Industrial dairy ultrafiltration project developed by Perinox to optimize Quark and Tvorog cheese production through crossflow filtration and tangential flow filtration (TFF), improving yield and protein valorization.
As part of its innovation strategy in membrane technologies for the dairy industry, Perinox developed an industrial ultrafiltration project aimed at optimizing the production of Quark and Tvorog cheese with different fat and total solids levels.
The project was carried out in collaboration with the Milk Technology Center of the Instituto Agrario de Castilla y León, enabling the industrial validation of a system capable of increasing yield, improving final product quality and reducing energy consumption compared to conventional technologies.
The results demonstrated significant improvements in protein and fat retention, achieving high efficiency levels in the production of fresh fermented cheeses through crossflow filtration and UF membrane technologies.
Crossflow filtration technologies in the dairy industry
Crossflow filtration, also known as tangential flow filtration (TFF), is increasingly transforming dairy processing operations by improving solids recovery, optimizing energy efficiency and enhancing the valorization of dairy proteins.
In applications such as fresh fermented cheese production, membrane technologies enable high protein retention rates and precise total solids control while maintaining operational stability and minimizing fouling phenomena commonly associated with dairy concentration processes.
The operational stability of these systems also depends on the proper control of TMP, flux and membrane fouling parameters. Additional technical information is available in the article about TMP, flux and fouling in tangential flow filtration.
For further information about membrane applications in milk and complex fluids, see the article on crossflow filtration in dairy processing and milk applications.
Ultrafiltration applied to fresh fermented cheese production
Quark and Tvorog are fresh fermented dairy products characterized by:
- Milky white appearance.
- Creamy and homogeneous texture.
- Easy spreadability.
- Low whey separation.
- Mild acidic flavor.
Conventional production processes may lead to significant protein and fat losses, especially when centrifugal separation or traditional whey drainage systems are used.
The application of tangential flow ultrafiltration technologies allows manufacturers to optimize dairy solids recovery, improve product stability and increase process profitability.
Objectives of the industrial project
The main objectives of the project developed by Perinox were:
- Increasing industrial process yield.
- Improving protein and fat retention.
- Optimizing product texture and stability.
- Reducing dairy solids losses.
- Minimizing energy consumption.
- Eliminating the need for diafiltration.
- Facilitating integration into existing production lines.
The ultrafiltration solution developed allows processing both whole and skimmed milk while maintaining precise control over total solids and final product formulation.
Advantages of tangential flow ultrafiltration in fresh cheese production
Tangential flow ultrafiltration applied to fermented dairy products offers several advantages compared to conventional technologies.
Higher industrial yield
High protein and fat retention significantly increases production yield.
Trials conducted during the project achieved yield improvements exceeding 18% compared to alternative production systems.
Improved product quality
The technology developed enabled the production of:
- Creamier and more homogeneous textures.
- Improved water retention capacity.
- Lower acidic whey presence.
- Greater structural stability.
Energy optimization
The elimination of additional concentration and diafiltration stages reduces energy consumption and operational costs.
Flexible production capabilities
The system can also be adapted for the production of:
- Fresh cheese.
- Cream cheese.
- Yogurt.
- Other fermented dairy specialties.
Additional information about similar applications can be found in the article on membrane technologies for yogurt production.
Results obtained during industrial validation
Quark/Tvorog cheese with 0.3% fat on total solids
The trials used:
- 3 kg of skimmed milk.
- 9.05% initial total solids.
Resulting in:
- 1 kg of final product.
- 15.33% final total solids.
Quark/Tvorog cheese with 9% fat on total solids
A second formulation used:
- 2.8 kg of partially skimmed milk.
- 11.44% initial total solids.
Resulting in:
- 1 kg of final product.
- 22.21% final total solids.
The results demonstrated high efficiency in dairy solids valorization and a significant improvement in process profitability.
Integration into existing industrial lines
One of the most important aspects of the solution developed by Perinox is its ability to be integrated into existing production lines without major modifications to the overall process scheme.
This facilitates:
- Rapid industrial implementation.
- Reduced adaptation costs.
- Production scalability.
- Improved return on investment.
In addition to fresh fermented cheese production, Perinox membrane technologies are also applied in:
- Cheese production by ultrafiltration.
- Whey valorization.
- Protein recovery.
- Milk concentration processes.
Further information is available in the article about cheese production through ultrafiltration and membrane technologies.
Membrane technologies for a more efficient dairy industry
The growing demand for more efficient and sustainable processes is driving the adoption of membrane technologies throughout the dairy industry.
Crossflow filtration and ultrafiltration technologies allow manufacturers to:
- Maximize protein and solids valorization.
- Improve industrial yield.
- Reduce product losses.
- Optimize energy consumption.
- Obtain higher quality and more stable products.
Through this development, Perinox continues strengthening its expertise in advanced tangential flow filtration solutions for the dairy industry and other complex fluid applications.
To better understand the global approach of these technologies, see the main article on crossflow filtration and industrial valorization.
