Microfiltration of gluten processing streams from corn wet milling

In corn wet milling, dry matter can be separated from liquids in process streams with centrifuges or vacuum belt filtration (VBF). Because separations usually are not complete, dry matter can be lost in the liquid streams (overflow from the gluten thickener centrifuge and filtrate from VBF). This represents a loss of nutrients, especially protein, to low valued coproducts and reduces quality of water for recycling within the process. The objective was to compare microfiltration of light and heavy gluten process streams to conventional separation methods. Batches of light and heavy gluten were obtained from a wet mill plant and processed by microfiltration. Samples of permeate and concentrate from microfiltration were analyzed and compared to corresponding streams from wet milling. Microfiltration of light gluten resulted in concentrate and permeate streams similar in composition to conventionally processed light gluten using a centrifuge, suggesting that microfiltration is as effective as centrifugation in partitioning solids and water in light gluten. Dewatering of heavy gluten found that conventional VBF caused dry matter concentrations in gluten cake to be higher than concentrate from microfiltration. Permeate from microfiltration of heavy gluten had higher concentrations of ash and lower soluble nitrogen than filtrate from VBF. Microfiltration was able to remove more ash from concentrate, which may improve the value of wet milling coproducts. These data demonstrated microfiltration has potential for separation of light and heavy gluten streams, but more data are needed on effectiveness and practicality.     

Characterization of gluten processing streams

Corn gluten meal (CGM) is a major coproduct of corn wet milling; it has value because of high protein. However, variation in composition and high P content reduce market value. Data that characterize gluten streams would be helpful in identifying key processing steps that could be modified to improve the quality of CGM and increase processing efficiency. Few data are published in the literature on the detailed composition of gluten processing streams. The objective was to characterize the gluten process streams in a corn wet milling plant.Samples were obtained from one plant over a six month period and analyzed for dry matter (DM), total N (protein), ash and elements. DM and macroelement content of the streams were increased significantly during processing. Ash, priority pollutant elements and microelement concentrations were low and of little concern. About 38% of the N (protein) in light gluten was not recovered in the CGM; most of this was lost at the gluten thickener step into the gluten thickener overflow. Much of the P also was removed at this step. Modification of the gluten thickener overflow to increase N and reduce P could make CGM a more valuable coproduct and improve processing efficiency.     

A two-stage ultrafiltration and nanofiltration process for recycling dairy wastewater

A two-stage ultrafiltration and nanofiltration (UF/NF) process for the treatment of model dairy wastewater was investigated to recycle nutrients and water from the wastewater. Ultracel PLGC and NF270 membranes were found to be the most suitable for this purpose. In the first stage, protein and lipid were concentrated by the Ultracel PLGC UF membrane and could be used for algae cultivation to produce biodiesel and biofuel, and the permeate from UF was concentrated by the NF270 membrane in the second stage to obtain lactose in retentate and reusable water in permeate, while the NF retentate could be recycled for anaerobic digestion to produce biogas. With this approach, most of dairy wastewater could be recycled to produce reusable water and substrates for bioenergy production. Compared with the single NF process, this two-stage UF/NF process had a higher efficiency and less membrane fouling.     

Membrane separation of protein precipitates: Studies with cross flow in hollow fibers

Hollow fiber ultrafiltration and microfiltration membranes are examined for the processing of isoelectric soya protein precipitate suspensions. A model based on the various resistances to permeate flux is used to describe membrane performance. The main resistance to permeate flux is due to the interaction between the active membrane and the soluble and precipitated protein; that is, as compared with resistances due to the active membrane itself or the membrane support structure, or arising from concentrated soluble or precipitated protein layers over the membrane surface. Soluble protein rejection and precipitate mean particle diameter are correlated with observed values of this main resistance.In contract to the ultrafiltration of soluble proteins, the flux rates observed when processing protein precipitate suspensions under a similar range of operating conditions do not approach a limiting value with increased transmembrane pressure. At high protein concentrations, greater flux rates may be achieved for precipitated as compared with soluble proteins. The use of a microfiltration membrane does not give further improvement in flux rate; this may be attributed to problems of pore fouling with precipitate particles.     

Separation of protein charge variants by ultrafiltration

The removal of product variants that form during downstream processing remains a challenge in the purification of recombinant therapeutic proteins. We examined the feasibility of separating variants with slightly different net charge using high-performance membrane ultrafiltration. A myoglobin variant was formed by reaction of the lysine epsilon-amino group with succinic anhydride. Sieving data were obtained over a range of solution conditions using commercial polyethersulfone ultrafiltration membranes. Maximum selectivity of about 7-fold was obtained at very low conductivity due to the strong electrostatic repulsion of the more negatively charged variant. Protein separations were performed by diafiltration. A two-stage process generated solutions of the normal myoglobin (in the permeate) and the charge variant (in the retentate), both at greater than 9-fold purification and 90% yield. These results provide the first demonstration that membrane systems can be used to separate proteins that differ by only a single charged amino acid residue.     

Characterization of light gluten and light steep water from a corn wet milling plant

The primary commodity of corn wet milling is starch, but two coproducts (corn gluten feed, CGF and corn gluten meal, CGM) also are produced. CGM and CGF are marketed as animal foodstuffs and are important economically; however, variation in composition reduces quality. There are few data on the effect of composition of the parent process streams, light steep water (LSW) and light gluten (LG), respectively, on composition of CGF and CGM. The objective was to characterize LG and LSW. Samples of LG and LSW were collected: (1) hourly for one day, (2) every 3 h for 3 days, and (3) daily for 3 weeks. Dry matter, N and ash were determined. Variation in composition of LG and LSW was greatest during longer periods of time (days and weeks) rather than shorter (hourly or every 3 h). There was significant variation in DM (solids) content, which directly affected the concentration of other components. Variation in N (protein) of LG and LSW accounted for much of the variation in CGF and CG. Processes that modify processing and reduce variation could increase the quality of CGF and CGM.     

Thin stillage fractionation using ultrafiltration: resistance in series model

The corn based dry grind process is the most widely used method in the US for fuel ethanol production. Fermentation of corn to ethanol produces whole stillage after ethanol is removed by distillation. It is centrifuged to separate thin stillage from wet grains. Thin stillage contains 5–10% solids. To concentrate solids of thin stillage, it requires evaporation of large amounts of water and maintenance of evaporators. Evaporator maintenance requires excess evaporator capacity at the facility, increasing capital expenses, requiring plant slowdowns or shut downs and results in revenue losses. Membrane filtration is one method that could lead to improved value of thin stillage and may offer an alternative to evaporation. Fractionation of thin stillage using ultrafiltration was conducted to evaluate membranes as an alternative to evaporators in the ethanol industry. Two regenerated cellulose membranes with molecular weight cut offs of 10 and 100 kDa were evaluated. Total solids (suspended and soluble) contents recovered through membrane separation process were similar to those from commercial evaporators. Permeate flux decline of thin stillage using a resistance in series model was determined. Each of the four components of total resistance was evaluated experimentally. Effects of operating variables such as transmembrane pressure and temperature on permeate flux rate and resistances were determined and optimum conditions for maximum flux rates were evaluated. Model equations were developed to evaluate the resistance components that are responsible for fouling and to predict total flux decline with respect to time. Modeling results were in agreement with experimental results (R ² > 0.98).     

Increasing the efficiency of the enzymatic hydrolysis of potato starch in a membrane reactor

The aim of the work was to define the physicochemical parameters of a reaction system that alter the effectiveness of a continuous recycle membrane reactor during potato starch hydrolysis. The enzymatic hydrolysis of starch in an ultrafiltration reaction system proceeded with a continuous decrease in the permeate flux, accompanied by an increase in dry substance content in both the permeate and retentate fractions. The decrease in the permeate flux was caused by an increase in feed viscosity. If a prehydrolysis process was conducted, it was possible to enzymatically hydrolyse potato starch in solutions with concentrations up to 20%. A quasi-steady state of starch enzymatic hydrolysis was reached in the ultrafiltration reaction system by alternately supplementing it with starch solution and water.     

Parameters for the recovery of proteases from surimi wash water.

Proteases are important bioactive compounds that have many applications in food processing. In this study, laboratory scale experiments were performed to establish conditions for recovery of a heat stable, acid protease from Pacific whiting (Merluccius productus) surimi process water. Reduction of proteinaceous solids and recovery of protease activity was maximized when process water was pre-treated with acid (pH 4) followed by heat (60 degrees C). In addition, acid plus heat treatment of process water appeared to improve membrane flux and concentration of protease activity (10-fold) was achieved in half as much time as treatments using acidification but not heat. Neither purification nor concentration of protease was effective using either 300 and 1000 kDa ultrafiltration or 0.3 microm microfiltration membranes. However, concentration of protease using 50 kDa ultrafiltration membranes was successful in recovering about 80% of original protease activity. Results provide conditions for further investigations into pilot plant recovery of protease from surimi process water.     

Microfiltration of streptococcal fermentation broths: study of the factors affecting the concentration effect

Streptokinase (SK) recovery from streptococcal fermentation broth by cross-flow microfiltration has been studied. Recovery of SK in the filtrate, independent of the volumetric concentration factor, is approximately two-fold lower than the initial SK activity in the fermentation broth; moreover, the SK activity in the retentate increase during the process, reaching a concentration factor of 2.73. These results show that the membrane works more as an ultrafiltration membrane, with rejection of S = 0.6, than as a microfiltration membrane. Under filtration conditions, the membrane permeation rate decreased with time. This decreased could be explained by deposition and interaction of material onto/with the membrane resulting in the concentration of permeable products. Studies of the individual concentration factors for the main streptococcal exocellular proteins, indicate clearly that the concentration of the proteins during the microfiltration process is independent of the size of the proteins, suggesting that other factors, such as charge and hydrophobicity, along with concentration-polarization, should be taken also into account for the understanding of this phenomenon. (c) 1994 John Wiley & Sons, Inc.     

Monitoring the fractionation of a whey protein isolate during dead‐end membrane filtration using fluorescence and chemometric methods

During membrane‐based separation of proteins, changes in protein concentration of the permeate and retentate streams occurs over time. The current work proposes a new approach for monitoring the changes in concentrations of proteins in both permeate and retentate by making use of data collected using fluorescence spectroscopy and intrinsic protein fluorescence analyzed by multivariate statistical techniques. Whey protein isolate consists mainly of α‐lactalbumin (α‐LA), β‐lactoglobulin (β‐LG), and small proportion of bovine serum albumin (BSA) and was used as a model system in this study. A fiber optic probe (FOP) was used to acquire multiwavelength fluorescence spectra for permeate and retentate streams at different times during UF‐based separation of the components from a multicomponent solution. Multivariate regression models were developed for predicting the concentrations of α‐LA, β‐LG, and BSA by establishing a calibration model between data acquired using the FOP and the corresponding protein concentration levels measured by size‐exclusion chromatography. The model was validated using FOP data that were not previously used for calibration of the regression models. This comparison showed that concentrations of α‐LA, β‐LG, and BSA could be predicted directly from FOP data within reasonable accuracy by making use of multivariate calibration tools. This approach has several attractive features including that it is nondestructive, fast, and relatively simple to perform. This technique has potential practical applications as it could offer the opportunity for in situ monitoring of membrane filtration processes by tracking individual protein transmission and selectivity of fractionation. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

Effectiveness of Biosorption-Assisted Microfiltration Process for Treatment of Domestic Wastewater

The efficiency of a biosorbent prepared from Eichhornia crassipes roots (ECR) was explored for the treatment of domestic sewage water in combination with low-cost ceramic microfiltration membrane. Batch sorption studies were conducted as a function of biosorbent dose, initial chemical oxygen demand (COD) loading, and temperature. Sorption equilibrium data of varying initial COD values (116–800 mg/L) indicated high potential of ECR for COD removal. Using 0.25 g/L of biosorbent dose, the equilibrium adsorption capacity was obtained as 2480 mg/g at 20°C for an initial COD loading of 800 mg/L. Microfiltration study was performed using ceramic membrane made from composition of α-alumina and clay. The effect of operating parameters on filtration characteristics was observed in terms of permeate flux. Permeate samples were characterized in terms of various parameters both for the direct filtration, as well as biosorbent-assisted filtration. The filtration behavior of wastewater at varying transmembrane pressure was explained using various membrane fouling models. The results suggested that microfiltration of domestic wastewater with incorporation of biosorbent (0.25 g/L) was highly effective for removal of organic load (>90%), turbidity (>99%), and total suspended solids (TSS) (93–95%) and the treated water quality was suitable for reuse in various purposes, such as gardening, floor and car washing, etc.     

Tangential flow microfiltration and ultrafiltration for human influenza A virus concentration and purification

Large scale purification of viruses and viral vectors for gene therapy applications and viral vaccines is a major separation challenge. Here tangential flow microfiltration and ultrafiltration using flat sheet membranes has been investigated for concentration of human influenza A virus. Ultrafiltration membranes with molecular weight cutoffs of 100 and 300 kDa as well as 0.1, 0.2 and 0.45 microm microfiltration membranes have been tested. The results indicate that use of 300 kDa membranes not only concentrate the virus particles but also lead to a significant removal of host cell proteins and DNA in the permeate. Tangential flow filtration may be used to fractionate virus particles. Human influenza A virus particles are spherical with an average size of 100 nm. Use of a 0.1 microm membrane leads to passage of virus particles less than 100 nm into the permeate and an increase of larger particles in the retentate. These results suggest that control of the transmembrane pressure, membrane pore size and pore size distribution could enable isolation of intact virus particles from damaged virions. Isolation of the virus particles of interest from viral fragments and other particulate matter could result in simplification of subsequent purification steps. Larger pore size membranes such as 0.45 microm that allow the passage of all virus particles may be used to remove host cell fragments. In addition virus particles attached to these fragments will be removed. Careful selection of membrane morphology and operating conditions will be essential in order to maximize the benefit of tangential flow filtration steps in the purification of viral products from cell cultures.     

Accelerating sample preparation through enzyme‐assisted microfiltration of Salmonella in chicken extract

Microfiltration of chicken extracts has the potential to significantly decrease the time required to detect Salmonella, as long as the extract can be efficiently filtered and the pathogenic microorganisms kept in a viable state during this process. We present conditions that enable microfiltration by adding endopeptidase from Bacillus amyloliquefaciens to chicken extracts or chicken rinse, prior to microfiltration with fluid flow on both retentate and permeate sides of 0.2 μm cutoff polysulfone and polyethersulfone hollow fiber membranes. After treatment with this protease, the distribution of micron, submicron, and nanometer particles in chicken extracts changes so that the size of the remaining particles corresponds to 0.4–1 μm. Together with alteration of dissolved proteins, this change helps to explain how membrane fouling might be minimized because the potential foulants are significantly smaller or larger than the membrane pore size. At the same time, we found that the presence of protein protects Salmonella from protease action, thus maintaining cell viability. Concentration and recovery of 1–10 CFU Salmonella/mL from 400 mL chicken rinse is possible in less than 4 h, with the microfiltration step requiring less than 25 min at fluxes of 0.028–0.32 mL/cm²  min. The entire procedure—from sample processing to detection by polymerase chain reaction—is completed in 8 h. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:1551–1562, 2015     

Membrane technology for surface water treatment: advancement from microfiltration to membrane bioreactor

Following the rapid proliferation of organic pollutants in the surface water, the application of microfiltration technology has been extensively studied for its treatment since the 1990s. Given that the conventional treatment processes were unable to treat the excessive dissolved organic compounds, microfiltration technologies have gained momentum as effective solutions to treat the surface water. The efficacy of low-pressure membrane filtration technologies such as microfiltration and ultrafiltration has been under scrutiny ever since, and numerous research studies have aimed at enhancing their capabilities to reject the suspended solids and organic matters. This paper reviews the development trajectory of membrane technology, ranging from microfiltration to membrane bioreactors, for treating dissolved organic matters in surface water and their future potential. This is a critical review of the physicochemical and biological options such as, but not limited to, pretreatment of water using coagulation, ozonation, adsorption and/or a combination of these. On the whole, it is concluded that the membrane bioreactor system, which combines biological process and physical rejection, showed high potential in treating polluted surface water, which needs to be further investigated extensively to promote its application in water treatment plants.     

Non-destructive approaches for assessing biofouling of household reverse osmosis membranes

Abstract

This study determined economic non-destructive methods to assess biofouling in point of use reverse osmosis (RO) membrane treatment systems. Three parallel household RO membrane units were operated under controlled feed water conditions to promote biofouling, inorganic fouling and a combination of both. Operational and biological parameters were monitored throughout the systems’ lifespan. Membrane autopsies assessed the degree and type of fouling. Statistical models determined statistically relevant parameters for fouling types that were validated with membrane autopsies. Permeate flow rates decreased differently with biofouling vs inorganic fouling. Large increases in permeate conductivity were noted in membranes suffering from biofouling and not in inorganically fouled membranes. The concentration of cell clumps from detached biofilm in the retentate increased in membranes experiencing biofouling and no increase was seen for inorganically fouled membranes. A combination of these methods could be used to conveniently assess the types of fouling experienced by RO systems.     

A novel membrane based process to isolate photosystem-I membrane complex from spinach

The isolation of photosystem-I (PS-I) from spinach has been conducted using ultrafiltration with 300 kDa molecular weight cut-off polyethersulfone membranes. The effects of ultrafiltration operating conditions on PS-I activity were optimized using parameter scanning ultrafiltration. These conditions included solution pH, ionic strength, stirring speed, and permeate flux. The effects of detergent (Triton X-100 and n-dodecyl-beta-D-maltoside) concentration on time dependent activity of PS-I were also studied using an O₂ electrode. Under optimized conditions, the PS-I purity obtained in the retentate was about 84% and the activity recovery was greater than 94% after ultrafiltration. To our knowledge, this is the first report of the isolation of a membrane protein using ultrafiltration alone.     

Murine leukemia virus clearance by flocculation and microfiltration

Clearance of murine leukemia virus from CHO cell suspensions by flocculation and microfiltration was investigated. Murine leukemia virus is a retrovirus that is recommended by the U.S. Food and Drug Administration for validating clearance of retrovirus-like particles. Due to biosafety considerations, an amphotropic murine leukemia virus vector (A-MLV) that is incapable of self-replication was used. Further, A-MLV is incapable of infecting CHO cells, thus ensuring that infection of the CHO cells in the feed did not result in a reduced virus titer in the permeate. The virus vector contains the gene for the enhanced green fluorescent protein (EGFP) to facilitate assaying for infectious virus particles. The virus particles are 80-130 nm in size. The feed streams were flocculated using a cationic polyelectrolyte. Microfiltration was conducted using 0.1 and 0.65 microm pore size hollow fiber membranes. The level of virus clearance in the permeate was determined. For the 0.1 microm pore size membranes a 1,000-fold reduction in the virus titer in the permeate was observed for feed streams consisting of A-MLV, A-MLV plus flocculant, A-MLV plus CHO cells, and A-MLV plus flocculant and CHO cells. While the flocculant had little effect on the level of virus clearance in the permeate for 0.1 microm pore size membranes, it did lead to higher permeate fluxes for the CHO cell feed streams. Virus clearance experiments conducted with 0.65 microm pore size membranes indicate little clearance of A-MLV from the permeate in the absence of flocculant. However, in the presence of flocculant the level of virus clearance in the permeate was similar to that observed for 0.1 microm pore size membranes. The results obtained here indicate that significant clearance of A-MLV is possible during tangential flow microfiltration. Addition of a flocculant is essential if the membrane pore size is greater than the diameter of the virus particles. Flocculation of the feed stream leads to an increase in the permeate flux.     

Purification of monoclonal antibodies derived from transgenic goat milk by ultrafiltration

With the goal of recovering heterologous immunoglobulin (IgG), which comprises 10-15% of the total proteins, from transgenic goat milk at 80% yield and 80% purity, we have developed and tested a two-step membrane isolation and purification process. In the first step, reported earlier by Baruah and Belfort, microfiltration was used to fractionate the milk proteins and recover > 90% of the original IgG at a purity of about 15-20% in the permeate stream. Here, we focus on ultrafiltration (UF) to increase the purity of the target protein to 80%, while maintaining a relatively high IgG yield (80%). Tangential flow UF experiments in diafiltration mode were conducted with 100 kDa cellulosic membranes to evaluate the optimal pH, ionic strength, and uniform transmembrane pressure (TMP). The TMP was kept uniform by permeate circulation in co-flow mode. The traditional approach of conducting the UF process close to the pI of the predominant whey proteins (15-40 kDa, pI 5.2), to transmit these proteins while retaining heterologous IgG (155 kDa), could not be applied here because of precipitation of residual casein at pH values lower than 8.5. Instead, the packing characteristics of the cake layer on the membrane wall, as elucidated in the Aggregate Transport Model presented by Baruah et al. was utilized to achieve a selectivity of > 15, which was sufficient to meet the stated goals of purity and yield for this difficult separation. This combined process is expected to reduce the load on subsequent purification and polishing steps for eventual therapeutic use.