No abstract

Fouling at interfaces deteriorates the efficiency and hygiene of processes within numerous industrial sectors, including the oil and gas, biomedical device, and food industries. In the food industry, the fouling of a complex food matrix to a heated stainless steel surface reduces production efficiency by increasing heating resistance, pumping requirements, and the frequency of cleaning operations. In this work, quartz crystal microbalance with dissipation (QCM-D) was used to study the interface formed by the fouling of milk on a stainless steel surface at different flow rates and protein concentrations at high temperatures (135 °C). Subsequently, the QCM-D response was recorded during the cleaning of the foulant. Two phases of fouling were identified. During phase-1, the fouling rate was dependent on the flow rate, while the fouling rate during phase-2 was dependent on the flow rate and protein concentration. During cleaning, foulants deposited at the higher flow rate swelled more than those deposited at the lower flow rate. The composition of the fouling deposits consisted of both protein and mineral species. Two crystalline phases of calcium phosphate, β-tricalcium phosphate and hydroxyapatite, were identified at both flow rates. Stratification in topography was observed across the surface of the QCM-D sensor with a brittle and cracked structure for deposits formed at 0.2 mL/min and a smooth and close-packed structure for deposits formed at 0.1 mL/min. These stratifications in the composition and topography were correlated to differences in the reaction time and flow dynamics at different flow rates. This high-temperature application of QCM-D to complex food systems illuminates the initial interaction between proteins and minerals and a stainless steel surface, which might otherwise be undetectable in low-temperature applications of QCM-D or at larger bench and industrial scales. The methods and results presented here have implications for optimizing processing scenarios that limit fouling formation while also enhancing removal during cleaning.

Molecular details concerning the induction phase of milk fouling on stainless steel at an elevated temperature range were established to better understand the effect of temperature on surface fouling during pasteurization. The liquid–solid interface that replicates an industrial heat exchanger (≤75°C), including four stages (preheating, heating, holding, and cooling), was investigated using both a quartz crystal microbalance (QCM-D) and a customized flow cell. We found that the milk fouling induction process is rate-limited by the synergistic effects of bulk reactions, mass transfer, and surface reactions, all of which are controlled by both liquid and surface temperatures. Surface milk foulant becomes more rigid and compact as it builds up. The presence of protein aggregates in the bulk fluid leads to a fast formation of surface deposit with a reduced Young’s modulus. Foulant adhesion and cohesion strength was enhanced as both interfacial temperature and processing time increased, while removal force increased with an increasing deposit thickness. During cleaning, caustic swelling and removal showed semilinear correlations with surface temperature ( T S ), where higher T S reduced swelling and enhanced removal. Our findings evidence that adsorption kinetics, characteristics of the foulant, and the subsequent removal mechanism are greatly dependent on the temperature profile, of which the surface temperature is the most critical one.

The thermal processing of milk is negatively impacted by fouling, which decreases the rate of heat transfer and increases the frequency of cleaning. Small-scale tools that can predict fouling on larger scales are crucial to understanding and mitigating fouling. In this work, milk fouling is compared between the submicron scale, using a high-pressure high-temperature quartz crystal microbalance with dissipation (HPHT QCM-D), and the pilot scale. Fouling rates are monitored in situ and foulants are characterized ex situ using Raman spectroscopy and atomic force microscopy (AFM). The results reveal that a proteinaceous foulant is formed on both scales. Also, a gradient in the magnitude of fouling is observed at both scales as a function of the local residence time and temperature with the greatest amount of fouling observed for the smallest local residence time and at the highest temperature (132 °C). The results suggest a scale-up factor of approximately 70−120 times when converting between QCM-D and pilot-scale fouling thicknesses. Similarities in the foulant properties and fouling rates support QCM-D as a viable technology for scale-up studies of milk fouling.