the dairy processing and products research unit dr. peggy m. tomasula research leader...
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The Dairy Processing and Products Research Unit
Dr. Peggy M. Tomasula
Research Leader
USDA/ARS/ERRC/DPPRU
600 E. Mermaid Ln
Wyndmoor, PA 19038
215-233-6703
Management Units
-Crop Conversion Science & Engineering - Kevin Hicks
-Dairy Processing and Products – Peggy Tomasula
-Fats, Oils, & Animal Co-Products - Bill Marmer
-Food Safety & Intervention Technologies – Don Thayer
-Microbial Biophysics & Residue Chemistry – Shu-I Tu
-Microbial Food Safety – John Luchansky
Resources - Unique Facilities
– Food, Dairy, & Bioengineering Pilot Plants
– Leather Research Tannery
– Wool Utilization Research Laboratory
– Botulism Research Laboratory
Resources - Unique Facilities
– Irradiation Laboratories
– Cesium-137, Gamma Radiation, 1 Million Curies
– Fruit Processing Pilot Plant (BL-2)
– Pathogen Compatible Food Processing Suite (BL-2)
Resources - Core Technologies
- Research Data Systems Unit – Bill Damert
- Microscopic Imaging Unit – Peter Cooke
- Scientific Information Resources Unit – Wendy Kramer
- Magnetic Resonance Spectroscopy Unit – Janine Brouillette
- Nucleic Acid Sequencing Unit – Connie Briggs
Technology Transfer Partnership
ARS’ MissionCollaborator’s
Interests
Area of Interaction
Jerry Crawford, Ph.D.Technology Transfer Coordinator
The Dairy Processing and Products Research Unit
Mission – To apply knowledge of the chemistry of milk to the development of new methods and processes to increase its utilization and safety.
http://www.arserrc.gov/dp
Who is the Dairy Processing and Products Research Unit and What
Do We Do?
The Dairy Processing and Products Research Unit
• Only group in ARS doing “postharvest” research on milk – farm to table
• Over 60 years of pioneering research on dairy science, specialized instrumentation, and new process development
• Perform long term research only • Personnel – 13 researchers – chemists, engineers,
food scientists, molecular biologists and 13 support scientists
Types of Dairy Research at ERRC
• Dairy Food Processing and Development• Dairy Starter Culture/Biotechnology• Dairy Food Quality and Preservation• Dairy Food Science and Technology• Biosecurity of Milk and Dairy Products• Support USDA and other action agencies (School
Lunch Program, Food for Peace, APHIS, the Military) • Share expertise and resources with our stakeholder
groups, our customers, and universities through CRADAS, trust agreements, and licenses.
Selected Accomplishments: ERRC Dairy Program
• Reduced lactose and lactose-free milk (Lactaid) and other products
Low-fat Mozzarella Cheese
• ERRC Mozzarella cheese has < 10% fat, melts well and has good texture.
• Used by the School Lunch Program, sales have reached over 23M pounds with an estimated value of $34.5M.
DPPRU Collaborators
The Dairy Processing and Products Research Unit, ERRC
Cal PolyCornellFort Valley St.LangstonNorth Carolina StPenn StateRutgersUniversity of ArkansasUniversity of DelawareUniversity of HawaiiUniversity of WisconsinUtah State University
Universities ARS
AthensBeltsvilleNCAURPenn StatePIADC
Other GovtAPHISFDANatickForeignCIAD, MexMooreparkEmbrapa, Br.
Stakeholder Groups
NMPFDFADMIIDFA
Companies
Devine FoodsEnerGeneticsGrande CheeseM&M MarsSMBIDupontAirLiquide
Molecular Basis for Improved Milk Protein Based Dairy Products
Use of Novel Processing Methods toDevelop Specialty CheesesWith Unique Functional Properties
New and ImprovedProcesses to Foster Utilization of Milk Components
Development of Lactic Fermentation Bacteria for the Production of Bioactive Food Ingredients
Protein Processing Using High Pressure Gases and Supercritical Fluids
Current Project Titles
Biosecurity of Milk from the Farm to the Dairy Processing Plant
Processing Methods for Specialty Cheese with Unique Functional Properties
Lead Scientist – D. VanHekken; M. Tunick; D. Olson; A. Bricker ; P. Tomasula
Why Hispanic-Style Cheeses?
• Growing Hispanic population in the US and a demand for this style of cheese for use by the food service industry.
• Functional and textural property data for these cheeses do not exist. No “standard of identity” definitions.
• Many are fresh style varieties and techniques are needed to extend their shelf-life for sale in the US and ensure their safety.
Objectives• Establish the properties of 3 selected Hispanic-style cheeses made
from raw or pasteurized milk. • Determine influence of proteolytic breakdown system on the
properties of the cheeses by either starter culture or indigenous microflora.
• Identify the cheesemaking steps that are key elements in developing the desired characteristics in these cheeses and that meet
US standards and retain properties of raw milk cheeses. • Develop cheesemaking procedures to extend the shelf life
of selected fresh – Hispanic style cheeses.
• Determine the flavor components and generate flavor profiles to define the cheeses. Identify microorganisms in the raw milk cheeses and evaluate their impact on flavor development.
Characterize Hispanic-style cheeses - pasteurized milk
Cheeses of interest– Soft - Queso Blanco, Queso Fresco, Panela– Semi-hard - Asadero, Oaxaca,
Menonita/Chihuahua™ – Hard - Cotija
Properties of interest- Functional - melt, color change
- Textural - TPA, torsion, viscoelastic
Soft cheesesQueso Blanco, Queso Fresco, Queso Blanco, Queso Fresco,
PanelaPanela
High moisture (45-58%), full fat (18-30%), High moisture (45-58%), full fat (18-30%),
protein (17-22%), salt 1-3%protein (17-22%), salt 1-3%
pH 6.3pH 6.3
Does not melt Does not melt
Good slicing and crumbling propertiesGood slicing and crumbling properties
Queso BlancoQueso Blanco
acid or rennet setacid or rennet set
Queso Fresco Queso Fresco rennet set, curd rennet set, curd
finely milled finely milled before saltingbefore salting
Panela Panela Combination acid Combination acid
and rennet set, and rennet set, CaClCaCl2 2 addedadded
Semi-hard CheesesAsadero, Oaxaca, Asadero, Oaxaca,
Mennonita/Quesadilla/ChihuahuaMennonita/Quesadilla/Chihuahua™™
medium moisture 40-48%, full fat 18-30%medium moisture 40-48%, full fat 18-30%protein 21-30%, salt 0.8-2.3% protein 21-30%, salt 0.8-2.3%
pH 5.0-5.5pH 5.0-5.5
Mesophilic starter cultures, rennet setMesophilic starter cultures, rennet setExcellent melt and slicing propertiesExcellent melt and slicing properties
Asadero Asadero add acid whey after add acid whey after
rennetrennetPasta filata stepPasta filata step
OaxacaOaxacaPasta filata Pasta filata
stepstep
MennonitaMennonitaCheddar Cheddar
stepstep
Collaboration with researchers at Centro de Investigacion en Alimentacion y Desarrollo,Cuauhtemoc, (CIAD) Chihuahua, Mexico
Functional Properties
Examine cooking propertiesExamine cooking propertiesMelting ability Melting ability
Color changes when broiled or Color changes when broiled or bakedbaked
Meltability
Blanco/
Fresco Panela
Cotija
QuesadillaOaxaca
0
1
2
3
Cheese
Me
lt
Mexican Mennonite cheeses made in Chihuahua, Mexico
Raw vs pasteurized milkCheeses from 13 manufacturers
Evaluated: CompositionRheological properties
Rheological PropertiesShear Rigidity (kPa)
Range Average raw 11-52 36
pasteurized 24-72 49
0
20
40
60
80
0.0 0.5 1.0 1.5 2.0
Shear Strain
Sh
ea
r S
tre
ss
(k
Pa
)
Raw milk cheese Pasteurized milk cheese
PRA
SensoryTraining panelists at ERRC to identify
flavors in fresh Hispanic-style cheeses.
Collaboration with MaryAnne Drake, NCSU
Sensory Data for a Hispanic Cheese
Basic and young flavors Aged flavors
012345
Brothy
Fruity
Free FattyAcid
Nutty
Sulfur
012345
Bitter
Sweet
Sour
Salty
Umami(MSG)
Milkfat
Cooked
Buttery
Whey
Preliminary Composition Data
Fat/ Grasas
30%
Protein/
Proteinas
25%
Moisture/
Humedad
40%
Other/Otro
5%
0
10
20
30
40
50P
erc
en
t
(%)
Other/Otro Protein/Proteinas Fat/Grasas Moisture/Humedad
Texture of Chihuahua Cheese
How well do the Chihuahua – Chester cheeses cluster
0
20
40
60
80
100
0.0 1.0 2.0 3.0
Shear Strain
Sh
ea
r S
tre
ss (
kP
a)
Food Safety Focal Points at ERRC
Raw Material
Slaughter Fabricate Process
Finished Product
• Chemical (Na Lactate)
• Mechanical (Design change)
Interventions• Physical (Irradiation)
• Biological (LAB)
Recovery/Characterization• Biosensors (Micro. & Immuno)
• Nucleic Acid (PCR, PFGE)
• Genomics & Proteomics
Modeling• Predictive Microbiology
(PMP, ComBase, CEMMI)
DPPRU Projects
• Determination of effectiveness of pasteurization in elimination of FMD Virus from milk – with Plum Island Animal Disease Center
• Evaluation of microbial pathogen food safety of fresh cheeses – Queso Fresco- shelf life studies, and interventions - with Microbial Food Safety RU.
ERRC Food Safety Collaborative Projects - Brazil
• Collaboration with Embrapa Dairy Cattle Center and the Dairy Technology Institute
• Developing specifications and evaluating safety of soft cheeses.
• Bacteriocins with activity against Salmonella and Listeria
• Survey of Food Safety Farm to Slaughter for Salmonella, Listeria, and E.Coli 0157:H7.
In Summary
The Dairy Processing and Products RU at ERRC maintains a multidisciplinary group of dairy professionals:
• To respond to the critical needs of our stakeholders
• To anticipate the needs of the dairy industry by incorporating new ideas in chemistry and biotechnology into processing, for the consumer of tomorrow
• To ensure the continued quality, utilization and safety of milk and milk products
U. S. Whey Products Range
Lactose derivatives
Lactose Sweet whey Modified Wheys
Permeate Whey Fractions
WPIs
WPCs
Feed
Food
Pharma Calcium
$0.37 - $5.00/ kg $0.35-0.50/ kg $1.5-2.0/ kg
>$500$1-10/ kg
$5-6.0/kg
New and Improved Processes to Foster Utilization of Milk Components
Lead Scientist – C. Onwulata; R. Konstance
Objectives1) Develop thermal and non-thermal extrusion-based processes that denature and functionalize milk proteins to create texturized casein and whey protein ingredients. 2) Develop process protocols for texturizing milk proteins through non-extrusion shear processes.
Why Extrusion?
• A twin-screw extruder, with its shearing screws operating at various speeds, uses mechanical and heat energy to cook, mix, pump and ultimately change the texture of dairy products.
• Low – shear processing – for pasta and doughs
• High-shear processing – for puffed products
Research Approach:
• Use new extrusion processing techniques to create texturized products based mainly on whey and nonfat dry milk
• Use other shear –based processes that manipulate the structure of whey proteins with other food ingredients.
Potential Products:
• Simulated Meat Products
• Meat extenders
• Functionalized protein products for inclusion in snack foods and meal-replacement bars
Protein Processing UsingHigh Pressure Gases and Supercritical Fluids
Lead Scientist – PM Tomasula; MF Kozempel
Objectives1) Design a new environmentally-benign process for producing enriched fractions of the whey proteins2) Develop new environmentally-benign processes for dairy protein modification that utilize supercritical fluids as reac- tion media and carriers.3) Develop new, cost effective technologies for processing protein fractions into non-food products
Why Use Carbon Dioxide?
• It’s an environmentally benign solvent in large supply; it’s cheap; it’s GRAS; and it can be reclaimed for re-use in the process.
Research Approach
• Use high pressure and supercritical carbon dioxide in new processes:
• to isolate casein from milk• to produce enriched fractions of the whey proteins • modify dairy proteins for food applications And • Investigate processing of dairy proteins for nonfood applications
Potential Products
• Increased utilization of milk and whey by creation of new protein products
• New technologies for dairy protein utilization
• Increased utilization of milk and milk products in nonfood products
Development of Lactic Fermentation Bacteria for the Production of Bioactive Food Ingredients
Lead Scientist – G. Somkuti
1) Develop lactic fermentation bacteria with the capacity to overproduce biologically active ingredients from milk proteins for improving the nutraceutical, functional and biopreservative properties of dairy foods2) Develop techniques for optimized and cost effective production of milk protein components by microbial technology and assess their impact on the quality and marketability of value-added dairy foods.
Objectives:
What are Bioactive Peptides?
• Bioactive peptides are the peptides generated from the native proteins in milk during the digestion process when milk or other dairy products are consumed. However, they are produced in small quantities.
Properties of Bioactive Peptides:
• Antihypertensive
• Antithrombotic
• Opioid
• Immunomodulatory
• Antitumor
• Antimicrobial
Research Approach:
• Use lactic fermentation bacteria to produce
large quantities of bioactive peptides for the
food and pharmaceutical companies.
Molecular Basis for Improved Milk Protein Based Dairy Products
Lead Scientist – H. Farrell; P. Hoagland; P. Qi; E. Malin
Objective – To elucidate the basic milk protein structural motifs responsible for protein-protein interactions in milk and dairy products, especially for lowfat cheeses.
Physical-chemical basis for protein functionality is evaluated and computer molecular models are used to augment interpretation of the structural information at the molecular level. Environmental factors influencing protein folding and micelle assembly in vitro are used to predict milk protein secretion in vivo.
Molecular Modeling
• Provides knowledge of the molecular basis for
structure/function behavior of dairy products and the ability to predict this behavior.
• Especially useful in the design of low-fat products where the functionality of the product relies on protein-protein interactions that replace the role of the fat.
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