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Membrane Technology for Food and Beverage Processing

Published by: BCC Research

Published: Aug. 1, 2006 - 183 Pages


Table of Contents


INTRODUCTION

STUDY GOALS AND OBJECTIVES

REASONS FOR DOING THE STUDY

CONTRIBUTIONS OF THE STUDY AND FOR WHOM

SCOPE AND FORMAT

METHODOLOGY

INFORMATION SOURCES

ANALYST'S CREDENTIALS

RELATED BCC RESEARCH PUBLICATIONS

DISCLAIMER

BCC ONLINE SERVICES




SUMMARY

Summary Table: U.S. FORECAST FOR MEMBRANES USED IN FOOD AND BEVERAGE PROCESSING, THROUGH 2011 ($ MILLIONS)

Summary Figure: U.S. FORECAST FOR MEMBRANES USED IN FOOD AND BEVERAGE PROCESSING, 1990-2011 ($ MILLIONS)




OVERVIEW OF MEMBRANE TECHNOLOGY

OVERVIEW OF MEMBRANE TECHNOLOGY


Table 1 MEMBRANE APPLICATIONS IN FOOD PROCESSING

Table 2 MEMBRANE APPLICATIONS IN BEVERAGE PROCESSING


TECHNOLOGY TYPES


REVERSE OSMOSIS

NANOFILTRATION

ULTRAFILTATION


UF Reactors


Table 3 APPLICATIONS FOR BIOCATALYTIC MEMBRANE REACTORS IN FOOD AND BEVERAGE PROCESSING



MICROFILTRATION

ELECTROCHEMICAL MEMBRANE SEPARATIONS


Electrodialysis

Bipolar Membrane Electrodialysis


OTHER


RELATIVE SIZE OF SEPARATED COMPONENTS


Table 4 TYPICAL DIMENSIONS OF SMALL PARTICLES, MOLECULES, AND IONS FOUND IN FOOD AND BEVERAGE PROCESSING (NANOMETERS)


MEMBRANE FOULING

HISTORY OF THE INDUSTRY


EARLY STUDIES

1920 TO 1950

1950 TO 1990

1990 TO PRESENT


Table 5 SELECTED CHRONOLOGY OF THE MEMBRANE INDUSTRY



THE APPEAL OF MEMBRANE TECHNOLOGY

VALUE OF THE MARKET BY FILTRATION TYPE


REVERSE OSMOSIS/NANOFILTRATION

ULTRAFILTRATION

MICROFILTRATION

ELECTRODEIONIZATION

OTHER


Table 6 MARKET FORECAST FOR MEMBRANES USED IN FOOD AND BEVERAGE PROCESSING BY FILTRATION TYPE, THROUGH 2011 ($ MILLIONS)

Figure 1 U.S. MARKET FORECAST FOR MEMBRANES USED IN FOOD AND BEVERAGE PROCESSING BY FILTRATION TYPE, 1990-2011 ($ MILLIONS)



THE MARKET FOR MEMBRANES BY CONFIGURATION


Table 7 CONFIGURATION CHOICES BASED ON PHYSICO-CHEMICAL PARAMETERS


VALUE OF THE MARKET FOR MEMBRANES BY CONFIGURATION


Table 8 U.S. MARKET FORECAST FOR MEMBRANES BY CONFIGURATION, THROUGH 2011 ($ MILLIONS)

Figure 2 U.S. MARKET FORECAST FOR MEMBRANES BY CONFIGURATION, 1990-2011 ($ MILLIONS)


TYPICAL PRODUCTS


Table 9 MEMBRANE MANUFACTURERS AND PRODUCTS




APPLICATIONS OVERVIEW

CONCENTRATION

CLARIFICATION

MICROBIOLOGICAL STABILIZATION

DEMINERALIZATION

WASTEWATER TREATMENT



Table 10 TYPICAL WATER-USE RATES FOR THE FOOD AND BEVERAGE PROCESSING INDUSTRY (GALLONS)


WASTEWATER REUSE


Zero Discharge/Zero Emissions



COMPETING TECHNOLOGIES


CONCENTRATION


Evaporation-Evaporation

Distillation-Distillation


SOLID/LIQUID SEPARATION, CLARIFICATION


Centrifugation-Centrifuges

Sedimentation-Sedimentation

Filtration-Filtration


DEMINERALIZATION


Ion-Exchange Resins


SOLID/LIQUID, LIQUID/LIQUID SEPARATIONS


Extraction


MICROBIOLOGICAL STABILIZATION


Pasteurization

Sterilization

Refrigeration/Freezing

Filtration-Filtration


WASTEWATER TREATMENT




GOVERNMENT REGULATIONS

FDA CRITERIA FOR PRODUCT CONTACT SURFACES

3A SANITARY STANDARDS

CLEAN IN PLACE


Table 11 TYPICAL CLEANING PROCEDURE FOR DAIRY ELEMENTS




FOOD INDUSTRY MARKETS


Table 12 BREAKDOWN OF THE FOOD INDUSTRY BY PRODUCT AND NAICS CODE


THE U.S. FOOD PROCESSING INDUSTRY


Table 13 VALUE OF FOOD SHIPMENTS BY INDUSTRY SECTOR, 2002 ($ BILLIONS)

Figure 3 VALUE OF FOOD SHIPMENTS BY INDUSTRY SECTOR, 2002 (%)


KEY STATES IN FOOD SHIPMENTS


Table 14 TOP 10 STATES IN FOOD SHIPMENTS, 2002 ($ BILLIONS)


VALUE OF THE MARKET BY APPLICATION


Table 15 U.S. MARKET FORECAST FOR FOOD AND BEVERAGE PROCESSING MEMBRANES BY APPLICATION, THROUGH 2011 ($ MILLIONS)

Figure 4 U.S. MARKET FORECAST FOR FOOD AND BEVERAGE PROCESSING MEMBRANES BY APPLICATION, 1990-2011 ($ MILLIONS)




GRAIN AND OILSEED MILL PRODUCTS

PRODUCTS TO SEPARATE


CORN MILLING

FATS AND OILS


SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS



Figure 5 CORN WET MILLING


RO


Steep Water

Steep Water Concentration

Steep Water Pasteurization

Starch Washing


UF/MF


Syrup Clarification

Functional Soy Proteins

Corn Protein Processing

Chemical Starch Modification

Fermentation

Saccharification

Oil Processing

Downstream Processing

Wheat Starch Processing


ED


Soy Protein Isolates



VALUE OF THE MARKET FOR MEMBRANES IN GRAIN AND OILSEED MILL PRODUCT PROCESSING


Table 16 U.S. MARKET FORECAST FOR MEMBRANES IN GRAIN AND OILSEED MILL PRODUCT PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 6 U.S. MARKET FORECAST FOR MEMBRANES IN GRAIN AND OILSEED MILL PRODUCT PROCESSING, 1990-2011 ($ MILLIONS)





SUGAR AND CONFECTIONERY

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS


RO/NF


Caustic Wash Water Recovery


UF/MF


Sugar Clarification

Honey Manufacture

Press Water Clarification


VALUE OF THE MARKET FOR MEMBRANES IN SUGAR AND CONFECTIONERY PRODUCT PROCESSING


Table 17 U.S. MARKET FORECAST FOR MEMBRANES IN SUGAR AND CONFECTIONERY PRODUCT PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 7 U.S. MARKET FORECAST FOR MEMBRANES IN SUGAR AND CONFECTIONERY PRODUCT PROCESSING, 1990-2011 ($ MILLIONS)




PRESERVED FRUITS AND VEGETABLES

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS


RO/NF


Pickle Brine Recovery


UF


Juice

Pickle Brine Recovery


MF


Juice Clarification

De-Bittering Citrus Juice

Juice Concentration and Aroma Recovery


PERVAPORATION


Flavor and Aroma Compound Recovery


ED


Inactivation of Polyphenol Oxidase



VALUE OF THE MARKET FOR MEMBRANES IN PRESERVED FRUIT AND VEGETABLE PROCESSING


Table 18 U.S. MARKET FORECAST FOR MEMBRANES IN PRESERVED FRUIT AND VEGETABLE PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 8 U.S. MARKET FORECAST FOR MEMBRANES IN PRESERVED FRUIT AND VEGETABLE PROCESSING, 1990-2011 ($ MILLIONS)




DAIRY PRODUCTS

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS


PASTEURIZED MILK ORDINANCE

FDA CRITERIA FOR PRODUCT CONTACT SURFACES


PROCESSES AND APPLICATIONS


RO


Whey Concentration

Milk Concentration

Evaporator Condensate Polishing


NF


Salt Whey


UF


Whey Processing

Cheese Production


Table 19 WHEY PROTEIN CONCENTRATE


Milk Standardization

Other UF Applications


MF


Whey Processing

Extended Shelf Life Milk

Milk Fractionation

Buttermilk Fractionation

Other MF Applications


ED


Whey Demineralization



VALUE OF THE MARKET FOR MEMBRANES IN DAIRY PROCESSING


Table 20 U.S. MARKET FORECAST FOR MEMBRANES IN DAIRY PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 9 U.S. MARKET FORECAST FOR MEMBRANES IN DAIRY PROCESSING, 1990-2011 ($ MILLIONS)




MEAT AND POULTRY

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS


RO/NF/MF/UF


Wastewater



VALUE OF THE MARKET FOR MEMBRANES IN MEAT AND POULTRY PROCESSING


Table 21 U.S. MARKET FORECAST FOR MEMBRANES IN MEAT AND POULTRY PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 10 U.S. MARKET FORECAST FOR MEMBRANES IN MEAT AND POULTRY PROCESSING, 1990-2011 ($ MILLIONS)




SEAFOOD PRODUCTS

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS


SEAFOOD INDUSTRY WASTE CONVERSION

UF


Protein Processing



VALUE OF THE MARKET FOR MEMBRANES IN SEAFOOD PROCESSING


Table 22 U.S. MARKET FORECAST FOR MEMBRANES IN SEAFOOD PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 11 U.S. MARKET FORECAST FOR MEMBRANES IN SEAFOOD PROCESSING, 1990-2011 ($ MILLIONS)




BAKERY PRODUCTS

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS

VALUE OF THE MARKET FOR MEMBRANES IN BAKERY PRODUCT PROCESSING


Table 23 U.S. MARKET FORECAST FOR MEMBRANES IN BAKERY PRODUCT PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 12 U.S. MARKET FORECAST FOR MEMBRANES IN BAKERY PRODUCT PROCESSING, 1990-2011 ($ MILLIONS)




OTHER MEMBRANE TECHNOLOGY MARKETS

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS


RO/NF

UF


Gelatin

Blood



Table 24 AVERAGE TOTAL BLOOD YIELDS, PER SLAUGHTERED ANIMAL (KG)


Blood Protein Recovery


Egg


Lysozyme Production

IgY Extraction Methods

Cholesterol-Reduced Egg Products

Vinegar


Polysaccharides, Gums, and Other Colloids

MSG

Wastewater



VALUE OF THE MARKET FOR MEMBRANES IN OTHER FOODS PROCESSING


Table 25 U.S. MARKET FORECAST FOR MEMBRANES IN OTHER FOODS PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 13 U.S. MARKET FORECAST FOR MEMBRANES IN OTHER FOODS PROCESSING, 1990-2011 ($ MILLIONS)




BEVERAGES

PRODUCTS TO SEPARATE

SECTOR CHALLENGES

SPECIFIC GOVERNMENT REGULATIONS

PROCESSES AND APPLICATIONS


RO


Bottled Water

Bottled Water Treatment


Table 26 COMPARISONS OF INTERNATIONAL DRINKING WATER AND BOTTLED WATER GUIDELINES (MILLIGRAMS/LITER)



MF


Wine

Beer


ED


Wine Tartrate Stabilization


Refrigeration

ED



PERSTRACTION


Alcohol Adjustment of Wine



VALUE OF THE MARKET FOR MEMBRANES IN BEVERAGE PROCESSING


Table 27 U.S. MARKET FORECAST FOR MEMBRANES IN BEVERAGE PROCESSING, THROUGH 2011 ($ MILLIONS)

Figure 14 U.S. MARKET FORECAST FOR MEMBRANES IN BEVERAGE PROCESSING, 1990-2011 ($ MILLIONS)




PATENT SURVEY

PATENT SURVEY

PATENTS BY APPLICATION


Table 28 PATENTS BY APPLICATION

Figure 15 PATENTS BY APPLICATION (%)


PATENTS BY COMPANY


Table 29 NUMBER OF PATENTS BY COMPANY

Figure 16 PATENTS BY COMPANY (%)




INTERNATIONAL ASPECTS

TECHNOLOGY


APPLICATIONS


Dairy

Sugar

Fruits and Vegetables

Beverages

Grain and Oilseed

Seafood

Wastewater





INDUSTRY STRUCTURE

STAYING COMPETITIVE


ACQUISITIONS


Table 30 MERGERS AND ACQUISITIONS, 1996-2006


PRODUCT MIX

PRODUCT DISTRIBUTION


BARRIERS TO GROWTH

INDUSTRY PLAYERS

MARKET SHARE


Table 31 MANUFACTURERS OF MEMBRANES USED IN FOOD AND BEVERAGE INDUSTRIES, MARKET SHARE (%)

Figure 17 MANUFACTURERS OF MEMBRANES USED IN FOOD AND BEVERAGE INDUSTRIES, MARKET SHARE (%)


COMPANY PROFILES


AQUAMARIJN-MICRO FILTRATION BV

AQUIOUS WATER TECHNOLOGIES/ITT INDUSTRIES

ASAHI KASEI CORP.

ATECH INNOVATIONS GMBH

BEKAERT FIBER TECHNOLOGIES

CERAMEM

CUNO, INC/3M

DONALDSON CO., INC.

DOW LIQUID SEPARATIONS/FILMTEC CORP.

EURODIA INDUSTRIE/AMERIDIA

FAIREY INDUSTRIAL CERAMICS

FLUXXION BV

GE WATER & PROCESS TECHNOLOGIES

GRAVER TECHNOLOGIES/THE MARMON GROUP

HYDRANAUTICS/NITTO DENKO

KOCH MEMBRANE SYSTEMS

KUBOTA CORP.

MEMBRANA/POLYPORE, INTL.

MEISSNER FILTRATION PRODUCTS, INC.

MICRODYN-NADIR GMBH

MILLENNIUMPORE

MILLIPORE CORP.

MITSUBISHI RAYON CO., LTD.

NEW LOGIC, INTL.

NORIT NV

NYSA MEMBRANE TECHNOLOGIES

ORELIS/NOVASEP

PALL CORP.

POLYMEM SA

PORES TECHNOLOGIES

PORVAIR FILTRATION GROUP

SAEHAN INDUSTRIES, INC.

SARTORIUS AG

SPINTEK

SYNDER FILTRATION

TAMI INDUSTRIES

TORAY INDUSTRIES

TRISEP CORP.

USFILTER/SIEMENS

ZENON ENVIRONMENTAL SERVICES




APPENDIX

PATENT LISTINGS


Table 32 PATENT LISTINGS


Abstract

INTRODUCTION

Food and beverage processing is one of the largest manufacturing sectors in the U.S., accounting for more than 10% of all manufacturing shipments. The industry also has considerable presence in the global economy, with more than one-third of the top 50 food and beverage industry processors located in the U.S. Leading processors include Archer Daniels Midland, Kraft Foods, Cargill, Pepsico, Tyson Foods, Coca-Cola, Mars, ConAgra, Anheuser Busch, and General Mills. These compete with major overseas companies, including Nestle (Switzerland), Unilever (U.K.), Groupe Danone (France), Diageo (U.K.), Kirin Brewery (Japan), SABMiller (South Africa), Cadbury Schweppes (U.K.), Heineken (Netherlands) and Asahi Brewery (Japan).

Separation science is essential to manufacturing food and beverage products. Evaporation, centrifugation, media filtration, distillation, and solvent extraction are just a few of the traditional processes used in solid/liquid and liquid/liquid separations needed in the sector. Since their debut in the food industry about 30 years ago, membranes have found both large-volume and niche applications across a range of food and beverage industries, including fluid milk, cheese, and other dairy products; grain and oilseed products; beer, wine, and soft drinks; frozen, canned, preserved, and juiced fruit and vegetables; sugar and other sweeteners; meat, poultry, and seafood products; and various miscellaneous foods and food additives.

STUDY GOALS AND OBJECTIVES

This study has been compiled to review the state of the art of membrane technology as applied to food and beverage processing, offer a valuation of the current market, and provide estimates of future growth for a market that has developed rapidly, but which also is becoming more fragmented.

The report will examine the crossflow membrane technologies: reverse osmosis (RO), nanofiltration (NF), ultrafiltration (UF), and microfiltration (MF), as well as dead-end UF/MF filtration. The smaller markets relating to ion-exchange membranes and membrane contactors also will be evaluated.

The market for membrane applications in process water and process fluids, wastewater treatment and water reuse, product recovery, and cleaner recycling will be considered. Membrane gas separations as needed in food and beverage manufacture will not be covered.

REASONS FOR DOING THE STUDY

The use of membrane technology in the food and beverage industries was dominated for many years, and to a large extent still is, by applications in the treatment of milk and whey. This market, although large (and still increasing), has little published information relating to market size and growth. Application areas such as juice and wine clarification, and protein processing are also relatively undocumented from a marketing perspective. The primary reason for the dearth of information is likely the competitive nature of the business, which has increased with maturation of the market and as some degree of commoditization has become accepted.

Most companies are unwilling to share any dollar amount or market share information for fear of encouraging 'poaching' by their competitors. This has become more critical as standard products (e.g., spirals for dairy applications) have become widespread, along with multiplication of the number of suppliers of these standard products and the increased experience of users with the technology. All of the above point to a need for objective analysis of the field.

CONTRIBUTIONS OF THE STUDY AND FOR WHOM

With the issues mentioned above as a background, this comprehensive report aims to better define the market and its opportunities for existing suppliers; those interested in investment, acquisition, or expansion into the membrane market; and end-user companies in the food industry. It seeks to provide these users with specific, detailed information crucial to making educated decisions. This study is an information source on the industry and a reference manual on this advanced technology, and a resource that provides information to decision makers who need to stay abreast of the state of the art.

This report is designed to be as comprehensive as possible, and to be useable by a broad audience of business, technical, and regulatory practitioners on a global scale. Senior marketing personnel, venture capitalists, executive planners, research directors, government officials, and suppliers to the membrane industry who want to discover and exploit current or projected market niches should find this report of value. Novice readers who wish to understand how regulations, market pressures, and technology interact in the membrane arena also will find this study worthwhile.

SCOPE AND FORMAT

Technology basics will be reviewed so that every reader begins with some level of technical understanding. The report moves on to an analysis of applications of the technology in nine fields of food and beverage manufacture, and finally presents predictions for emerging applications in the industry. The report also contains some background on regulatory requirements for both membranes and modules used in sanitary applications.

Where appropriate, detailed information on specific products, supplier companies, and market information will be detailed for the specific application in order to present a complete and stand alone analysis. Five-year projections are provided for market activity and value. Industry structure, trends, pricing considerations, R&D, government regulations, company profiles, and competitive technologies are included.

METHODOLOGY

Research for this report began with a re-analysis of the available technical and business literature, as well as an evaluation of the personal records of the membrane industry available to the author. Conversations with industry experts and company representatives, and a review of their published works provide the backbone for the market evaluation. Other sources of information include product literature from system suppliers, patent information, annual reports, and BCC Research's monthly newsletter, Membrane & Separation Technology News. Forecasts in this report are based on announced projects and anticipated capacity additions over the next 5 years. Costs are based on published data and interviews with industry participants.

The term "membranes" refers to sheet, hollow fiber, or tubular membrane material enclosed in housings (where relevant), which are packaged into modules, capsules, cartridges, or cassettes. Membranes used in crossflow systems, dead-end systems, and electrochemical systems are included.

Calculations are based on the retail price of products rather than the discounted costs available to large-volume users and OEMs (original equipment manufacturers). Sales of replacement membranes are included in market sizes and forecasts.

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