hour, 13.5 m2 filters.
Stage 2: 675/1170 liters/hour, 9 m2 filters.
Stage 3: 320/585 liters/hour, 4.5 m2 filters.
Stage 4: 300/585 liters/hour, 4.5 m2 filters, 15 bar.

Filter: plate and frame type, manufacturer: Tetra Pak - DDS, model: M37

Complete unit including:
* Stainless steel frame.
* 2 balance tanks with spray bowl (feed and permeate return).
* Feed pump Tetra LKH.
* 4 circulation loops including circulation pumps.
First stage with centrifugal pump, 3 stages with Waukesha 320-U2 rotary piston high-pressure pumps.
Last stage up to 15 bar pressure for highly viscous products.

3) Quark silo, cooler, and pump.

Manufacturer: Schwarte-Milfor
Type: Quarksilo
Serial number: 3580
Year: 2011
Capacity: 5,000 liters
Description:
Robust conical design for very viscous products.
Insulated.
Hermetic, ultra-clean with sterile air.
Sensors for level and temperature.

On inlet:
- Plate cooler
Manufacturer: Tetra
Model: Clip line C6
Thermal cycle: 45 -> approx. 18°C

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