Abstract: A process for transferring energy to the contents of a vat. An embodiment transfers an amount of heat energy needed to heat cheese curd and whey inside the vat according to a specified time and temperature. An energy substrate, such as steam and/or water, carries heat energy to a vat jacket. The embodiment calculates the total process energy required to be transferred to the vat contents to cook the cheese in accordance with a recipe. The total process energy is a function of the energy input to the vat minus the energy output from the vat. Small losses of energy from the vat to the atmosphere occur. These small losses are accounted for by use of historical efficiency data for each vat. The historical efficiency is continuously monitored and any deviation from the historical efficiency is factored into the energy transfer calculation for subsequent cheese batches.

Abstract: An air-lift dryer for processing a high-lactose aqueous fluid (HLAF), such as permeate from ultrafiltration of whey fluid, is provided. The air-lift dryer has an enclosed drying chamber with diverging interior sidewalls that define an intermediate interior space having a cross-sectional area that increases as the diverging interior sidewalls extend away from a lower portion toward an upper portion.

Abstract: A method for processing a high-lactose aqueous fluid (HLAF), such as permeate from ultrafiltration of whey fluid, is described. The process includes spraying a partially crystallized high-lactose aqueous fluid upward into an air-lift dryer having diverging sidewalls.

Abstract: A method for processing a high-lactose aqueous fluid (HLAF), such as permeate from ultrafiltration of whey fluid, is provided. The method includes a step of drying the partially crystallized HLAF in an air-lift dryer which has diverging sidewalls to form a product rich in crystalline alpha-lactose monohydrate.

Abstract: A method for processing a high-lactose aqueous fluid (HLAF), such as permeate from ultrafiltration of whey fluid, is provided. The process includes introducing highly concentrated high-lactose aqueous fluid into a cooling, concentrating, crystallizing apparatus, exposing the highly concentrated HLAF to a gaseous fluid to create a cooling, concentrating, crystallizing cascade to form a partially crystallized HLAF.

Abstract: A method for processing a high-lactose aqueous fluid (HLAF), such as permeate from ultrafiltration of whey fluid, is provided. The process includes introducing a highly concentrated high-lactose aqueous fluid into a cooling, concentrating, crystallizing apparatus in which the highly concentrated high-lactose aqueous fluid is exposed to mixing and to movement of a gaseous fluid at a temperature, moisture content and air speed effective to create a cooling, concentrating, crystallizing cascade to generate a partially crystallized high-lactose aqueous fluid and spraying the partially crystallized high-lactose aqueous fluid into an enclosed drying chamber containing hot air to form a high-solids crystalline product rich in crystalline alpha-lactose monohydrate crystals.

Abstract: Systems and methods for processing a high-lactose aqueous fluid (HLAF), such as permeate from ultrafiltration of whey fluid, are described. The preferred process includes concentrating HLAF containing from about 1 to about 35% solids, wherein at least 50% of the solids are lactose, to form a concentrated HLAF containing from about 45 to about 65% solids; further concentrating the HLAF to form a highly concentrated HLAF containing from about 70 to about 80% solids; cooling the highly concentrated HLAF with a gaseous fluid to create a cooling, concentrating, crystallizing cascade to further concentrate the HLAF to form a partially crystallized HLAF containing from about 78 to about 88% solids; and drying the partially crystallized HLAF in an air-lift dryer to form a product rich in crystalline alpha-lactose monohydrate. An air-lift dryer having diverging sidewalls and methods of using same are also disclosed.

Abstract: A failsafe valve assembly for use in clean-in-place systems that arranges multiple product blocking valves with one bleed valve. The failsafe valve assembly having a junction providing fluid communication between the primary isolation valve, the one bleed valve and the multiple product valves. The failsafe valve assembly further providing continuous flow cleaning capabilities.

Abstract: A method of forming a concentrate, the concentrate having a predetermined concentration of a component in the concentrate. The method comprising the steps of: filtering a fluid thereby separating the fluid into a permeation and the concentrate; determining the concentration of the component in the concentrate; and if concentration of the component is greater than a predetermined concentration, decreasing the concentration of the component to the predetermined concentration. Dilution is achieved by feeding permeate into the concentrate or by controlling a pressure differential within a filter.