Patent Description:
Membrane filtration processes are non-thermal fractionation and concentration technologies for fluids. When a fluid is passed through a semi-permeable membrane under pressure, the components that get retained on the surface of the membranes are called retentates or concentrates, while the materials that pass through the membrane are collectively called the permeate. Membrane technologies generally do not involve heat or chemicals for fractionation or concentration, and therefore do not adversely affect the properties of the fluid, which is beneficial for milk and its components. When fluids like milk are fractionated by these membrane technologies, typically proteins do not get denatured, enzymes do not get inactivated, vitamins are not destroyed, and reactions between proteins and sugars do not occur.

<CIT> discloses processes for preparing dry or powder dairy compositions having low lactose contents and containing polyphenol compounds. The resultant dry or powder dairy compositions can be used to form reconstituted fluid dairy products, which can have improved organoleptic properties, such as less cooked flavor, sulfur odor, and brown color.

<NPL> discloses a multi-stage membrane-integrated hybrid reactor system for fermentative production of high purity acetic acid and whey protein from waste cheese whey.

<CIT> discloses methods for preparing dairy compositions using an ultrafiltration step and a nanofiltration step, followed by diafiltration of the nanofiltration retentate, and then at least one of a reverse osmosis and a forward osmosis step.

Consistent with embodiments of this invention, a method for making a dairy composition is disclosed. This method comprises (i) ultrafiltering a milk product to produce a UF permeate fraction and a UF retentate fraction; (ii) nanofiltering the UF permeate fraction to produce a NF permeate fraction and a NF retentate fraction; (iii) subjecting the NF permeate fraction to a forward osmosis step to produce a mineral concentrate, wherein the forward osmosis step is conducted at a pressure of less than or equal to <NUM> MPa (<NUM> psig), at a temperature in a range from <NUM> to <NUM>, and at a concentration factor of at least <NUM> and less than or equal to <NUM>, based on wt. % solids; and (iv) combining at least the UF retentate fraction and the mineral concentrate to form the dairy composition.

In one embodiment, the combining step further comprises adding a fat-rich fraction to form the dairy composition.

In one embodiment, the combining step further comprises adding water to form the dairy composition.

In one embodiment, step (iii) comprises subjecting the NF permeate fraction to the forward osmosis step to produce the mineral concentrate and a diluted draw solution; and the method further comprises (v) removing at least a portion of water from the diluted draw solution to form a draw solution.

In one embodiment, the step of removing at least a portion of water from the diluted draw solution comprises subjecting the diluted draw solution to reverse osmosis or evaporation.

In one embodiment, the milk product comprises skim milk; and the method further comprises a step of separating a raw milk into the milk product and the fat-rich fraction.

In one embodiment, the UF retentate fraction is treated with lactase enzyme prior to the combining step; and/or the mineral concentrate is treated with lactase enzyme prior to the combining step.

In one embodiment, the combining step further comprises the addition of an ingredient, wherein the ingredient comprises a sugar/sweetener, a flavorant, a preservative, a stabilizer, an emulsifier, a prebiotic substance, a special probiotic bacteria, a vitamin, a mineral, an omega <NUM> fatty acid, a phyto-sterol, an antioxidant, a colorant, or any combination thereof.

In one embodiment, the method further comprises a step of heat treating the dairy composition; and the step of heat treating comprises: UHT sterilization at a temperature in a range from <NUM> to <NUM> for a time period in a range from <NUM> to <NUM> seconds; or pasteurizing at a temperature in a range from <NUM> to <NUM> for a time period in a range from <NUM> to <NUM> minutes.

In one embodiment, the forward osmosis step is conducted at a concentration factor of at least <NUM>, based on wt. % minerals.

In one embodiment, the forward osmosis step is conducted at a concentration factor of less than or equal to <NUM>, based on wt. % minerals.

In one embodiment, the forward osmosis step is conducted using a membrane system having pore sizes of less than or equal to <NUM>.

In one embodiment, the forward osmosis step utilizes a forward osmosis draw solution comprising: sodium, potassium, chloride, or a combination thereof.

In one embodiment, the forward osmosis step utilizes a forward osmosis draw solution comprising: sucrose, glucose, galactose, lactose, fructose, maltose, or a combination thereof.

In one embodiment, the forward osmosis step utilizes a forward osmosis draw solution comprising potassium lactate.

In one embodiment, the forward osmosis step utilizes a forward osmosis draw solution comprising milk minerals.

Beneficially, and unexpectedly, the forward osmosis step can produce from the NF permeate fraction, at low operating temperatures and pressures, a mineral concentrate with very high mineral and solids contents, in some cases an order of magnitude greater than what can be achieved using traditional reverse osmosis techniques.

<FIG> presents a schematic flow diagram of a separations process consistent with embodiments of this disclosure, which utilizes forward osmosis.

To define more clearly the terms used herein, the following definitions are provided. Unless otherwise indicated, the following definitions are applicable to this disclosure. If a term is used in this disclosure but is not specifically defined herein, the definition from the <NPL>), can be applied, as long as that definition does not conflict with any other disclosure or definition applied herein, or render indefinite or non-enabled any claim to which that definition can be applied.

In this disclosure, while the method is often described in terms of "comprising" various components or steps, the method can also "consist essentially of" or "consist of" the various steps, unless stated otherwise.

The terms "a," "an," and "the" are intended to include plural alternatives, e.g., at least one, unless otherwise specified.

In the disclosed method, the term "combining" encompasses the contacting or addition of components in any order, in any manner, and for any length of time, unless otherwise specified. For example, the components can be combined by blending or mixing.

The "lactose fraction" is meant to encompass a milk component fraction that is rich in lactose or any derivatives thereof, e.g., hydrolyzed, un-hydrolyzed, epimerized, isomerized, or converted to oligosaccharides, as would be recognized by one of skill in the art. Moreover, unless stated otherwise, this term also is meant to encompass glucose/galactose, such as may be produced by the treatment of lactose with lactase enzyme.

Various numerical ranges are disclosed herein. When a range of any type is disclosed herein, the intent is to disclose individually each possible number that such a range could reasonably encompass, including end points of the range as well as any sub-ranges and combinations of sub-ranges encompassed therein, unless otherwise specified.

The term "about" can mean within <NUM>% of the reported numerical value, preferably within <NUM>% of the reported numerical value.

A method for making dairy compositions is disclosed and described herein. Such a method utilizes ultrafiltration, nanofiltration, and forward osmosis. Specifically, in the method, the nanofiltration permeate (NF permeate) is subjected to a forward osmosis step to produce a mineral concentrate. The forward osmosis step is conducted at -a pressure of less than or equal to <NUM> MPa (<NUM> psig); a temperature in a range from <NUM> to <NUM>; and a concentration factor of at least <NUM> and less than or equal to <NUM>, based on wt.

In accordance with this invention, the method for making a dairy composition comprises (or consists essentially of, or consists of) (i) ultrafiltering a milk product to produce a UF permeate fraction and a UF retentate fraction, (ii) nanofiltering the UF permeate fraction to produce a NF permeate fraction and a NF retentate fraction, (iii) subjecting the NF permeate fraction to a forward osmosis step to produce a mineral concentrate, the forward osmosis step being conducted at a pressure of less than or equal to <NUM> MPa (<NUM> psig), at a temperature in a range from <NUM> to <NUM>, and at a concentration factor of at least <NUM> and less than or equal to <NUM>, based on wt. % solids, and (iv) combining at least the UF retentate fraction and the mineral concentrate to form the dairy composition. In some embodiments, the combining step comprises combining at least a fat-rich fraction, the UF retentate fraction, and the mineral concentrate. Water also can be added in the combining step to form the dairy composition. Thus, in some embodiments, the combining step comprises combining the UF retentate fraction, water, and the mineral concentrate. Alternatively, the combining step can comprise combining a fat-rich fraction, the UF retentate fraction, water, and the mineral concentrate.

The features of the method (e.g., the characteristics of the milk product, the ultrafiltering step and the resultant UF permeate fraction and UF retentate fraction, the nanofiltering step and the resultant NF permeate fraction and NF retentate fraction, the forward osmosis step and the resultant mineral concentrate, and the components that are combined to form the dairy composition, among others) are described below. Moreover, other process steps can be conducted before, during, and/or after any of the steps listed in the disclosed method, unless stated otherwise. Additionally, any dairy compositions (e.g., finished milk products, ready for consumption) produced in accordance with the disclosed method are described below.

Filtration technologies (e.g., ultrafiltration, nanofiltration, forward osmosis, etc.) can separate or concentrate components in mixtures - such as milk - by passing the mixture through a membrane system (or selective barrier) under suitable conditions (e.g., pressure). The concentration/separation can be, therefore, based on molecular size. The stream that is retained by the membrane is called the retentate (or concentrate).

The milk product in step (i) can comprise (or consist essentially of, or consist of) skim milk, or alternatively, whole milk. The method further comprises a step of separating (e.g., centrifugally separating) a raw milk or fresh milk (whole milk) into the milk product (also referred to as skim milk) and a fat-rich fraction (also referred to as cream or butter fat). Thus, according to one embodiment, the milk product comprises skim milk; and the method further comprises a step of separating a raw milk into the milk product and the fat-rich fraction. The raw milk or fresh milk (whole milk) can be cow's milk, which contains approximately <NUM> wt. % water, <NUM>-<NUM> wt. % protein, <NUM>-<NUM> wt. % carbohydrates/lactose, <NUM>-<NUM> wt. % fat, and <NUM>-<NUM> wt. % minerals. When the fresh or raw milk product is separated into the skim milk product and the fat-rich fraction, the fat-rich fraction typically contains high levels of fat (e.g., <NUM>-<NUM> wt. % fat, or <NUM>-<NUM> wt. % fat) and solids (e.g., <NUM>-<NUM> wt. %, or <NUM>-<NUM> wt. %), and often contains approximately <NUM>-<NUM> wt. % protein, <NUM>-<NUM> wt. % lactose, and <NUM>-<NUM> wt. % minerals, although not limited thereto.

In step (i), ultrafiltering of the milk product can be conducted using ultrafiltration membranes with pore sizes that typically are in the <NUM> to <NUM> range, or the <NUM> to <NUM> range. In the dairy industry, the ultrafiltration membranes often are identified based on molecular weight cut-off (MWCO), rather than pore size. The molecular weight cut-off for ultrafiltration membranes can vary from <NUM>-<NUM>,<NUM> Daltons, or from <NUM>,<NUM>-<NUM>,<NUM> Daltons. For instance, the milk product can be ultrafiltered using a polymeric membrane system (ceramic membranes also can be employed). The polymeric membrane system (or ceramic membrane system) can be configured with pore sizes such that the materials having molecular weights greater than about <NUM>,<NUM> Daltons, greater than about <NUM>,<NUM> Daltons, or greater than about <NUM>,<NUM> Daltons, are retained, while lower molecular weight species pass through. For instance, UF membrane systems with a molecular weight cut-off of <NUM>,<NUM> Daltons can be used in the dairy industry for separating and concentrating milk proteins. In some embodiments, the step of ultrafiltering utilizes a membrane system having pore sizes in a range from about <NUM> to about <NUM>, and operating pressures typically in the <NUM>-<NUM> MPa (<NUM>-<NUM> psig) range, or the <NUM>-<NUM> MPa (<NUM>-<NUM> psig) range. While not being limited thereto, the ultrafiltration step often can be conducted at a temperature in a range from about <NUM> to about <NUM>.

In step (ii), the UF permeate fraction is subjected to a nanofiltration step to produce a NF permeate fraction and a NF retentate fraction. Nanofiltration in the dairy industry typically uses membrane elements that retain particles with molecular weights above approximately <NUM>-<NUM> Da. Nanofiltration is a pressure driven process in which the liquid is forced through a membrane under pressure, and materials having a molecular weight greater than the specified cut-off are retained, while smaller particles pass though the membrane pores. For generally separating lactose from minerals in a UF permeate stream, a pore size can be selected for maximum retention of lactose. Like ultrafiltration, nanofiltration can simultaneously perform both concentration and separation.

Nanofiltering of the UF permeate fraction can be conducted using nanofiltration membranes with pore sizes that typically are in the <NUM> to <NUM> micron range, for example, pore sizes in a range from about <NUM> to about <NUM>. In some embodiments, the step of nanofiltration utilizes a membrane system having pore sizes in a range from <NUM> to about <NUM>, with operating pressures typically in the <NUM>-<NUM> MPa (<NUM>-<NUM> psig) range, and operating temperatures ranging from about <NUM> to about <NUM> (or from about <NUM> to about <NUM>), although not limited thereto.

In step (iii), the NF permeate fraction is subjected to a forward osmosis step to produce a mineral concentrate. Additionally, water can be removed from the NF permeate fraction in the forward osmosis step to form a diluted draw solution. Forward osmosis is typically performed at much lower pressures (and uses less energy) than standard reverse osmosis, and utilizes a semi-permeable membrane system having pore sizes such that water passes through, while other materials (e.g., proteins, fats, lactose or other sugars, and minerals) do not. Operating pressures are less than or equal to <NUM> MPa (<NUM> psig). The operating pressure may be less than or equal to about <NUM>. 14MPa (<NUM> psig). Thus, the operating pressure of the forward osmosis step include from about <NUM> MPa (<NUM> psig (atmospheric pressure)) to <NUM> MPa (<NUM> psig),, such as from about <NUM> MPa (<NUM> psig) to about <NUM> MPa (<NUM> psig), from about <NUM> MPa (<NUM> psig) to <NUM> MPa (<NUM> psig), from about <NUM> MPa (<NUM> psig) to about <NUM> MPa (<NUM> psig), from about <NUM> MPa (<NUM> psig) to <NUM> MPa (<NUM> psig), from about <NUM> MPa (<NUM> psig) to about <NUM> MPa (<NUM> psig).

The forward osmosis step is conducted at a temperature in a range from <NUM> to <NUM>. While not being limited thereto, forward osmosis membrane systems have a molecular weight cutoff of much less than <NUM> Da and, therefore, components other than water can be concentrated in the forward osmosis process (e.g., minerals). Generally, forward osmosis comprises a membrane system having pore sizes of less than or equal to about <NUM>.

The forward osmosis step is conducted at a concentration factor of at least <NUM> and less than or equal to <NUM>, based on wt.

As compared to reverse osmosis, the forward osmosis step consistent with this invention can efficiently achieve higher solids content and higher minerals content. Further, there is less fouling during forward osmosis, as compared to reverse osmosis, and fouling can be removed easily, resulting in lower costs and less downtime for membrane cleaning and replacement. Moreover, forward osmosis systems generally are smaller in size and footprint than reverse osmosis systems, so retrofitting in small or congested spaces can be achieved.

Any suitable draw solution that has a higher concentration of solutes or ions than the solution from which water is to be drawn through a semipermeable membrane can be used for the forward osmosis step. Generally, a solution containing a high concentration of monovalent ions can be used, such as sodium, potassium, chloride, and the like, as well as combinations thereof. Additionally or alternatively, the draw solution can contain a high concentration of any suitable sugar, representative examples of which can include sucrose, glucose, galactose, lactose, fructose, maltose, and the like, as well as combinations thereof. Additionally or alternatively, the draw solution can contain a high concentration of milk minerals, and the concentrated mineral solution can be derived from any suitable source. The concentration difference between a feed stream (e.g., the NF permeate) and the draw solution is used to remove water from the feed stream. Generally, forward osmosis removes water from a lower concentration solution (feed side) to a higher concentration solution (draw solution) by osmotic pressure, when there is a semipermeable membrane or barrier (e.g., a polymeric membrane) between the two solutions. Thus, minerals and other non-water components of the feed stream (e.g., the NF permeate) are concentrated in forward osmosis, resulting in the mineral concentrate described herein.

The mineral concentrate, after the forward osmosis step, can contain less than or equal to about <NUM> wt. % lactose, or less than or equal to about <NUM> wt. % lactose, and often at least about <NUM> wt. % lactose, or at least about <NUM> wt. % lactose, but is not limited thereto. Non-limiting examples of the protein content of the mineral concentrate include from about <NUM> to about <NUM> wt. % protein, from about <NUM> to about <NUM> wt. % protein, from about <NUM> to about <NUM> wt. % protein, and the like.

The mineral content of the mineral concentrate, surprisingly, can be very high, and typically falls within the range from about <NUM> wt. % minerals to about <NUM> wt. % minerals. For example, the mineral concentrate can contain from about <NUM> to about <NUM> wt. % minerals in one embodiment, from about <NUM> to about <NUM> wt. % minerals in another embodiment, from about <NUM> to about <NUM> wt. % minerals in yet another embodiment, and from about <NUM> to about <NUM> wt. % minerals in still another embodiment. As disclosed herein, mineral contents are quantified by the ash test.

Likewise, the solids content of the mineral concentrate, surprisingly, can be very high, and typically falls within the range from about <NUM> wt. % solids to about <NUM> wt. For example, the mineral concentrate can contain from about <NUM> to about <NUM> wt. % solids, such as from about <NUM> to about <NUM> wt. % solids, such as from about <NUM> to about <NUM> wt. % solids, and such as from about <NUM> to about <NUM> wt.

Unexpectedly, the forward osmosis step disclosed herein is a very effective technique for increasing the mineral content and solids content of the incoming feed stream, in this case, the NF permeate fraction. Concentration factors of at least <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, and at least about <NUM>, can be achieved via the forward osmosis step disclosed herein, and often, the concentration factor can be as much as <NUM>, <NUM>, or <NUM>. These concentration factors are applicable to a wt. % solids basis. For example, subjecting a NF permeate fraction having <NUM> wt. % minerals and <NUM> wt. % solids to forward osmosis, resulting in a mineral concentrate having <NUM> wt. % minerals and <NUM> wt. % solids, would translate to a concentration factor of <NUM> based on minerals and a concentration factor of <NUM> based on solids. The concentration factor encompassed herein, at which the reverse osmosis step is conducted, is at least <NUM> and less than or equal to <NUM>, such as from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>, and these concentration factors are applicable to a wt. % solids basis.

Beneficially, the mineral concentrate (after forward osmosis in the methods disclosed herein) can have a wt. % solids content (or a wt. % minerals content) that is - unexpectedly - significantly greater than that of a wt. % solids content (or a wt. % minerals content) of a reverse osmosis retentate fraction (RO retentate fraction) obtained by subjecting an otherwise equivalent NF permeate fraction to a reverse osmosis step. Thus, replacing a reverse osmosis step with a forward osmosis step results in a retentate stream having much greater amounts of minerals and solids. For example, the wt. % solids content (or wt. % minerals content) of the mineral concentrate can be <NUM> times, <NUM> times, <NUM> times, or <NUM> times greater than (and often can range up to <NUM>-<NUM> times, or <NUM>-<NUM> times, or more, greater than) the corresponding wt. % solids content (or wt. % minerals content) of a RO retentate fraction obtained by subjecting an otherwise equivalent NF permeate fraction to a reverse osmosis step.

In one embodiment, step (iii) comprises subjecting the NF permeate fraction to the forward osmosis step to produce the mineral concentrate and a diluted draw solution; and the method further comprises (v) removing at least a portion of water from the diluted straw solution to form a draw solution. Thus, the diluted draw solution resulting from forward osmosis can be subjected to a step of removing at least a portion of water from the diluted draw solution to form a draw solution. The draw solution can be re-used in the forward osmosis step. In one embodiment, removing at least a portion of water from the diluted draw solution comprises subjecting the diluted draw solution to reverse osmosis or evaporation. Thus, removing at least a portion of water from the diluted draw solution to form a draw solution may comprise subjecting the diluted draw solution to reverse osmosis. Reverse osmosis is a fine filtration process or concentration process in which substantially all components are retained (retentate) other than water, which passes through the reverse osmosis membrane. Often, reverse osmosis membrane systems have a molecular weight cutoff of much less than <NUM> Da and, therefore, components other than water are concentrated in the reverse osmosis process (e.g., minerals). Generally, reverse osmosis comprises a membrane system having pore sizes of less than or equal to about <NUM>. Operating pressures typically are in the <NUM>-<NUM> MPa (<NUM>-<NUM> psig), or <NUM>-<NUM> MPa (<NUM>-<NUM> psig), range. Temperatures ranging from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>, often can be used.

Alternatively, removing at least a portion of water from the diluted draw solution can comprise subjecting the diluted draw solution to evaporation. While not limited thereto, temperatures of greater than <NUM> often are employed, as well as sub-atmospheric pressures. Whether evaporation or reverse osmosis, the resulting water fraction is substantially free of all of the milk components and draw solution components (from forward osmosis). Thus, the water fraction can be substantially all water, for instance, at least about <NUM> wt. % water, at least about <NUM> wt. % water, or at least about <NUM> wt.

Step (iv) of the method of making a dairy composition comprises combining at least the UF retentate fraction and the mineral concentrate to form the dairy composition. In one embodiment, the combining step further comprises adding a fat-rich fraction to form the dairy composition. These components can be mixed or combined, in any suitable relative proportions, to form the dairy composition. Moreover, an ingredient and/or an additional milk fraction also can be added in the combining step. Additionally or alternatively, an ingredient and/or an additional milk fraction can be added to the dairy composition after the combining step. Non-limiting examples of suitable ingredients can include a sugar/sweetener, a flavorant, a preservative (e.g., to prevent yeast or mold growth), a stabilizer, an emulsifier, a prebiotic substance, a special probiotic bacteria, a vitamin, a mineral, an omega <NUM> fatty acid, a phyto-sterol, an antioxidant, or a colorant, and the like, as well as any mixture or combination thereof.

The additional milk fraction can be a "component-rich fraction," which is meant to encompass any fraction containing at least <NUM>% more of a component of milk (protein, lactose/sugar, fat, minerals) than that found in cow's milk. For instance, a lactose-rich fraction often can contain from about <NUM> to about <NUM> wt. % sugar (i.e., in any form, such as lactose, glucose, galactose, etc.), from about <NUM> to about <NUM> wt. % sugar, or from about <NUM> to about <NUM> wt. A mineral-rich fraction can contain from about <NUM> to about <NUM> wt. % minerals, from about <NUM> to about <NUM> wt. % minerals, or from about <NUM> to about <NUM> wt. % minerals. A fat-rich fraction often can contain from about <NUM> to about <NUM> wt. % fat, from about <NUM> to about <NUM> wt. % fat, or from about <NUM> to about <NUM> wt.

These component-rich milk fractions can be produced as described herein or by any technique known to those of skill in the art, such as by membrane filtration processes disclosed in <CIT>, <CIT>, and <CIT>. Additionally or alternatively, the component-rich milk fraction (or milk fractions) can be produced by a process comprising mixing water and a powder ingredient (e.g., protein powder, lactose powder, mineral powder, etc.).

Any suitable vessel and conditions can be used for any combining step disclosed herein, and such can be accomplished batchwise or continuously. As an example, the components can be combined in a suitable vessel (e.g., a tank, a silo, etc.) under atmospheric pressure, optionally with agitation or mixing, and optionally with an ingredient (or ingredients) and/or an additional milk fraction (or milk fractions), to form a batch of the finished dairy composition. As another example, the components can be combined continuously in a pipe or other suitable vessel under slight pressure (e.g., <NUM>-<NUM> MPa (<NUM>-<NUM> psig)), optionally mixed with ingredients and/or additional milk fractions, and the finished dairy composition can be transferred to a storage tank or filled into containers for retail distribution and sale. Representative systems that can be used for this continuous combining, mixing, and/or packaging can include tetra aldose systems and tetra flexidose systems. Other appropriate methods, systems, and apparatus for combining the components and other ingredients and/or milk fractions are readily apparent from this disclosure.

Step (iv) comprises combining at least the UF retentate fraction and the mineral concentrate. In one embodiment, step (iv) comprises combining, at least, the fat-rich fraction, the UF retentate fraction, and the mineral concentrate. Lactase enzyme can be added to any component or all components prior to the combining step, or lactase enzyme can be added to the resultant dairy composition. As described herein, these components can be combined in any suitable proportions, and optionally, any suitable ingredient and/or additional milk fraction can added in step (iv) to form the dairy composition. Additionally or alternatively, any suitable ingredient and/or additional milk fraction can be added to the dairy composition after the combining step.

According to one embodiment, the UF retentate fraction is treated with lactase enzyme prior to the combining step; and/or the mineral concentrate is treated with lactase enzyme prior to the combining step. Thus, the UF retentate fraction can be treated with lactase enzyme prior to the combining step, if desired. Likewise, if desired, the mineral concentrate can be treated with lactase enzyme prior to the combining step. Additionally or alternatively, the lactase enzyme can be added during step (iv), or the dairy composition - after step (iv) - can be treated with lactase enzyme. In these circumstances, the lactose content can be reduced to less than about <NUM> wt. %, less than about <NUM> wt. %, less than about <NUM> wt. %, or less than about <NUM> wt.

Optionally, the method described herein can further comprise a step of microfiltering the milk product (e.g., skim milk) prior to the ultrafiltering step, resulting in a MF permeate fraction and a MF retentate fraction. In such instances, step (i) can comprise ultrafiltering the MF permeate fraction to produce a UF permeate fraction and a UF retentate fraction. Microfiltering can be conducted using microfiltration membranes with relatively large pore sizes that typically are in the <NUM> to <NUM> micron range, for example, pore sizes in a range from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. In some embodiments, the step of microfiltering utilizes a membrane system having pore sizes in a range from about <NUM> to about <NUM>, with operating pressures typically less than about <NUM> MPa (<NUM> psig) (e.g., <NUM>-<NUM> MPa (<NUM>-<NUM> psig)) and operating temperatures ranging from about <NUM> to about <NUM> (or from about <NUM> to about <NUM>), although not limited thereto.

Often, microfiltration membranes can be used in the dairy industry to remove bacteria, bacterial spores, somatic cells, and other extraneous suspended materials from fluid milk, and therefore improve the quality and shelf-life of the resultant milk product. Microfiltration membranes can be used to separate fat from cheese or cheese whey and to separate milk fat from fluid milks, as an alternative to centrifugal separation. Microfiltration systems also can be used to separate casein proteins of milk from whey proteins of milk. The MF membrane elements can be made from polysulfones (polymeric) or ceramics.

The protein content of the UF retentate fraction often can be at least about <NUM> wt. %, at least about <NUM> wt. %, at least about <NUM> wt. %, at least about <NUM> wt. %, or at least about <NUM> wt. Illustrative and non-limiting ranges for the protein content of the UF retentate can include from about <NUM> to about <NUM> wt. % protein, from about <NUM> to about <NUM> wt. % protein, or from about <NUM> to about <NUM> wt.

Similarly, while not being limited thereto, the lactose content of the UF permeate fraction and/or the UF retentate fraction generally can be less than or equal to about <NUM> wt. %, or less than or equal to about <NUM> wt. %, but greater than or equal to about <NUM> wt. %, or greater than or equal to about <NUM> wt.

The lactose content of the NF retentate fraction can be at least about <NUM> wt. %, at least about <NUM> wt. %, at least about <NUM> wt. %, at least about <NUM> wt. %, or at least about <NUM> wt. % lactose, but is not limited thereto. Illustrative and non-limiting ranges for the lactose content of the NF retentate fraction can include from about <NUM> to about <NUM> wt. %, from about <NUM> to about <NUM> wt. %, from about <NUM> to about <NUM> wt. %, from about <NUM> to about <NUM> wt. %, or from about <NUM> to about <NUM> wt. The NF retentate fraction typically contains minimal amounts of protein, typically less than about <NUM> wt. %, less than about <NUM> wt. %, less than about <NUM> wt. %, or less than about <NUM> wt.

Moreover, the method disclosed herein also can further comprise a step of heat treating the dairy composition. The step of heat treating can comprise pasteurizing at a temperature in a range from about <NUM> to about <NUM> for a time period in a range from less than one minute (e.g., from <NUM> to <NUM> seconds) up to about <NUM> minutes. In one embodiment, the step of heat treating comprises UHT sterilization at a temperature in a range from <NUM> to <NUM> for a time period in a range from <NUM> to <NUM> seconds. Other appropriate pasteurization or sterilization temperature and time conditions are readily apparent from this disclosure. Any suitable technique and apparatus for performing the pasteurization/sterilization process can be employed, whether operated batchwise or continuously.

The method for making a dairy composition, after a heat treatment step, can further comprise a step of packaging (aseptically or otherwise) the dairy composition in any suitable container and under any suitable conditions. Thus, after combining the various components, ingredients, and additional milk fractions as described herein to form the dairy composition, the dairy composition can be packaged under aseptic conditions (or non-aseptic conditions) in a container. Any suitable container can be used, such as might be used for the distribution and/or sale of dairy products in a retail outlet. Illustrative and non-limiting examples of typical containers include a cup, a bottle, a bag, or a pouch, and the like. The container can be made from any suitable material, such as glass, metal, plastics, and the like, as well as combinations thereof.

While not being limited thereto, the dairy composition can have a protein content of from about <NUM> to about <NUM> wt. %, or from about <NUM> to about <NUM> wt. Additionally or alternatively, the dairy composition can have a fat content of from about <NUM> to about <NUM> wt. %, or from about <NUM> to about <NUM> wt. Additionally or alternatively, the dairy composition can have a mineral content of from about <NUM> to about <NUM> wt. Additionally or alternatively, the dairy composition can have a lactose content of less than or equal to about <NUM> wt.

An example of a dairy composition made using the method according to the present disclosure can contain less than or equal to about <NUM> wt. % fat, from about <NUM> to about <NUM> wt. % protein, from about <NUM> to about <NUM> wt. % minerals, and less than or equal to about <NUM> wt. Another example of a dairy composition made using the method according to the present disclosure can contain from about <NUM> to about <NUM> wt. % fat, from about <NUM> to about <NUM> wt. % protein, from about <NUM> to about <NUM> wt. % minerals, and less than or equal to about <NUM> wt. Yet, another example of a dairy composition made using the method according to the present disclosure can contain from about <NUM> to about <NUM> wt. % fat, from about <NUM> to about <NUM> wt. % protein, from about <NUM> to about <NUM> wt. % minerals, and less than or equal to about <NUM> wt. Moreover, another example of a dairy composition made using the method according to the present disclosure can contain from about <NUM> to about <NUM> wt. % fat, from about <NUM> to about <NUM> wt. % protein, from about <NUM> to about <NUM> wt. % minerals, and less than or equal to about <NUM>% fat.

Additional examples of typical dairy compositions that can be produced by the method disclosed herein include whole milk, low-fat milk, skim milk, buttermilk, flavored milk, low lactose milk, high protein milk, lactose-free milk, ultra-filtered milk, micro-filtered milk, concentrated milk, evaporated milk, high protein, high calcium, and reduced sugar milk, and the like.

An example of a suitable separations process consistent with this disclosure is shown in <FIG>. First, fresh whole milk is separated into cream and a skim milk product. The skim milk product is then subjected to ultrafiltration, such as via a polymeric membrane system, as described herein, resulting in a UF retentate often referred to as a protein-rich milk fraction, and a UF permeate. The UF permeate is then subjected to nanofiltration, resulting in a NF permeate and a NF retentate (which is lactose-rich).

The NF permeate in <FIG> is subjected to forward osmosis, resulting in a forward osmosis retentate (mineral concentrate) and a diluted draw solution. The forward osmosis step is conducted at a pressure of less than or equal to <NUM> MPa (<NUM> psig); a temperature in a range from <NUM> to <NUM>; and a concentration factor of at least <NUM> and less than or equal to <NUM>, based on wt. The diluted draw solution can be subjected to reverse osmosis or evaporation, resulting in the recovery of a draw solution (which can be used in the forward osmosis step) and water (which can be blended with other components to form a dairy composition).

Total solids (wt. %) was determined in accordance with procedure SMEDP <NUM> C by CEM Turbo Solids and Moisture Analyzer (CEM Corporation, Matthews, North Carolina). Ash is the residue remaining after ignition in a suitable apparatus at <NUM> to a constant weight; such treatment at <NUM> typically eliminates all organic matter, with the remaining material being primarily minerals (<NPL>). The ash test was performed by using a Phoenix (CEM Microwave Furnace), which heated the samples at <NUM> for <NUM>. The ash content (or mineral content) was determined in wt.

Example <NUM> summarizes a series of experiments in which raw milk was separated into cream (a fat-rich fraction) and skim milk, which was subjected to an ultrafiltration step to produce a UF permeate fraction and a UF retentate fraction (a protein-rich fraction), having the respective compositions (concentration ranges) shown in Table I. The UF permeate fraction then was subjected to a nanofiltration step to produce a NF permeate fraction and a NF retentate fraction (a lactose-rich fraction), followed by subjecting the NF permeate fraction to reverse osmosis to produce a RO retentate fraction (a mineral-rich fraction) and a RO permeate fraction (a milk water fraction). In Table I, the mineral content (in wt. %) is generally similar to the ash content (wt. %), and thus the result of an ash test is used for quantification of the total mineral content in this disclosure. For each of the milk fractions in Table I, Table II summarizes the respective Ca, Mg, Na, K, Cl, and P contents (concentration ranges) in ppm by weight.

Specific Ca, Mg, Na, and K contents were determined using a Perkin Elmer Atomic Absorption Spectrophotometer. Samples were treated with trichloroacetic acid to precipitate proteins and the filtrate was analyzed by the Atomic Absorption Spectrophotometer. Phosphorus content was determined via Inductively Coupled Plasma Spectrometry (official method of <NPL>). Chlorine content was determined by the official method of analysis of <NPL>; AOAC International, Gaithersburg, MD (<NUM>).

Similar to Example <NUM>, Example <NUM> fractionated skim milk using ultrafiltration (to produce a UF permeate fraction and a UF retentate fraction) and nanofiltration of the UF permeate fraction (to produce a NF permeate fraction and a NF retentate fraction) using a GEA Engineering Pilot filtration unit. Then, the NF permeate fraction was subjected to forward osmosis at a temperature of approximately <NUM> and a pressure of <NUM>-<NUM> MPa (<NUM>-<NUM> psig), using a Ederna Micro-Pilot unit (Toulouse Cedex <NUM>, France) with an Ederna draw solution containing a high concentration of potassium lactate. The membrane used was a spiral wound cellulose triacetate membrane (Ederna, France). Table III summarizes the respective compositions of the NF permeate fraction and the FO retentate (the mineral concentrate), while Table IV summarizes the respective Ca, Mg, Na, K, Cl, and P contents in ppm by weight.

Beneficially, the mineral and solids contents were significantly increased with the forward osmosis step. The NF permeate fraction contained <NUM> wt. % minerals and <NUM> wt. % solids, and the FO retentate (the mineral concentrate) contained <NUM> wt. % minerals and <NUM> wt. This translates to unexpectedly high concentration factors of <NUM> based on minerals, and <NUM> based on solids. Further, the respective mineral and solids contents of the FO retentate in Table III are about <NUM> times that of the respective mineral and solids contents of the RO retentate in Table I.

In Example <NUM>, a dairy composition was produced having the respective compositions shown in Tables V-VI by blending, at appropriate relative amounts, the UF retentate fraction (see Tables I-II), water, and the FO retentate (mineral concentrate; see Tables III-IV). In similar fashion, a wide variety of dairy compositions can be produced via the methods described herein, having a wide range of fat, protein, lactose, mineral (ash), and total solids contents.

Example <NUM> was performed similarly to that of Example <NUM>, except that the NF permeate fraction was subjected to forward osmosis at a temperature of approximately <NUM>. Table VII summarizes the respective compositions of the NF permeate fraction and the FO retentate (the mineral concentrate), while Table VIII summarizes the respective Ca, Mg, Na, K, Cl, and P contents in ppm by weight.

Beneficially, the mineral and solids contents were significantly increased with the forward osmosis step. The NF permeate fraction contained <NUM> wt. % minerals and <NUM> wt. % solids, and the FO retentate (the mineral concentrate) contained <NUM> wt. % minerals and <NUM> wt. This translates to unexpectedly high concentration factors of <NUM> based on minerals, and <NUM> based on solids. Further, the respective mineral and solids contents of the FO retentate in Table VII are about <NUM>-<NUM> times that of the respective mineral and solids contents of the RO retentate in Table I.

Claim 1:
A method for making a dairy composition, the method comprising:
(i) ultrafiltering a milk product to produce a UF permeate fraction and a UF retentate fraction;
(ii) nanofiltering the UF permeate fraction to produce a NF permeate fraction and a NF retentate fraction;
(iii) subjecting the NF permeate fraction to a forward osmosis step to produce a mineral concentrate, wherein the forward osmosis step is conducted at:
- a pressure of less than or equal to <NUM> MPa (<NUM> psig);
- a temperature in a range from <NUM> to <NUM>; and
- a concentration factor of at least <NUM> and less than or equal to <NUM>, based on wt. % solids;
and
(iv) combining at least the UF retentate fraction and the mineral concentrate to form the dairy composition.