Water filtration is a critical aspect of dairy processing, ensuring the quality and safety of products while also contributing to overall efficiency and sustainability.

As dairy processors seek the right water filtration solutions for their facilities, there are numerous key considerations to keep in mind.

Chief among them is finding a system that enables a company to fully understand the quality of the water being used in the facility. Dairy processors should test their water sources for contaminants such as sediments, chlorine, bacteria, and other impurities that could affect the taste and quality of dairy products. Understanding the specific contaminants present will guide the choice of filtration technologies.

“Like many industries, dairy processors are increasingly examining their water use, looking for opportunities to reduce, reuse and recycle water while still meeting demand,” said Thomas Hughes, technical resource manager for Naperville, Ill.-based Nalco Water, Ecolab’s water and process management business. “Water filtration solutions serve a critical purpose in helping dairy processors to treat and use water efficiently.”

As an example, he explained that reverse osmosis (RO) technologies remain a popular, effective filtration option for dairy processors, particularly in pre-treatment, boiler and wastewater applications, as it takes out a wide range of contaminants, including dissolved solids and organic compounds.

Other water filtration systems used by dairy processors are activated carbon filters, which help to remove chlorine, odors and certain organic compounds; microfiltration, which utilizes membranes to remove fine particles and microorganisms from water, improving clarity and safety; RO; and ultraviolet disinfection, a chemical-free method that effectively kills bacteria and viruses.

“Processors should evaluate their specific needs and choose filtration technologies that best address the contaminants present in their water supply,” said Zach Eastling, process growth sales director for Veolia Water Technologies & Solutions. “For instance, dairy processors should consider the capacity and scalability of the solution to ensure it’s capable of handling the facility’s current water usage and be scalable to accommodate any future changes in production.”

Dairy processors must comply with various regulations and standards related to water quality and safety, he added, including local, state and federal regulations. Therefore, he said it’s vital that filtration systems meet or exceed these standards to ensure the production of safe, high-quality dairy products and avoid potential penalties and reputational damage.

Key considerations

When building a water treatment strategy, dairy processors need a clear understanding of the existing quality and quantity of water they have versus the quality and quantity of water they need for production.

“Water filtration goes beyond taking solids out of water; removing minerals and contaminants, such as iron, for instance, is also critical during filtration,” Hughes said. “Water varies dramatically depending on the location of where it is sourced — for instance, a municipal source or private well. A thorough water analysis can help dairy processors evaluate the most effective treatment methods and equipment.”

Linda Englander Mills, vice president of sales for Gardena, Calif.-based Clean Water Technology, noted the company’s GEM (gas, energy, mixing) system for the wastewater area offers a much smaller footprint, requires less chemical usage and offers better contaminant removal, while generating significantly drier sludge.

“All of those impact the environment and offer a sustainable benefit that more processors are looking for,” she said.

The GEM system effectively removes total suspended solids (TSS), fats, oils and grease (FOG), and suspended components of Biological Oxygen Demand (BOD), and Chemical Oxygen Demand (COD).

Nalco Water provides a variety of water filtration programs, including advanced treatment products, RO membrane systems, basic multimedia filters, advanced filters and more.

“Our programs combine chemistry with digital monitoring and expertise to provide dairy processors with a comprehensive solution that addresses their water needs and requirements holistically,” Hughes said. “As an example, 3D TRASAR technology for membranes is an automation and monitoring system that helps control critical operating parameters for reverse osmosis systems in real time.”

In one instance, a 3D TRASAR system detected high-oxidant levels at a US-based dairy producer. The system generated an immediate alarm, which prompted an Ecolab Global Intelligence Center engineer to investigate and intervene. The engineer determined the root cause of the issue, which helped the producer avoid replacing the membrane prematurely, saving an estimated $87,000.

A majority of Veolia Water Technologies & Solutions’ focus in the dairy industry is around the processing of whey, lactose and dairy byproducts with regards to the spiral wound membrane products.

“A big thing to consider is the lifetime you will get out of your systems, so you’re getting more value,” Eastling said. “There’s also been a big push towards sustainability and reducing carbon emissions. We have a line that will reduce the amount of bypass flow around the element, improving the overall efficiency of the concentration process, and reduce the amount of power consumed by equipment itself, resulting in a 5-9% power consumption reduction.”

Maintenance matters

Each piece of equipment has a specific, unique cleaning protocol to address scale, fouling, microbiological growth and other conditions.

“RO membranes require the most robust strategy, and a clean in place strategy is typically custom designed to the local water quality and application,” Hughes said.

It’s wise for dairy processors to evaluate the maintenance requirements and operational costs of different filtration systems before selecting what’s best for them. After all, regular maintenance, including filter replacement and cleaning, is essential to keep systems running efficiently so factoring in ongoing costs should be part of selecting the best system.

“Energy efficiency is another important consideration,” Eastling said. “Some filtration systems, such as reverse osmosis, can be energy-intensive, so processors should explore energy-efficient options to minimize operating costs and environmental impact.”

While initial costs can be significant, the long-term benefits, such as improved product quality, increased efficiency and compliance with regulations, can outweigh the upfront expense. All of these should be included when dairy processors choose the right water filtration system.

Daniel Murphy, technical sales engineer for Vacaville, Calif.-based Synder Filtration, noted processors should take care to regularly diagnose their membranes to understand their life cycles.

“Maximizing life span of a membrane while also pinpointing the best time to replace can be tricky,” he said. “Processors should take measurements of any concentrate leakage, as well as clean water flux measurements after CIP. These measurements can serve as diagnostic tools to find the best time to replace a membrane.”

Membranes and filtration equipment continue to become more sophisticated, robust and efficient, so it’s important to understand all aspects.

“While spiral-wound filtration membranes have remained the same at their core for many years, materials and processing optimizations have continued to improve,” Murphy said. “These improvements continue to benefit processors.”