New PureFerm centrifuge set to blaze a trail for next-generation food producers

The PureFerm 750 N is the latest  technology from Alfa Laval’s range of centrifuges set for launch into the next-gen food industry, filling a gap in the market for processing that faces higher fermentation density duties and needs to deliver high product recovery while handling higher solids concentration.  

Its arrival into the world of alternative dairy production for a start-up in Europe has created positive ripples in this emerging food market.  Installed at a customer’s contract manufacturing site, the technology has delivered remarkable results in the manufacture of lab-grown casein thanks to its higher separation efficiency, resulting in drastically lower load on downstream processing steps.   

Tackling the viscosity challenge     

As a functional protein ingredient, lab-grown casein is used in alternative milk, cheese, yoghurt, and protein-enriched foods, providing structure, texture, and nutritional value comparable to traditional dairy casein.    

The casein produced through precision fermentation typically features high-solids density feed and viscosity, particularly during downstream processing after cell disruption. This high viscosity makes separation far more complex than in conventional treatment processes in this industry.  

In this case, the customer managed to achieve a 10-fold reduction in solids carry-over in their product after deploying PureFerm 750 N, when compared to their pilot plant results. This effectively reduced clogging and frequent cleaning requirements in their subsequent downstream purification steps. 

This result leads to improvements in the downstream processes, such as filtration and drying, resulting in more predictable quality for the final ingredient, translating to less product loss and more profitability. These results are achieved thanks to the unique Alfa Laval Hermetic Design™, which ensures gentle product handling. 

 The PureFerm 750 also managed to achieve a very high concentration factor that halved the number of washing steps of the heavy phase downstream, saving downstream process time and fresh water.  

This is the first time that Alfa Laval has manufactured this type of machine, so we are on a journey with the customer, and it has been a win-win for both of us,” says Balaji Iyengar, Global Sales, Separation Technology.  

 “The customer has been super-happy with the  results, and it is true to say that it has outperformed our expectations,  providing around 30 to 40% extra capacity than we thought it could.”  

A different approach to precision fermentation   

Alfa Laval was already supplying this customer with separation equipment at the contract manufacturing facility when they were approached by the start-up to help with a new challenge.  

In this emerging industry, producers are continually seeking innovative solutions that can transform their operations, and for this customer there were real challenges with low separation efficiency, loss of product in side stream, and difficulties in downstream  processes.   

“We had a new model that looked like it would fit well with their requirements,” explains Balaji. “We co-ordinated with the customer and the contract facility, with our engineers and R&D in support to develop the solution.”   

The new PureFerm model tackled the challenges head-on. The Hermetic Design, with a gentle inlet, means there is a lower shear on sensitive cells, minimized foaming risk, and a minimal temperature increase.  

Balaji says: “There are centrifuges available in the market that have similar technology, but they are not bottom-fed, or hermetically designed, or centre-to-centre. That is what makes the PureFerm 750 N machine unique and gives it a real advantage as it ensures the highest possible recovery.”  

As the alternative protein food production industry develops, so gaps appear in those markets as possibilities are explored and ideas expanded. As the deployment of the PureFerm 750 N shows, Alfa Laval is perfectly placed to move with the markets and quickly and efficiently support those demands and meet those challenges. 

“We are filling a gap in the market here,” says Balaji. “As high-density feed becomes a trend, customers want to maximize yield, and our experts at Alfa Laval deliver the solution. We are always striving to be in the right place at the right time.”