Westfalia Separator

Food Tec
Mechanical Separation
Division

Separators
for the
Dairy Industry

Contents

4

1. Dairy Technology Today

6 2. Factors Affecting Creaming

of Whole Milk
6

2.1

Factors Affecting Milk

Production

2.1.1

Breed of cow, climate

feeding conditions

2.1.2

Mechanical stress in milk

production

2.2

Factors Affecting Milk

Processing

2.2.1

Transporting the whole milk

to the dairy

2.2.2

Milk reception, whole milk store

10

2.2.3

Age of the milk

11

2.2.4

Quality of the whole milk

15

2.2.5 Size distribution of the fat globules

15

2.2.6 Effect of air in the milk on

separation efficiency

18

2.2.7

18

2.2.7.1 Warm milk separation

20

2.2.7.2 Cold milk separation

20

2.2.8 Fat content in the cream

21

2.2.9 Throughput of the separator

22

2.2.10 Design criteria for the milk

processing line

22

2.2.10.1 Balance tank

23

2.2.10.2 Pumps

23

2.2.10.3 Pipeline system

23

2.2.10.4 Plate heat exchangers

24

2.2.10.5 Separator settings

25

2.2.10.6 Installation of
cold milk separators

27

2.2.11 Cleaning-in-place (CIP)

Separation temperature

28 3.

Milk Separators

28

3.1

Type of Construction

28

3.1.1

Separators with solid-wall bowl

29

3.1.2

Separators with self-cleaning bowl

29

3.2

Warm Milk Separators

29

3.2.1

General

30

3.2.2

Skimming separator with HydroSoft

feed system

30

3.3

Cold Milk Separators

1
3

3.4

Hydraulic System for Automatic

Bowl Ejections

33 3.5


34 4.

Separator Types and

Feed Capacities

34

4.1

Buttermilk Separation

34

4.1.1

The product as a criterion for selecting

the right separator model

34

4.1.2

Process parameters

35

4.1.3

Separation efficiency

36

4.2

Whey Separation

36

4.2.1

Criteria for designing a whey

separation line

36

4.3

Whey Concentrate Separation

36

4.4

Retentate Separation

37

4.5

Cream Concentration

37

4.5.1

Concentration of low cream

content to 4050 percent

37 4.5.2


38 5.

Special Processes

Increasing the concentration

of 40 percent cream
Measuring Methods for Determining
the Residual Fat Content of the Skim Milk

40 6. Automatic Fat Standardising

Installations

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Westfalia Separator

1. Dairy Technology Today

Today, there are applications for separators in all
areas of milk processing such as:

Warm milk separation

Cold milk separation
Whey separation
Buttermilk separation
Milk and whey clarification
Milk standardisation
And the removal of bacteria from
milk and dairy products

Continued rationalisation and automation in dairies

has made it necessary for engineers to modernise
old processes and develop new ones. Centrifugal
separators are playing an important part in this
rethinking process.
The advanced technological sophistication of separators enables the updating of processes to meet
modern economic demands. Todays separator installations, incorporating cleaning-in-place
systems, can be operated 24 hours a day.

The processing of certain products such as:

Quark (soft cheese)

Double cream cheese
Butteroil
Low-fat whey powders, such as WPCs
Optimisation in production of lactose
Recovery of single fractions such as fats and
proteins is no longer possible without the aid
of specially designed separators

All the separators represent the state-of-the-art

in centrifuge construction. They can be operated
continuously and offer the highest level of product
safety and efficiency.

Westfalia Separator HyVOLPROPLUS separators with integrated Protein-Plus-System

When it comes to making decisions about new
investments, Westfalia Separator offers a new standard in milk processing.
Westfalia Separator HyVOLPROPLUS brands: the
new separator generation that combines the excellent features of the HyVOL separators with
PROPLUS, the Protein-Plus-System. The benefits are
substantially increased protein yield and significant
cost savings.

A new generation milk

separator with
SoftStream inlet system,
type MSE 500-01-777

Fast payback times and additional profit from the

raw milk used throughout the entire lifecycle are the
results you can expect right from the outset.

Westfalia Separator HyVOLPROPLUS separators give

you the following benefits:

PROPLUS, the Protein-Plus-System

Increased protein yield, reduced water consumption, reduction of the solids volume
Absolute availability
High throughputs, high efficiency, high
economy, a universal solution
Absolute integration
Flexible processing, high product quality

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Absolute product protection

Gentle feed system, gentle product treatment
Absolute intelligence
Easy operation, uniform solids discharge,
optimum yield
Absolute economy
Low maintenance costs, low operating costs,
low water consumption, low energy requirement
Absolute robustness
Problem-free operation, service-friendly,
long service life


Westfalia Separator

2. Factors Affecting Creaming

of Whole Milk
Next to protein, milk fat is the most valuable component of the milk. Based on the dry matter content, the milk fat constitutes about 30 percent of
the milk.

In addition to explaining the design possibilities of

centrifugal separation technology as applied to the
separation of whole milk, this document deals in
particular with a number of important technical and
engineering parameters that have a decisive influence on the residual fat content in the skim milk.

The following interdependent criteria and variables

are of great importance:

1000 tonnes

Nutritive value
Variables: breed of cow, lactation time,
climate and feeding
Physical properties
Variables: mechanical and
heat treatment
Chemical properties
Variables: enzyme reactions,
bacterial influence
Economic importance
Variables: efficiency of mechanical
separation processes

2.1 Factors affecting milk production

2.1.1 Breed of cow, climate, feeding
conditions
Apart from a number of individual tests which do
not represent an acceptable cross section, insufficient tests have been carried out to provide indisputable evidence of the effect of the relationship
between the mentioned factors on the separability
of the whole milk. It can be said, with certainty,
that seasonal differences in the separability of the
whole milk do occur. These seasonally-dependent
deviations can vary in intensity depending on the
differences in the amounts of milk delivered. Deviations occurring in the nutritive value of the feed type
composition and little or no control of the lactation
periods can lead to variations in the amount of milk
delivered. However, the effect on separability also
depends on differences in the sizes of the fat globules dispersed in the whole milk.

260
234
208
182

Figures 3 and 4 are extreme examples of differences

in the amounts delivered which are typical for the
dairy industry in New Zealand.

156
130
104

2.1.2 Mechanical strain in milk production

78
52

The various sequential processes that are part of

milk production greatly influence the separability of
the whole milk.

26
0
0

10 15 20 25 30 35 40 45 50
Calendar week

Fig. 3

Whole milk average

Proportion of delivered milk

values:

in an annual cycle

Fat:

3.75.3%

Protein: 3.34.3%


Westfalia Separator

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Volume units per [ml]

Skim milk average values:

1 April-June x = 0.04 in % by vol. (Gerber*)
2 November-February x = 0.05 in % by vol. (Gerber*)
* Spun 5 times in the skim milk butyrometer

12,000

8000
2

3.0

3.25
3.5
3.75
4.0
4.25
4.5

2.5

2.75

2.0

2.25

1.75

1.5

1.25

1.0

0.5

0.75

4000

Fat globule diameter [mm]

Fig. 4
Size distribution of the fat
globules in an annual cycle

As can be seen from figures 1 and 2, the air used to

transport the milk is worked into the milk if pipeline
cross-sections are small.

These include:
Preserving extraction of the milk
Transport of the milk through the
milking plant. Care must be taken
to separate the air necessary for
transport of the milk as much
as possible from the milk itself

In the case of large capacity cross-sections 3 and 4,

the air has adequate space above the milk.

Necessary to achieve this are:

Low vacuum level

Minimal inclines in the pipeline system
Avoidance of leaks in the pipeline network
Adequate pipeline cross-sections for the
capacity of the plant

Fig. 5
Diagram of different milk line
diameters for the same milk
28/30
1

38/40
2

50/52
3

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66/70
4


Westfalia Separator

flow

Vacuum level [kPa]

Fig. 6
Diagram of the
permissible vacuum

Not permissible

levels in milking plants

50
48
46

permissible

permissible

42
40

70/66

50/44
52/50

40/34
40/38

1 1/2 in

1 in

Pipeline diameter
Pipeline plant

If optimum transport of the milk is to be achieved,

the absolute vacuum level must be adjusted so that
it is commensurate with the energy consumed.
Fig. 6 gives the different permissible vacuum ranges
for pipeline and bucket milking plants, as well as the
relevant pipeline diameters.
Cooling of the milk on the farm is also of great
importance.
Here, attention must be paid, among other things,
to the following:

Large temperature fluctuations by thermostatic

control which have switching intervals of
e.g. 34C.
In comparison, switching intervals of approx.
1C can be achieved with electronic thermostats. This helps to reduce the danger of icing
of the milk, particularly with the milk from the
first milking, e.g. by setting the cooling temperature to 3C
Entering the area of critical temperature
According to Prof. Kessler, Weihenstephan, particularly high levels of free fat (FF) can be produced by
mechanical strain, e.g. by the stirring process, in
the temperature range of 2030C. As can be seen
from the diagram, a small optimum area occurs in
the production of free fatty acids (FFA) in the temperature range of 15C.

Avoidance of foaming, particularly when

the milk from the first milking is fed into
large refrigerated tanks

Centrifugable or extractable
free fat content

Free fatty acids

Free fat content

Bucket milking plant

Free fatty
acids

Fig. 7
Quality curve of the free
0

10

20

30

40

50

fatty acid content and free

60

fatty acids after mechanical

Temperature in C

strain of the milk or cream


Westfalia Separator

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Fig. 8
Cooling the milk

on the farm
30

Critical area

25

20

1st milking

1st + 2nd milking

P
0.6 0.7

1st + 2nd + 3rd milking

P 0.8 0.9
P rising tendency
P = pyrovate content

15
max 12C

~2h

up to 10 h ~ 1 h

10

max 1 h bis 10 h

~1h

max 1 h
Time (h)

First of all, it is important to avoid as much as

possible the entrainment of extraneous air during
emptying of the milk truck and filling of the tanks.
The type and design of the agitator can also affect
the milk.

Fig. 8 shows that in fact only in the case of the

first milking is there danger of damage to the
fat, as the second and all other milkings do not
enter the critical temperature range owing to the
instantaneously occurring mixing temperature.

Normally it is not possible to completely avoid the

entrainment of air in the milk. Consequently, the
whole milk should be given sufficient time to degas before further processing. For this reason, the
whole milk should not be fed directly from the milk
truck into the processing line.

2.2 Factors affecting milk processing

2.2.1 Transporting the whole milk
to the dairy
Care must be taken when transporting the whole
milk that the cooling chain is not broken. Consequently the milk transporting vehicles must be
equipped to suit the transporting times and climatic
conditions.

It is also important to ensure that each pumping

process employed for conveying the milk has optimum hydraulic efficiency. If the feed conditions
are subject to fluctuation, the pumps should be
equipped with a variable-speed drive. They can then
be set to their optimum speed of operation via comparison of the reference and actual values, e.g. by
inductive measurement of flow.

The motion of tank vehicles only partially filled causes turbulence in the liquid, and this can damage the
milk. Correct cleaning of the tank (CIP) is essential.

This gentle pumping process has no measurable

effect on the separability of the whole milk. However, there is a negative effect with pumps that are
throttled, for example to 6070 percent of their
maximum speed. As a consequence, an additional
residual fat content of as much as 10 percent or
more is obtained in the skim milk.

2.2.2 Milk reception, whole milk store

Three particularly important conditions must be met
with respect to the intake of the milk at the dairy
if the separability of the whole milk is not to be
impaired.

As shown in Fig. 9, it should not be possible to influence the operation of the pumps.

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Westfalia Separator

1)

PI
PI

Bad:
Tank filled from above
Hose line to pump

Better:
Tank filled from below
Gravity feed by fixed pipeline
Pipeline diameter adequate

2)

Bad:
Tank filled and emptied
via a single pipeline
Better:
One tank being filled
One tank being emptied

3)

Bad:
Parallel switching of pumps

Better:
Each pump has its own
suction line

Fig. 9
Different pump operations

Example 1) shows the problem of air entrainment. In

examples 2) and 3), in comparison, mutual impairment of pump operation also leads to entrainment
of air and mechanical strain of the milk. In example
3) the pump connected in parallel impairs separation
efficiency by up to 1/100 percent.

2.2.3 Age of the milk

Because of the two-day collection of the milk from
the farms customary today, and the consequent
need to keep the milk cold at temperatures of
35 C, the separability of the whole milk is reduced.
The reason is that, as the milk is held for so long at
a low temperature, very small water droplets bind
with the fat globules. With the whole milk simultaneously subjected to mechanical strain, e.g. due
to stirring, the fat globule membrane undergoes a
partial structural change. An increase in specific density occurs, on the one hand due to the exchange
of the original membrane components with proteins
from the serum (carrier liquid), or as pure protein
absorption of the membrane. However, the greater
portion remains in the skim milk, thereby increasing
the residual fat content.

Fat content in skim milk as a multiple of the

fat content at 55C

for transporting the raw milk

2.5
Refrigerated and
stored milk

1.5

Fresh milk

20

30

40

Fig. 10
Residual fat content in the skim
milk after processing of cold-stored
and fresh whole milk

10
Westfalia Separator

50

60

Milk separation temperature C

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This process is to some extent reversible. By increasing the separation temperature the fat globule membranes can be returned almost to their original state.
For this reason, higher separation temperatures are
used today than were customary in the past. Fig. 10
illustrates the behaviour of separation efficiency as a
function of the holding time at low temperature.

which the whole milk has already been subjected to

mechanical strain, and thereby to possible damage
of the milk fat.

2.2.4 Quality of the whole milk

The values for FFA at delivery of the whole milk

to the dairies obtained from the literature and our
own measurements at the end of the 1960s was
0.40.5 milliequiv./kg. If the data obtained since
the middle of the 1980s is used as a base, then, in
the milk producing countries with a relatively high
level of industrialisation of milk production, the FFA
values are between 0.8 1.0 milliequiv./kg as a
rule today. Fig. 11 shows, among other things, the
curve of the FFA taken over the course of a year in
Switzerland during the second half of the 1980s.
Knowledge of the FFA value has a certain importance today in judging cold, unpasteurised whole
milk, butter and cheese-making processes.

The separability of raw milk depends, in addition to

total bacterial count, among other things on the:

pH level
Free fat values (FF)
Free fatty acids (FFA)
Size distribution of the fat globules

Free fatty acids

Lipolysable fat (milliequiv./l)

The influence of foreign particles is normally not

important. However, if there is a high level of impurity in the milk, centrifugal clarification, e.g. directly
after delivery, will improve its separability. If these
influencing factors have been largely taken care
of, a statement can be made as to the extent to

Statements and their limitations through

detection of FFA (free fatty acids by the
BDI-Method)

1.3
1.2

LF

1.1
1.0
0.9
0.8

FFS

0.7
0.6
Jan.

Feb.

Tank truck route I

March

Apr.

May

June

July

Aug.

Sept.

Oct.

Nov.

Dec.

Tank truck route K

Fig. 11
Content of free fatty acids and
lipolysable fat in whole milk
on delivery to the dairy during
the year (Zurich)

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11
Westfalia Separator

FFA

milliquiv./l

Fig. 12
FFA value as a function of
the shelf life and the initial
FFA value

1.5
1.4

+35.2%

1.3
1.2

+31.5%

1.1
1.0

+19.3%

0.9
0.8
0.7
0.6
0.5

x
x

0.4
0

x
x

x
x

+13.3%

12
h

Fig. 12 shows clearly that the results obtained

depend to a great extent on the level of the initial
value. The test results are thereby not reproducible.
It is quite clear even with a low FFA value that the
incubation time hardly plays a part. To obtain reliable values, the incubation time should be at least
3 hours at 36C.
An additional factor that negatively affects the reliability of the FFA value is that the production of FFA
is time dependent, because of the presence of the
lipase enzyme and free fat (FF).
The speed of this reaction depends, among other
things, on the quality of the free, or extractable fat,
the amount of active lipase enzyme present and the
product temperature. Consequently, the increase in
FFA is not proportional to the increase in the effect
on the separability of the whole milk.

12
Westfalia Separator

As already mentioned, the product temperature has

a direct influence on the reliability of the FFA values
obtained. It has already been shown in fig. 8 (Milk
cooling on the farm), that there are two optimum
temperatures (15C and 40C). Moreover, the lipase
enzyme is almost inactive below 10C and is theoretically killed off at temperatures L 60C. Practical
tests, however, still show negligible lipase activity
above a temperature of about 50C.

Free fat
Methods for measuring the level of free fat (FF)
which provide reliable and reproducible results have
been available for some time. Two methods, the
centrifugal and extraction methods can be used,
however, only the extraction method gives reliable
information. The difference is that the centrifugal
method measures only the fat outside the fat globule membrane. With the extraction method the
fat enveloped by a porous, i.e. partially damaged
membrane, is also measured. The latter damage
has a noticeable effect, particularly with long storage times, as the fat turns to oil with time. If active
lipase is present, there is also the risk of lipolytic
attack in the event of damaged membranes.

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Fig. 13
FFA1
FFA2

]
1.4

1.3

1.2

1.5

F measured
Residual fat contet, FMM SK
FSK min

in the skim milk

[ ]

values and residual fat content

FFA2
Free fatty acids, FF


FFA1

Relationship between FFA

1.5

FFA content in delivered milk

FF content in milk immediatly
before separation

1.4

1.3

1.2
FSK

1.1

1.1

1.0

1.0

measured by
gravimetric analysis

9
Samples

and mechanical strain for

different qualities of whole milk
1
2
3

In the case of machine milked, cold-stored milk

the samples must be stored for at least
24 hours at 46C to allow reliable testing
of the FF
An AGF value of 4 percent is given as the
maximum for a still well-separated whole milk,
as from 4 percent there is a steep rise in the
curve to an upper measurement (case 2) as
early as the first basic operation (In the test the
mechanical strain specifically exceeded the
normal measurement)
At 23 percent AGF in the initial sample the
first mechanical strain (case 3) raises the FF
value, but only the second takes the value
from about 4 percent to the high upper level

Hand milked
Every 2 days from farmers i.e. 4 milkings
Whole milk from balance tank in dairy
fresh tested
24 h 56C storage temp.
36 h 56C storage temp.

AGF [%]

Interrelation of the FF values

FFA [milliquiv./l]

Inspection of test series (2) and (3) shows an identical tendency in the slope of the curve. This allows
the following conclusions to be drawn with respect
to the FF values:

Fig. 14

Effect of cold
clarification

The curve of the FFA value, ( ) in Fig. 14, would

lead to wrong conclusions. Test series 1 = milked by
hand, shows clearly the high quality of fresh handmilked whole milk ( ). At the same time, however,
there is the quite negative effect of cold storage
( , ).

16

1.6
1.4
1.2

14

1.0

12

0.8

10

0.6

0.4

0.2

4
2
1

1'

1''

2'

2''

3'

3''

' Mechanical basic action superposed on the milk

'' The same mechanical basic action superposed twice
on the milk

Food Tec

13
Westfalia Separator

1572864

Whole milk: FRG

Fat content: 4%
Period tested: 2/87

1048576

II
50

Volume units in l

75

524288

25

1.03
1.09
1.10
1.23
1.30
1.38
1.47
1.56
1.65
1.75
1.86
1.97
2.10
2.22
2.36
2.50
2.66
2.82
2.99
3.18
3.37
3.58
3.80
4.03
4.27
4.54
4.81
5.11
5.42
5.75
6.10
6.48
6.57
7.30
7.74
8.22
8.72
9.25
9.82
10.42
11.06
11.73

Fat globule diameter in m

Fig. 15
Size distribution of the fat
globules in the whole milk.
Values I and II are for the different catchment areas.

8192

75

4096

50

II

25

Volume units in l

12288

Period tested: 2/'87

7.52

6.67

5.93

5.26

4.67

4.15

3.68

3.27

2.90

2.58

2.29

2.03

1.81

1.60

1.42

1.26

1.12

1.00

0.89

0.79

0.70

Fat globule diameter in m

Fig. 16
Size distribution of the fat
globules in the skim milk

14
Westfalia Separator

Food Tec

96 100
II

64

50

25

32

EI = 98.875 %
EII = 98.65 %
Product temperature 53 C
Cream fat content 42 %
Period tested: 2/'87

7.52

6.67

5.93

5.26

4.67

4.15

3.68

3.27

2.90

2.58

2.29

2.03

1.81

1.60

1.42

1.26

1.12

1.00

0.89

0.79

0.70

Fat globule diameter in m

Fig. 17
Separation curves (whole
milk to skim milk)

2.2.5 Size distribution of the fat globules

The relatively slight differences in the size distribution of the fat globules in the whole milk (see Fig.
15) only allow trends to be identified to a limited
extent. Values I and II are for the different catchment areas. Fig. 16 shows the size distribution of
the fat globules in the skim milk (SK). Curves I and
II illustrate the effectiveness of the installation concepts and process parameters. However, it is possible to optimise the values in installation II. As already
mentioned, the absolute residual fat content in the
skim milk that would be attainable, can only be
determined as a trend. By means of a particle count,
the diagram in Fig. 17 shows even more clearly the
difficulty of providing a reliable assessment of the
quality of the separability of whole milk. Here, the
size distribution of the fat globules in the whole milk
and skim milk are compared. It can be seen that
the separation curves I and II are almost congruent
in their behaviour. In comparison with Fig. 16 the
skim milk II has a distinctly higher residual fat content. The residual fat levels in SK I and SK II, tested
in the laboratory by the Gerber method, were 0.045
(I) and 0.054 (II).

Food Tec

Thus counting the fat globules in the whole milk

or skim milk has only limited validity. If Fig. 15 is
taken for comparison, then with a clear shift of
the optimum for the size distribution towards small
diameters, an impairment of separability can be
expected. On the other hand, the size distribution
in the residual fat content of the SK (Fig. 16) does
not follow the usual course. Curve II in Fig. 16, however, justifies the claim that this separation line can
be optimised.

2.2.6 Effect of air in the product on

separation efficiency
Free air carried by the product can have a direct
effect on the separation efficiency of the milk separator, in addition to the negative effect on the quality of the end product. In evaluating these effects
the following should be borne in mind: whole milk
generally contains a certain amount of combined
gas; the gas saturation point of the milk decreases
with increasing temperature; gas can therefore be
liberated by heat treatment.

15
Westfalia Separator

Separation in %

75

Saturation point mgO2 /l

is measured as an
increase in free air
content

20

x
x
x

This gives an air volume of:

G
Vair = L

L
-6
= 25 10 -3

1.293

10



< 20 10-3 dm3
Vair < 20 cm3 (first approximation)

20 cm3/Liter = 2%

15

10

5 mg O2 = ca. 25 mg air

25 10-6 kg air

Specific density of air:

10

20

30

40

50

Oxygen saturation in water as a function of the

kg
= 1.293 3
m

temperature

xx Oxygen saturation in the milk

Fig. 18
Saturation point of gas
in liquids as a function of
temperature

If the milk is tested to ascertain the actual volumes

of liberated gas, the following should be borne in
mind:
In the case of a change in temperature, the
gas absorption into the milk varies
If the milk is exposed to vacuum, the saturation point is lowered considerably
In the case of overpressure, the saturation
point is raised only very slightly
It can be seen from the curve in Fig. 18 that with
heat treatment of the whole milk in the milk separation line, gas (air) is automatically liberated. In order
to be able to evaluate the air content in the whole
milk upstream of the separator under normal conditions.
In accordance with the diagram, approx. 5 mg O2/l
gas is liberated when the temperature of the whole
milk is increased from 10C to 55C. It can be
assumed that the saturation behaviour of nitrogen
(N2) is similar to that of oxygen (O2). This content
of free air is not yet sufficient to impair separation
efficiency.

16
Westfalia Separator

A further increase in gas content is normally

attributable to the following causes:
The product contains foreign gas when processing commences
The balance tanks are too small, or flow conditions in the balance tanks are unfavourable
during filling and emptying
Parts of the installation are not air-tight
In a system under pressure, air can be drawn in
without loss of product due to the
injector effect
The separator discharge pressures have not
been correctly adjusted
The pressure stages in the system are too large
(a sudden drop in pressure causes gas to be
released)
If the volume of free air increases to values > 2.5 percent (approx. 55C), it will have a negative effect on
the separability of the product in the separator.

Food Tec

1 Special design

2 Standard design

Westfalia Separator
xx

xxx

xxx
xxx
xxx
xxx
xxx
xxx

Fig. 19
Flat bottom flask
for gas tests

If tests for gas are to be carried out in existing installations, the following should be borne in mind:

One reason for this is:

The dispersed air enters the disc stack of the separator with the product and, because of its low specific
density, the greater part of this air is fed to the centre
of the bowl. Due to the falling pressure, the air bubbles expand and spread. Therefore, there is a danger
if there are large amounts of air that occasional air
blockages will occur in the product flows, with a
resulting negative effect on separation efficiency.
On the other hand, air bubbles, which bind with the
membranes of the fat globules in the event of pressure changes, cause damage to the membranes. This
results in an increase in FF content and impairment of
separability.
Extensive testing in the years from 1985 to 1987 at
the southern German Testing and Research Institute
for the Dairy Industry, Weihenstephan, have confirmed
the direct influence of increased air content on the
separability of the whole milk.

Food Tec

When samples are taken, no additional foreign

gas must be allowed to get into the sample
Attention must be paid to temperature when
there are different sampling points
To avoid gas bubbles, only slender sampling
vessels should be used (see Fig. 19)
The samples are placed in a water bath at the
same temperature as the samples themselves.
The samples are then de-gased for max. 20
min.
A further, relatively simple method of testing for
entrainment of foreign gas, e.g. in complex enclosed
systems, is to install sight glasses at special points
on the pipelines. Then when operating with water,
it is possible to observe at these points whether the
water is clear or turbid. The latter indicates that free
air has entered the water because of leakage.

17
Westfalia Separator

2.2.7 Separation temperature

As the equation shows, the speed of sedimentation

depends on the following:

2.2.7.1 Warm milk separation

Difference in density between the particles to
be separated (e.g. fat globules)
Particle size
Viscosity of the liquid
Bowl speed
Bowl radius
Settling area of the discs

Other effects of product temperature on the level

of the residual fat in the skim milk are described in
this section. If the separation of a fat globule from
its carrier liquid (skim milk) in the separator bowl is
considered as a physical process, then the sedimentation speed between the discs is subject to Stokess
Law.

2
= centrifugation coefficient = r
g



= radius [m]
1
= angular velocity
s

1.035

1
0.98

1.03

0.96

1.025

0.94

1.02

0.92

1.015

0.90

1.01

0.88

1.005

0.86
10

Density skim milk g/cm3

[ ]

The figures illustrate the temperature dependence

of the product parameters ( and ). From Fig. 20 it
can clearly be seen that the optimum product temperature is around 55C, since the dynamic viscosity of the milk is virtually stable in this temperature
range and protein precipitation must be expected
at higher temperatures. At product temperatures
> 60C there is already precipitation of proteins,
which has a negative effect on separability. These
proteins form a thin-film segment on the surface of
the disc, and with disc interspaces of only 0.3 to
0.6 mm, these deposits have a detrimental effect
on the conditions of flow. Fig. 22 shows the flow
conditions of the product components being separated in a disc interspace. A fat globule is consid-

Dyn. viscosity [CP] (thousand)

2
= d g
18

= settling speed in centrifugal field [m/s]
= diameter of fat globule [m]
= 1 2
= density of the skim milk [kg/m3]
= density of the fat globules [kg/m3]
= dynamic viscosity [kg/ms]
= acceleration due to gravity [9,81 m/s2]

Density of the cream/milk fat g/cm3

vZ

v z
d

1
2

g

7
6
5
4
3
2
1
0
70

1
20

30

40

50

60

Skim milk
Skim milk

Cream 40%

50

40

30

60 70 80
Temperature C

20

10

5
3
Temperature C

Whole milk

Milk fat
Fig. 20
Density and dynamic
viscosity as a function of
the temperature

18
Westfalia Separator

Food Tec

FSK min

FSK measured

Feed,
whole milk

2.0
I

1.9

II

1.8
Cream

1.7

II

1.6
1.5
1.4

III

1.3

r1

IV

1.2

Sediment

1.1
1.0

a
20

25

Fig. 21
Residual fat content in the
skim milk at different
cold-storage times of the
whole milk and separator
types as a function of the
separation temperature

30

40

50
60
Separation temperature C

I Cooled stored milk

MSA system
II Fresh milk MSA system
III Cooled and stored milk
MS-.-separator with
SoftStream system
IV Fresh milk
MS-.-separator with
SoftStream system

ered to have been removed from the liquid when

it reaches the upper surface of the disc below.
Due to the negative value for in the formula
for the sedimentation speed v z, the fat globule
moves inwards against the centrifugal field in the
disc interspace towards the centre of the separator
bowl. A second reason is that the tendency for fat
globules to agglomerate decreases drastically above
60C. The consequence to be drawn from this is
that all process steps which significantly increase or
decrease the dynamic viscosity of the liquid are to
be avoided. Thus, the mixing of additives with the
whole milk, such as proteins or skim milk concentrates which would increase the dynamic viscosity,
is to be avoided, as this can only be compensated
to a limited extent by adjustment of the separation
temperature. It can also be seen that the addition
of homogenized milk (recycling) to the whole milk
has an overall negative effect on the fat balance.
This is because of the over-proportional accumulation of very small highly dispersed fat globules in the
skim milk, which reduces the density difference ,
so that the sedimentation speed is reduced. However, the admixing of whole milk with the skim milk
has a positive effect. It allows badly separated skim

Food Tec

Skim milk

r2

Fig. 22
Single separation
space in a milk separator

milk to be re-separated in the centrifuge, so that a

better residual fat content can be achieved in the
total balance. The reason for this is not in the significant change in the parameters of the product,
as the change in relates to the solids particles to
be separated out, but in an improved agglomeration of the smaller fat globules to produce a larger
volume density of the fat globules. Separators that
have been specially designed for warm-milk separation operate with a minimum product temperature
between 20C and 25C. This is because the viscosity of the cream increases drastically with falling
temperature. In addition to a reduction in the sedimentation speed, it also results in reduced fluidity
of the cream. A further reduction in temperature
would lead to blockage of individual flow paths.
Even at 2025C the fat content of the cream
should be adjusted to approx. 15 percent fat. It
is therefore not expedient, e.g. to separate cold
milk at 1525C under normal circumstances, as
the optimum temperature for damage to the fat is
25C, and for the formation of FFA 15C. On the
other hand, product temperatures of 412C can
be accommodated in specially designed cold-milk
separators without difficulty.

19
Westfalia Separator

0.25

Residual fat content in the skim milk as a

function of the residual fat content at 45%

Fat content in the skim milk [%]

Milk stored over a prolonged

period (mean values)
Fresh milk (mean values)

0.3
Q = 100%

0.2
Q = 75%
0.15
0.1

Q = 50%

0.05

1.75

1.50
Grenzbereich

1.25

1.00

5 C

8 C

12 C

40

15 C

Fig. 23

Fig. 24

Skim milk fat content according

Residual fat content in the

to Rse-Gottlieb as a function

skim milk as a function of the

of the separation temperature

fat content in the cream

50

60
70
Cream fat content [%]

and rated capacity

2.2.7.2 Cold milk separation

2.2.8 Fat content in the cream

A basic mode of operation of the cold milk separator is to control the cream flow by adjusting the
pressure of the product feed. By means of this pressure, the cold, 40 percent cream can be made to
discharge from the centre of the separator bowl
under pressure, in spite of its extremely high viscosity. However this can only be achieved with the
aid of hermetically-sealed product feed and cream
discharge lines. When we consider the sedimentation speed in cold milk separation, we find that it is
influenced by the increased dynamic viscosity. Flow
characteristics of the cream are also affected, so that
separability is considerably less than with warm milk
separation. The relatively low residual fat content in
the skim milk shown in Fig. 23 can only be achieved,
however, when the period of dwell of a particle in
the disc stack is increased by reduction of the feed
throughput. At product temperatures < 4C there
is the disadvantage that the flow paths in the disc
stack become blocked in a very short time.

The adjustments of the discharge pressures necessary to control the fat content in the cream have
no effect on separation efficiency up to the limiting
range (see Fig. 24). If this limiting range is exceeded, a slightly higher residual fat content can be
expected in the skim milk. Fig. 24 shows the residual
fat content in the skim milk as a function of the fat
content in the cream. Within the limiting range, the
residual fat content in the skim milk can be maintained at almost a constant level. This is achieved as
follows: the level of fat in the cream must be kept
stable. Any volume increase in the fat content of
the feed results automatically in approximately a 10fold increase in its concentration in the cream. If the
fat content in the whole milk were to change from
4.0 to 4.5 percent, then, with the same settings on
the separator, the fat content in the cream would
increase, for example, from 45 to 50 percent.

20
Westfalia Separator

Food Tec

% FQ
% FQN

1.5

1.2
1.0
0.9
0.75 QN

QN

1.25 QN

1.5 QN
FQN = Fat content at nominal capacity

Fig. 25
Feed throughput of the
separator as a function
of the residual fat content
in the skim milk

2.2.9 Throughput of the separator

On the other hand, the upper range of the appropriate separation temperature (5560C) should be
chosen if the fat content in the cream is high. Thus,
if the cream fat content is above the limiting range,
i.e. between 60 and 80 percent, a product temperature between about 60 and max. 75C must be
chosen with an increasing fat content. The production of such high-percentage creams from an initial
product of (3040 percent) cream or whole milk
naturally has a particular effect on the residual fat
content in the respective skim milk. However, this
will not be further discussed in this document.

Fig. 25 shows the relation between the volume of

whole milk fed to the separator and the residual fat
content in the skim milk. It is particularly important
for perfect separation of the whole milk into skim
milk and cream that the flow conditions in the bowl
are maintained at a constant level. A constantly
changing feed throughput means that a new static
condition must be created inside the bowl. Consequently, sudden changes must be avoided.
Fig. 26 shows different systems for control of the
feed throughput.

Fig. 26
System for control of the
separator feed throughput
System

Flexibility

Price

Product influence

Influence on

feed pump

Flow constrictor

limited

OPTIMAL

acceptable

causes pressure loss

Control valve (FIC signal)

acceptable

acceptable

acceptable

causes pressure loss

Frequency controlled

acceptable

operates the pump

pump (FIC signal)

OPTIMAL

depending kW

OPTIMAL

in the optimum hydraulic

rating of motor

working range

Food Tec

21
Westfalia Separator

18

17

15

14

13

FI

PI

FC

2
3

FC

5
Fig. 27
Flow diagram of a milk
processing line

10

12

4 6

11

16
7 Milk skimming
separator
8 Flow meter
9 Adjustable flow
constrictor
10 Cream heater/cooler
11 Line to cream tank

1 Storage tank
2 Pump
3 Balance tank
4 Feed pump
5 Flow constrictor
6 Plate heat exchanger

Frequently, different feed throughput capacities are

necessary as defined by production requirements. In
such cases, it is expedient to control the feed to the
separator by frequency control of the drive of the
feed pump. If, under these operating conditions the
drive were to be operated at the maximum fixed
speed, it is fairly safe to assume that at lower feed
throughputs there would be increased damage to
the fat globules. The negative consequences for
the residual fat content in the skim milk have been
described in the previous sections.
If a flow constrictor is installed, it is necessary to
ensure that it operates correctly by a correct choice
of the upstream and downstream pressures. Correct
operation of the flow constrictor is only assured
when:

2.2.10 Design criteria for the milk

processing line
Fig. 27 illustrates a processing line in simplified form
for separation of warm milk.

2.2.10.1 Balance tank

The balance tank must be designed to avoid turbulence in the product. On change-over the min.
level in the balance tank must be high enough
to prevent air from being drawn in by pump 4.
It is also important to ensure that pumps 2 and
4 do not work against each other. For example, directly facing feeds and discharges are to be
avoided. Standard value for filling volume approx.
23 percent of the hourly capacity.

the Dp between initial pressure and the

pressure after the flow constrictor is < 1.5 bar
the pressure after the flow constrictor is
> 0.5 bar

22
Westfalia Separator

12 Solid tank
13 Pressure gauge
14 Constant pressure valve
15 Heat holding section
16 Booster pump
17 Pressure holding valve
18 Flow divertion valve

Food Tec

2.2.10.2 Pumps

2.2.10.4 Plate heat exchangers

Much has already been said on this subject. However, it should also be mentioned that in our opinion
a great deal more attention should be paid to the
design and operation of pumps than is generally the
case today.

The plate heat exchanger for pasteurizing the milk

only has an indirect effect on the separation of the
milk. The legal requirements for operation of heat
exchanger installations provide well-defined specifications for pressure conditions in the different
sections. However, the regulations can vary from
country to country. The feed pressure to the separator and the design and dimensions of the necessary
pressure-boosting pump have the greatest effect on
the pressure level. This is evident from the curves in
Fig. 28.

2.2.10.3 Pipeline system

In addition to the necessity for a clean-in-place capability, it is important that sudden changes in pipeline
cross-section are avoided, as otherwise pressure and
expansion shocks will contribute to the increase in
FF. It is also important that certain limiting values
for the flow velocity of the transported liquid are
neither exceeded nor unattained:

In order to provide high feed-pressure separators see

Fig. 28 (
) with a lower pressure level to reduce
the pressure loading on the plate heat exchanger,
a booster pump should be installed directly before
the separator.

Milk products max. 2 m/s

Cream and higher percentage fat
products max. 1.5 m/s
Flow velocity for the CIP agent min. 2 m/s

However, this pressure boosting pump adds to the

mechanical strain on the whole milk and, consequently, also influences the separability of the milk.

Fig. 28
Pressure curve in the
pasteuriser for a given
throughput capacity
(Representation based on the

p (bar)

German milk regulations)

Pressure diff. 2
Pressure diff. 1

6
5

KDV
4

Pressure diff. 2

Pressure diff. 1
Exchanger 2

Exchanger 1

2
Separator

1
0

Exchanger 2
Heater

Exchanger 1
0

Booster pump

Heat holding
6

Separator with
low feed pressure
Separator with
high feed pressure

Food Tec

Cooler

23
Westfalia Separator

10

11

Fig. 29
Control and measuring
1

device for the separator

feed and discharge

P1

P4

P3

1 Constant pressure valve

2 Flowmeter

PI

P5

FI

p1 Feed pressure 1.0 bar

p3 5 bar discharge pressure
of skim milk from
separator
P4 max. 4.5 bar pressure of
downstream apparatus
p5 5,2 bar discharge pressure
of cream from separator

2.2.10.5 Separator settings

One of the most important requirements for achieving a low residual fat content in the skim milk is
correct adjustment of pressure on the separator. Key
pressures for separation efficiency on the skim milk
side are p3 and p4 (see Fig. 29). p3 determines the
separation zone in the disc stack of the separator
and has a crucial effect on separability. For this reason it can also be seen that pressure fluctuations at
p3 will have a negative effect. To allow the individual
fat globules the longest possible settling path in the
disc stack, the p3 pressure must be set to a level that
just prevents an overflow from occuring on the skim

24
Westfalia Separator

milk side. In practice this pressure is approximately

0.5 bar less than the overflow pressure. To prevent
pressure fluctuations in the equipment downstream
of the separator from affecting p3, a constant pressure valve (2) is installed on the skim milk side. To
ensure correct operation of the constant pressure
valve, pressure p4, 4.5 bar in the example, must not
be exceeded. If the pressure is higher, it is necessary to install a booster pump in the downstream
apparatus to provide pressure relief. The max. cream
pressure p5 depends on pressure p3. The cream fat
content can be adjusted by means of a hand control
valve.

Food Tec

11

12

13

14

PI

PI

FIC

PIC
Viac

FIC

1
Fig. 30
Installation diagram for
cold milk separation

10

1 Storage tank
(whole milk)
2 Pump
3 Balance tank
4 Feed pump
5 Inductive
flowmeter

9
6 Automatic valve
7 Pressure gauge
8 Rinse line
9 Cold milk separator
10 Control valve (skim milk)
11 Line to tank (skim milk)

2.2.10.6 Installation of cold milk separators

The cold whole milk is fed into balance tank (3) by
pump (2) or under gravity (see fig. 30). The balance tank must be adequately dimensioned so that
there is always sufficient milk in the vessel to prevent foreign air from being drawn in by the pump
(4). The adjustable positive displacement pump (4)
conveys the milk into the separator (9). The speed
of pump (4) is controlled by the measuring signal
of inductive flow meter (5). The product flowing
to the separator is thus maintained constant. The
separator feed pressure, which depends to a great
extent on the throughput, is 34 bar. The concentration of the discharging cream is directly determined by the skim milk discharge pressure. When
adjusting the fat content of the cream it is necessary
to proceed as follows: set a pressure of 52 bar
with constant pressure valve (10) in accordance with
the feed throughput, so that thin cream discharges
(approx. 30 percent). By gradually reducing the skim
milk pressure and, at the same time, controlling the
cream fat content, the desired cream fat content
can be adjusted.

Food Tec

15
12 Pressure gauge
3 Mass flow meter
1
14 Control valve
15 Cream storage tank
16 Pump

Fine adjustment is carried out by slightly throttling

the cream discharge with the fine adjusting valve
(14). The pressure in the cream discharge line, from
throttling or from the cream line itself, must not
exceed 2 bar.
The adjustment of the fat content in the cream can be
partially automated. The measuring signals from the
inductive flowmeter in the cream line and from the
flowmeter in the feed line (in the case of varying
feed rates) are compared in a control unit.
For this to function satisfactorily, the fat content
in the incoming whole milk must be constant. The
cream is collected in a tank situated in the vicinity of
the separator and conveyed further with a positive
displacement pump.

25
Westfalia Separator

16

Displacement
with water

Overflow

Total ejection

Filling of bowl

Overflow

Total ejection

After attainment
of temperature
30 60 min.

Lye

Overflow

Total ejection

Intermediate flushing
with water

Overflow

Total ejection

After attainment
of temperature,
15 30 min.

Acid

Overflow

Depending on the
installation ~ 5 mins

Total ejection

Bowl flushing
with water

Fig. 31

5 60 min.

Automatic overflow

CIP program for

before each total ejection

milk separators

26
Westfalia Separator

Food Tec

2.2.11 Cleaning-in-place (CIP)

As a rule one should start with the following

parameters:

With the ever longer production cycles between

cleaning processes usual today, it is of particular
importance that the CIP process is optimally tailored
to the individual components of the installation.
During cleaning-in-place, the solids are removed
from the cleaning solution in the separator and are
then automatically ejected during the ejection process.
Fig. 31 shows the CIP program for separators recommended by Westfalia Separator. Depending on the
process and plant, other programs may be required
in consultation with Westfalia Separator.

Lye:

Temperature 7080C
Concentration 1.52.0 percent

Acid: Temperature 55max. 60C

Concentration 0.51.0 percent
Here we would like to refer to the DIN technical
report No. 18: Dairy installations, Cleaning and Disinfection in CIP Processes, published by the Beuth
Verlag, 1988.
These brochures cover all relevant questions relating
to cleaning-in-place of dairy installations.

The recommendations of the manufacturer should

be followed for the temperature and concentration
of the cleaning solution.

The bacteria-removing separator HyVOL CSE 500 stands for highest capacities in the bacterial clarification of milk. The model from the innovative E-generation reliably separates even the smallest spore
formers. With a top capacity of up to 50,000 l/h, this separator is moving into a new dimension. An
essential feature of the CSE series is the Westfalia Separator HydroSoft system. It operates with a comparatively small feed pressure and minimises the shear forces. The gentle treatment guarantees premium product quality. Thanks to the total ejection option, the E-generation also improves the efficiency
of CIP.

Food Tec

27
Westfalia Separator

3. Milk Separators
3.1 Type of construction
Two basic types of construction are used for milk
separators. Separators with solid-wall bowl are used
for discontinuous processing and separators with
self-cleaning bowl for continuous processing.

in the solids holding space. For chemical cleaning,

the bowl must be dismantled after each production phase and cleaned manually. The duration of
one production phase depends on the amount of
separated solids, i.e. the solids content in the product feed. Production must be halted and the bowl
cleaned by the time the solids reach the edge of the
disc stack.

3.1.1 Separators with solid-wall bowl

The solids holding space in the discontinuously operating separators is formed by the solid bowl wall.
Solids which are separated out of the milk or milk
product accumulate on the inner wall of the bowl

28
Westfalia Separator

Food Tec

3.1.2 Self-cleaning separators

These separators are for applications that require
continuous processing. Separation takes place in the
disc stack; the solids are separated out in the solids
holding space. The solids holding space is of double
conical form and incorporates ejection ports which
can be opened and closed by hydraulically lowering
and raising the sliding piston.
During production the accumulated solids can be
ejected instantaneously at preset intervals by lowering the sliding piston. At the end of the production phase the separator is automatically cleaned in
place. Operation can be fully automated by installing
suitable control units.

As the above K1 equation shows, the geometry of

the discs, the speed of the bowl and, thereby, the
centrifugal acceleration have a crucial bearing on
separation efficiency. In addition to the observance
of mathematical relations, it is of particular importance, if the highest separation efficiency is to be
attained, that the treatment of milk flows inside the
bowl is as gentle and preserving as possible.
When designing separators, particular attention is
paid to the avoidance of vacuum and shear forces
which might act on the product. Depending on their
relative magnitude, shear forces, and vacuum are
capable of destroying agglomerates of fat globules,
as well as causing partial damage to the membranes.
The result is an increase in FF, an increase in the
number of fine fat globules and, consequently, an
increase in the residual fat content in the skim milk.

3.2 Warm milk separators

3.2.1 General
Design engineers have mathematical models available for the design of milk separators. For the separation efficiency of a warm milk separator, the socalled K1 factor, based on Stokess Law, is the most
important mathematical computational base.

K1

w
r 2
r 1

a
Q M

QM
= 3

(r23 r13) . tana

= Angular velocity of bowl [1/s]
= Effective outside radius of disc [cm]
= Mean radius relative to position
of rising channels [cm]
= Angle of discs to horizontal
= Flow of feed milk per sec. [cm3/s]
and disc interspace

Food Tec

This problem can only be avoided if the distributor

chamber, the centre of the separator bowl, is constantly filled. Constructionally this is achieved by hermetically sealing the separator feed and discharge
lines with the rotating bowl by means of mechanical
seals.
By this means a reliable seal is assured at high
speeds of rotation and radial movement of the
bowl. However, these systems also require cooling
and lubricating systems, as well as an expensive
control system. As a rule, this system also requires
an extremely high feed pressure a disadvantage,
among other things, when integrating these separators in a pasteurising line. With the HydroSoft inlet,
Westfalia Separator presents a system which ensures
constant filling of the distributor without the need
for mechanical seals.

29
Westfalia Separator

2
5

3
4

Fig. 32
Schematic of the
separator

1 Feed tube
2 Bore
3 Distributor
4 Bore
5 Rising channel
6 Cream centripetal pump

3.2.2 Skimming separators with

HydroSoft feed system

3.3 Cold milk separators

The HydroSoft feed system from Westfalia Separator

combines the advantages of the SoftStream system
with those of the hydrohermetic feed system. Combining these systems allows very gentle acceleration
of the product at a low pressure level. The system
offers a high degree of flexibility in terms of feed
capacity. Owing to the cream centripetal pump (6)
situated above the system, which is immersed in
the cream during production, the inlet chamber is
hydrohermetically sealed off from the outer air. Air
intake into the product is therefore not possible.
The stationary feed tube (1) allows the product to
flow into the centrally-located bore (2) of the rotating distributor (3). The central bore has no ribs so
avoids shear effect on the product. The product is
gently fed through the radially arranged bores (4)
into the inner rising channels (5) of the disk stack
where it is separated into skim milk and cream.

30
Westfalia Separator

Fig. 33 shows the semi-hermetic cold milk separator.

The product flows through feed pipe (3) into the
bowl and is separated into light and heavy liquid
phases in the disc stack (4). The light liquid phase
flows to the centre of the bowl from where it is discharged foam-free and under pressure at outlet (2).
The heavy liquid phase is conveyed foam-free under
pressure to outlet (1).
The separated solids are collected in the sediment
holding space (5) from where they are instantly
ejected at periodic intervals through ports (6) by
means of the hydraulically operated sliding piston
(7), whereby the closing liquid is fed through piston
valve. The ejection cycles are initiated via the control
unit.
Feed and discharge of the product are effected
through an enclosed pipeline system, whereby the
feed and discharge of the light liquid phase are connected to the rotating bowl by means of hermetic
seals. The two liquid phases are discharged under
pressure. The operating pressure for adjustment of
the separator is set by means of a control valve in

Food Tec

Fig. 33
Cold milk separator

5 Sediment holding space
6 Solids ejection ports
7 Sliding piston

1 Heavy phase discharge

2 Light phase discharge
3 Feed
4 Disc stack

the discharge line of the heavy liquid phase.

The two liquid phases are discharged under pressure. The operating pressure for adjustment of the
separator is set by a control valve in the discharge
line of the heavy liquid phase.
The discharging light liquid phase is also adjusted by
a control valve.
During start up and run down of the separator, and
in the event of any interruption during production,
cooling water must be fed to the rotating seals in
the feed and discharge lines of the light liquid phase.
This is effected automatically by the control program
for the separator.

3.4 Hydraulic system for automatic

bowl ejection
Separators with self-cleaning bowls eject the separated solids automatically at pre-selected intervals
whilst the bowl is rotating at operating speed. During partial ejections the product feed to the separator is not interrupted. In this mode of operation the
separation process is assured 24 hours a day.

Food Tec

Depending on the processing conditions and the

properties of the milk or milk product, self-cleaning
separators can be set to carry out partial or total
ejection.
For partial ejection the bowl ejection ports are only
opened briefly, so that only a pre-determined volume
of solids is ejected. The liquid phase remains in the
bowl. With total ejection the ejection ports are fully
opened and remain open until the total contents of
the bowl have been ejected. In this case the product
feed to the separator must be interrupted.
Mention has already been made of the necessity for
constant flow conditions. In this respect particular
attention must be paid to the ejection mechanism,
as each ejection of the bowl leads to turbulence.
To meet the requirements for extremely fast and
volumetrically small, but exactly reproducible partial
ejections (PE), a double piston valve with metering
system was developed which works in conjunction
with an optimally configured sliding piston.

31
Westfalia Separator

0,18
0,16

Bowl revolutions during partial ejection

Opening of ejection ports in mm

0,20

System with
1 piston valve

I

System with
2 piston valves

II

70

System mit
metering piston
and
1 piston valve

III

System with
differential
metering piston
and
2 piston valves

IV

60
50
40

0,14
0,12

30

0,10
0,08

20

0,06
0,04

10

0,02

Opening of ejection ports

Number of bowl revolutions

Fig. 34
Development stages of the
hydraulic system for automatic
bowl ejection

Fig. 34 illustrates the different development stages

leading to the system in use today. Item. IV shows
the widest possible opening of the ports in the
shortest possible time. This allows a partial ejection to be carried out in only a few revolutions of
the bowl. It also allows the smallest possible partial
ejection to be carried out with precision. As a result
there is of course an impairment of the flow conditions, but looked at over the complete separator
line it is only of short duration and consequently of
minimal effect.
Fig. 35 shows the operation diagram of the hydraulic system of the milk separator. When a partial ejec-

32
Westfalia Separator

tion is initiated, opening water valve (7) opens and

the amount of water preset in metering chamber
(6) is fed instantly under pressure into the opening
chamber of the bowl. The closing operation begins
automatically when the required amount of opening
water flows away through the piston valves. Closing
water (3) is fed in throughout the process.
Before the ejection, the metering chamber is filled
by opening of the filling water valve (4) at pre-selectable time intervals. Finally, by opening of valve (2),
air pressure is applied to the piston in the metering
device, so that the water fed for the next partial
ejection is under a defined pressure.

Food Tec

3.5 Separator types and feed capacities

Westfalia Separator supplies hot milk skimming
separators with rated capacities from 600 to
60,000 l/h (3,000 to 70,000 l/h for standardisation). The models with capacity specifications can
be found in the technical data sheet.
Westfalia Separator supplies cold milk skimming
separators with rated capacities of 10,000 to
50,000 l/h. The models with capacity specifications
can be found in the technical data sheet.

Fig. 36
Milk processing line

Fig. 35
Operation diagram of the
hydraulic system for opening
and closing the bowl

1 Control unit
2 Pilot valve
3 Closing water valve
4 Filling water valve
5 Non-return valve
6 Metering unit

7 Opening water valve

8 Sliding piston
9 Piston valve
10 Closing water drain hole
11 Opening water hole
12 Closing water hole
13 Closing water chamber

Food Tec

33
Westfalia Separator

4. Special Processes
4.1 Buttermilk separation

For the separation of sour cream buttermilk only

self-cleaning separators can be used. The coagulated protein is separated out and accumulates in the
sediment holding space. It is automatically ejected
through ports at pre-set intervals.

In buttermilk separation, the type of buttermilk

must be taken into consideration when selecting
the separator model.


4.1.1 The product as a criterion for selecting
the right separator model

4.1.2 Process parameters

There are four main types:

Buttermilk
Buttermilk
Buttermilk
Buttermilk

from
from
from
from

sweet cream
sour cream
neutralised cream
the cask churning process

Self-cleaning separators and separators with solidwall bowl (not self-cleaning) can be used for the
separation of sweet cream buttermilk. This is owing
to the relatively small amount of coagulated protein which is separated out. This also applies to the
separation of buttermilk produced from churning
neutralised cream or buttermilk recovered from the
cask churning process.

34
Westfalia Separator

The process diagram is shown in Fig. 37. The buttermilk is pumped from the buttermaking machine
(1) to the silo (5). The buttermilk should be stored
at a temperature of 68C. In plate heat exchanger
(7), sweet cream buttermilk is heated to 3040C
and sour cream buttermilk to 3235C. The buttermilk from the neutralised cream churning and cask
churning processes can be treated in the same way
as sweet cream buttermilk. The separator throughput capacity should be approx. 50 percent of the
rated capacity for sour cream buttermilk and up to
100 percent of the rated capacity for sweet cream
buttermilk. The cream flows from the separator into
a cream collecting tank (10). The butterfat content
in the cream must be adjusted with the aid of a fine
adjustment valve to approx. 25 percent. The construction of the disc stack depends on the type of
buttermilk to be processed.

Food Tec

2
3

5
9

10

11

Fig. 37

7 Plate heat exchanger

8 Milk separator
9 Storage tank for separated
buttermilk
10 Cream collecting tank
11 Pump

1 Buttermaking machine
2 Buttermilk collecting vat
3 Pump
4 Cooler
5 Storage tank
6 Pump

Installation diagram for

buttermilk separation

4.1.3 Separation efficiency

Fat recovery [%]

The residual butterfat content in the separated buttermilk can only be estimated as lying somewhere
between 50 and 70 percent of the initial butterfat
content unless extensive tests are carried out. This
is due to important parameters in the buttermaking process such as cream treatment, type of buttermaking machine and butter production process.
These technical and technological parameters affect
the separability and hence the residual fat content
in the buttermilk. However, if the initial butterfat
content is known, the residual fat content in the
separated buttermilk can be estimated with a fairly
high degree of accuracy.

100 %
80 %

Limit of economic
efficiency

60 %

Range of results

40 %
Yield
20 %

0.5 %

Fig. 38 illustrates the butterfat yield as a function

of the initial butterfat content. The separability of
buttermilk from the cask churning process deviates
from the pattern illustrated in Fig. 40. A fat recovery
yield of 20 percent can be considered as the upper
limit.

Fig. 38
The butterfat yield as
a function of the initial
butterfat content

Westfalia Separator supplies buttermilk skimming

separators with a large capacity range. Details of
the models and their capacities are available on
request.

Food Tec

1%

Initial fat content [%]

35
Westfalia Separator

Fig. 39
Concentration of
protein in an
ultrafiltration plant

4.2 Whey separation

Separation temperature is between 40

and 60C
Feed throughput to the separator is between
60 and 70 percent of the respective milk
separation feed capacity

Here we would like to refer the reader to our whey

brochure in which all relevant questions are discussed2).

Westfalia Separator supplies whey skimming separators with a large capacity range. Details of the models and their specifications are available on request.

Difficulties are encountered with separation of

whey concentrate when, with increasing temperature during concentration, whey proteins are already
precipitated out or, because of excessive vacuum,
too many fat globules are already damaged. Here,
we would also like to refer the reader to our whey
brochure.

4.3 Whey concentrate separation

4.4 Retentate separation

The limiting factors affecting the separability of

whey concentrate are the level of concentration, the
product temperature and the content in centrifu-
gable sediment.

To improve the quality of the whey protein concentrates (WPCs), part of the concentrated fat can be
removed by re-separation. This can be employed, for
example to bring the final fat content of an 80 percent WPC to approx. 5 percent. Without re-separation the final fat content would be 7 percent under
optimum conditions.

4.2.1 Criteria for designing a whey

separation line

Optimum values can only be attained when the following conditions are met:
The degree of concentration in the evaporator
is m 1:4, corresponding to a max. dry
matter content of 25 percent DM

36
Westfalia Separator

Food Tec

Generally the following assumptions can be made

for re-separation of retentate (whey protein concentrate):
Feed to the separator is approx. 50 percent of
the feed throughput for separation of milk
in the appropriate separator
Separation temperature is approx. 55C
Dry matter content in the retentate is
1030 percent DM
Separable solids are max. 0.40.8 percent V/V
Depending on the whey and type of membranes,
reductions in the initial fat value of 2030 percent
can be achieved.

4.5 Cream concentration

4.5.1 Concentration of low cream
content 4050 percent
This process is employed in plants where cream with
a low concentration (approx.15 percent) is obtained,
e.g. during re-separation of skim milk, separation
of buttermilk or whey concentrate and washing
of cream. If cream is to be churned into butter by
the process described earlier, then concentration is
possible in warm milk separators specially modified
for this purpose. The concentration capacity corresponds to about half the rated capacity for warm
milk separation.

4.5.2 Increasing the concentration of

40 percent cream
Without destabilisation
A basic requirement for production of a highly concentrated high quality cream is extremely gentle and
preserving treatment in milk separators equipped
with the soft stream system. The increase in viscosity with rising fat content defines the limit for
the cream butterfat content. Fat levels between 75
and 78 percent are quite possible. Modified warm
or cold milk separators are used for concentration
of the cream. The throughput capacities achievable
depend on the degree of concentration and the
permissible residual fat content in the skim milk. In
most cases the feed capacity is half the rated capacity of a milk separator.

With destabilisation
Destabilisation of the cream is carried out when a
cream concentration > 80 percent is to be obtained.
Before the cream is concentrated the fat globules
are reduced in size by homogenizing, whereby a
higher dispersion of the fat is obtained at the same
density. More detailed information is contained in
the documentation on production of butteroil.

Food Tec

37
Westfalia Separator

5. Measuring Methods for

Determining the Residual Fat
Content of the Skim Milk
Naturally, the method selected for determining the
residual fat content in the skim milk has no direct
influence on the fat content. However, there can be
an influence on the separability of the milk if misinterpretation of the values obtained leads to wrong
decisions being taken.
This exposition will deal with some typical differences between the measuring methods (see Fig. 40) in
use. The most important difference in the measuring
methods is in analysis by weight and volume. In the
case of analysis by volume the phospholipids in the
skim milk are not detected, whereas with the weight
analysis method (e.g. by Rse-Gottlieb) they are
detected. In the case of fat content specifications,
the method of analysis must always be stated.

aration of whole milk is measured. However, it can

vary markedly in other separation processes, such
as the production of high percentage creams (7080
percent).
Fig. 41 below illustrates the greatest differences
between the measuring methods.
How delicate these comparisons are can be seen
from the tests between Mojonnier and Rse-Gottlieb
methods in Fig. 41. The sole difference is that different measuring flasks are used. If the Mojonnier flask
shown in Fig. 42 is used for the Rse-Gottlieb test,
then the results of the Rse-Gottlieb and Mojonnier
methods will correspond.

The residual difference defined in Fig. 40 normally

exhibits a relatively constant magnitude when the
residual fat content in the skim milk obtained in sep-

Adjust to this
height with
distilled water

Fig. 42
Mojonnier-measuring flask

38
Westfalia Separator

Food Tec

Residual fat content %

0.07
0.06

Gravimetric analysis as per Rse-Gottlieb

0.05
0.04
0.03

Volumetric measuring method as per

Gerber

0.02
Traces
0.01

Number of times spun in a cup centrifuge

Fig. 40
Comparison of measuring

0.12
Modified
Bobcock
0.10

Original
Bobcock

1.6

0.08

1.3
1.0

0.06

0.7
0.04
0.4
0.02

Rse-Gottlieb

0.02
0.04
0.06
0.08
0.10
0.12
% fat in the skim milk by different methods of analysis

Fig. 41
Comparison of
different fat testing
methods

Food Tec

39
Westfalia Separator

% fat in powder
Example: separated whey concentrated 16 times

% fat in the skim milk sample by the Mojonnier test method

methods

6. Automatic Fat
Standardising Installations
Milk and cream standardisation is a process for
adjusting the butterfat content of the milk or cream
to a predetermined value. Exceeding the maximum
butterfat content means a financial loss for the
dairy.

Separator STANDOMAT base unit. For all milk applications a control signal is supplied for the feed flow
to the separator.

Models
The tendency today is for consumers to prefer milk
with a low fat content. Consequently, it is necessary
to market a wide range of products, e.g. milk with a
fat content of 0.5 percent, 1.5 percent, 2.6 percent,
3.0 percent and 3.5 percent.
Since the end of the 1980s Westfalia Separator has
been supplying solutions incorporating automatic
standardising systems to meet all market requirements.

Depending on the application and the control task

you can choose amongst 7 different Westfalia Separator
STANDOMAT models:

Control system
With all models the cream fat content is determined
via density measurement in a mass flow meter. The
cream fat control is effected by variation of the
cream flow. Control procedures adapted to the different operating conditions (start up, production,
bowl discharge, shut down) take into account the
specific requirements of the separator. For standardising, a part of the cream flow is controlled via
an inductive flow meter and dosed back into the
skim milk. The control components for the skim
milk backpressure are integrated on the Westfalia

40
Westfalia Separator

Westfalia Separator STANDOMAT WC

fat control for whey cream
Westfalia Separator STANDOMAT C
fat control for cream
Westfalia Separator STANDOMAT CB
fat control for cream
+ complete back blending (whole milk)
Westfalia Separator STANDOMAT MC
fat control for cream
+ fat control for milk
Westfalia Separator STANDOMAT MCL
fat control for cream
+ low fat cream < 28 percent
+ fat control for milk
Westfalia Separator STANDOMAT
PROSPEC MCFD
fat control for cream
+ fat in dry matter control for cheese milk
Westfalia Separator STANDOMAT MCA
fat control for cream
+ fat control for milk
+ additive dosing

Food Tec

Fig. 43
Westfalia Separator
STANDOMAT

Food Tec

41
Westfalia Separator

42
Westfalia Separator

Food Tec

Westfalia Separator CapitalCare

Increased Availability, Budget
Reliability, Improved Efficiency
Westfalia Separator CapitalCare combines decades of experience in providing
services relating to centrifugal separating technology.

For investors, this provides the options of increased

availability, maintenance for fixed budgets and the
ability to boost efficiency. With Westfalia Separator
CapitalCare we have created an instrument that
supports the work of our customers and develops
solutions before problems occur on the production
facilities.
Westfalia Separator CapitalCare means comprehensive service right from the very first discussion
onward. Specialists work with customers to identify solutions that are specifically tailored to meet
their needs. From project planning and assembly
right through to extensive support for your systems,
you receive comprehensive support from the new
Westfalia Separator CapitalCare.

Act proactively
With Westfalia Separator CapitalCare, our customers not only benefit from traditional services such
as inspection, maintenance, original spare part procurement and repairs, they also benefit from proactive risk-avoiding solutions, e.g. the online and
offline monitoring facility with Westfalia Separator
WEWATCH. Modernisation, supporting a companys work, or upgrading to reflect state-of-the-art
technology, also helps boost performance.

Food Tec

Optimum support guaranteed

In further-training programmes, on your premises or
in our modern training centre, your employees learn
how to work with the high-tech installations. And
if problems do occasionally occur, or if a spare part
is required quickly, we are able to provide immediate assistance. We guarantee this with more than
50 sales and service companies and 60 other sales
partners worldwide.

Programmed quality
There are, of course, even more areas of application for separators and decanters apart from beverage technology, dairy technology and vegetable
oil processing. As one of the leading companies
in the field of mechanical separating technology
in the world, Westfalia Separator also operates in
many other areas. Please contact us as required for
processing systems, for applications in the chemical
and pharmaceutical industries, biotechnology, oil and
fat recovery, the starch industry, industrial biotechnology, marine, energy, oil field, industry and environmental technology.

43
Westfalia Separator

 Beverage Technology

Dairy Technology

Oils and Fats Processing

Chemicals, Pharmaceuticals
and Biotechnology

Oils and Fats Recovery

Starch Technology and
Industrial Biotechnology

Environmental Technology
Marine
Energy
Oilfield
Industry
Engineering
Second Hand Machinery
Service

The information contained in this brochure merely

serves as a non-binding description of our products
and is without guarantee.
Binding information, in particular relating to capacity

Westfalia Separator
Food Tec GmbH
Werner-Habig-Strae 1
59302 Oelde (Germany)

data and suitability for specific applications, can

only be provided within the framework of concrete
inquiries.
Printed on chlorine-free bleached paper

Phone +49 2522 77-0

Fax +49 2522 77-2089
foodtec@gea-westfalia.de
www.westfalia-separator.com

9997-8239-040/0206 EN
Printed in Germany
Subject to modification

Westfalia Separator
Food Tec
Take the Best Separate the Rest
A company of GEA Group