technological challenges of high milk protein formulations

TECHNOLOGICAL CHALLENGES

OF HIGH MILK PROTEIN

FORMULATIONS

Juan M. Gonzalez, PhD, MBA

MPC

MILK CALCIUM

PROTEIN

WHEY

MUSCLE

LEUCINE

JM Gonzalez ©

NEW PRODUCT LAUNCHES WITH HIGH PROTEIN CLAIMS ARE 3-FOLD HIGHER IN THE US THAN ANYWHERE ELSE IN THE WORLD

DAIRY PROTEINS - FOCUS ON NUTRITION:

SATIETY MUSCLE GROWTH AND REBUILD HEALTHY WEIGHT

DAIRY PROTEINS - VERSATILITY:

FLAVOR TEXTURIZERS EMULSIFIERS SOLUBILITY

market growth for high protein foods

Ref: US consumers have a healthy appetite for high protein food. The US leads the way in global launches of high protein products. MINTEL. 2012

THE DEVELOPMENT OF NOVEL NUTRITIONAL FOOD PRODUCTS IS TRACED ACROSS INTER-RELATED DRIVERS.

PRODUCT FUNCTIONALITY IS REFLECTED IN THE NUTRITIONAL, HEALTH, PHYSICO-CHEMICAL AND SENSORY EXPERIENCE DRIVERS.

Physico-chemical

Nutritional Law -

Economics Enabler

INDUSTRY

DRIVERS

Sensory Health

Ref: The role of Food Science in Ingredient Functionality and Food Systems. JM Gonzalez. In: Consumer

Behavior and Food Science Innovations for Optimal Nutrition. 2014. Sackler Int Nutr Sci. NY Acad Sci.

drivers for nutritional product development

JM Gonzalez ©

High Milk Protein Foods Development

LAW /ECONOMICS

• Market: Need-Want, Price, Supply-Demand

• Regulation: Law, Safety • Sustainability: energy,

environment, pollution

ENABLER

• Processes- make ingredient • Products - ingredient make • Attributes – define

ingredient/ product (Convenience, Portable, Ready-to-eat, Shelf-life, Life Style)

HEALTH

• IMMUNITY • MUSCLE FIBER

GROWTH & REGENERATION

• WEIGHT MANAGEMENT

NUTRITIONAL PROPERTIES

• HIGH QUALITY

PROTEIN • BRANCHED CHAIN

AMINO ACIDS

SENSORY PROPERTIES

• FLAVOR • TEXTURE • AROMA • COLOR

PHYSICO-CHEMICAL PROPERTIES

• HYDRATION • VISCOSITY • GELATION • COAGULATION

drivers for nutritional product development

Ref: The role of Food Science in Ingredient Functionality and Food Systems. JM Gonzalez. In: Consumer

Behavior and Food Science Innovations for Optimal Nutrition. 2014. Sackler Int Nutr Sci. NY Acad Sci.

JM Gonzalez ©

SPORTS NUTRITION

PREMATURE INFANTS

GERIATRIC FOODS

HIGH DAIRY

PROTEIN

FOODS

focus areas for high milk protein foods

WEIGHT MANAGEMENT

MEDICAL FOODS

JM Gonzalez ©

HIGH DAIRY

PROTEIN

FOODS

LIQUID

POWDER

ASEPTIC

RETORT

DRY POWDER

BLENDING

DRIED SLURRY

• BARS

• EXTRUDED FOODS

• SPOONABLE FOODS

PRODUCT

FORMAT MANUFACTURING

PROCESS

JM Gonzalez ©

STABILITY SENSORY

EXPERIENCE

FORMULATION PROCESS

technology challenges

MPC WMP SMP WPC, WPI CASEIN WHEY + CASEIN HYDROLYZATES


TARGET PROTEIN LEVEL

AMINO ACID PROFILE

PROTEIN INGREDIENT SELECTION

INGREDIENT HISTORY

FORMULATION

DEGREE OF HYDROLYSIS

PEPTIDE PROFILE

JM Gonzalez ©


FORMULATION

All products are registered trademarks

Information c.2015 from brand websites

g PROTEIN / 100 ml

A.B.B. PURE PRO 50 11.80

NUTRAMINO PROTEIN XL 10.00

MAXI PROTEIN MILK EXTREME RECOVER 10.00

MAXI PROTEIN MILK RECOVER 9.09

PROTINO 8.88

MUSCLE BUILDER 8.47

MILK 2 GO 8.00

TEAM SKY 7.88

SLIM FAST 6.78

ENSURE HIGH PROTEIN SHAKE 6.75

BOOST HIGH PROTEIN SHAKE 6.33

KELLOGG'S BREAKFAST SHAKE 3.34

ENFAMIL PREMATURE 30 Cal 3.00

JM Gonzalez ©


• SOLIDS CONTENT

• DISPERSIBILITY

• HYDRATION

• ORDER OF INGREDIENT ADDITION

• INTERACTION WITH OTHER INGREDIENTS

• FOAMING

BEHAVIOR:

THERMAL pH RHEOLOGY (VISCOSITY)

PROCESS

• COLOR CHANGES (BROWNING)

• FLAVOR DEGRADATION

• FLAVOR BINDING

• NUTRIENT DEGRADATION

• LACTOSE CRYSTALLIZATION

• GRAININESS

• AGED THICKENING

• AGED GELATION

• SERUM SEPARATION

• SEDIMENTATION


STABILITY & SENSORY EXPERIENCE

DENATURATION

AGGREGATION

GELATION

COAGULATION

PRECIPITATION

FOULING (BURN ON)


PROCESS - THERMAL & pH BEHAVIOR

LOSS OF BIOACTIVITY

MAILLARD REACTION:

COLOR CHANGE

NON-ENZYMATIC GLYCOSYLATION

(LACTOSYLATION)

MAILLARD REACTION

• pH >7

• HEAT

• CREATE:

COLOR & FLAVOR

LACTOSYL-LYSINE

• LOSS: NUTRITIONAL VALUE

• Relationship between blocked lysine and carbohydrate composition of infant formulas. Evangelisti, F., Calcagno, C., Zunin, P. J

Food Sci. 1994. 59(2):335

• Investigation of lactosylation of whey proteins by liquid chromatography – mass spectrometry. Czerwenka, C., Maier, I., Pittner, F.,

Linder, W. J Agric Food Chem. 2006. 54:8874-8882



~ 1.6 moles lactose / b-lg mole



Skim milk: pH Increase from 6.5 to 7.1

• k-casein and whey proteins

dissociate from casein micelle.

• Serum concentration of k-casein and whey proteins increases.

• Casein micelles reduce in size

k-casein

a- b- casein

a-lac

b-lg

Unheated

Heated

Ref: Effect of the pH of skim milk at heating on milk concentrate viscosity. Anema,

S.G., Lowe, A.K., Lee , S.K., Klostermeyer, H. Intl. Dairy J. 2014. 39:336-343

Heat at pH 6.5: • Denaturation of whey proteins (WP) onto casein micelles. • Casein micelle volume increases. • Viscosity increases.

Heat at pH 7.1: • Denaturation of WP and association with k-casein (kC) • WP-kC volume increases

LOW PROTEIN CONCENTRATIONS

• No major viscosity increase due to separation distance of species (casein micelles, WP-kC) in bulk

HIGH PROTEIN CONCENTRATIONS

• Proximity of species leads to increase in viscosity



Ref: Effect of the pH of skim milk at heating on milk concentrate viscosity. Anema, S.G., Lowe, A.K., Lee , S.K., Klostermeyer, H. Intl. Dairy J. 2014. 39:336

VISCOSITY INCREASE

CHALLENGE TO:

HEAT TRANSFER FOULING / BURN-ON GEL FORMATION ADDITION OF OTHER INGREDIENTS PUMP SLURRY DRYING SENSORY EXPERIENCE


PROCESS - VISCOSITY

ULTRASOUND

• MICROBUBBLES IN AQUEOUS PHASE EXPAND UNDER ULTRASOUND CAVITATION

• INSIDE BUBBLE: HIGH TEMPERATURE AND PRESSURE

• BUBBLE COLLAPSE GENERATES MECHANICAL EFFECTS (SHOCKWAVE)

• INTER- AND INTRA-MOLECULAR INTERACTIONS ARE DISRUPTED


PROCESS - VISCOSITY

Ref: Application of ultrasound to reduce viscosity and control the rate of age thickening of

concentrated skim milk. Zisu, b., Schleyer, M., Chandrapala, J. Intl. Dairy J. 2013. 31:41-43


PROCESS - VISCOSITY

Ref: Application of ultrasound to reduce viscosity and control the rate of age thickening of concentrated

skim milk. Zisu, b., Schleyer, M., Chandrapala, J. Intl. Dairy J. 2013. 31:41-43

ULTRASOUND

• VISCOSITY OF 50% T.S. SKIM MILK CONCENTRATE- REDUCED

• FOAM - CONTROLLED

• EFFECTIVE ONLY IF APPLIED IMMEDIATELY AFTER EVAPORATION.

• LIMITED VISCOSITY REDUCTION IF AGE THICKENING INITIATED


PROCESS - VISCOSITY

PRIMARY NOZZLE

SECONDARY NOZZLE MIXING

CHAMBER DIFFUSER

SHOCKWAVE

Ref: A high-solids steam injection process for the manufacture of powdered infant milk formula.

Murphy, E.G., Tobin, J.T., Roos, Y.H., Fenelon, M.A. Dairy Sci. Technol. 2013. 93:463–475

SHOCKWAVE STEAM INJECTOR • DIRECT TRANSFER OF HEAT,

MASS AND MOMENTUM BETWEEN TWO PHASES.

• SHOCKWAVE OCCURS AT THE EXIT OF THE MIXING CHAMBER IN THE DIFFUSER

• PROCESS HIGH SOLIDS WITH MINIMAL VISCOSITY INCREASE: • 60-65% T.S.


PROCESS - VISCOSITY

r 1

m 1

r 2 m 2

HIGH PROTEIN SYSTEM: CONVENTIONAL HEAT + SHEAR

• PROTEINS DENATURE AND UNFOLD • CASEIN-WHEY PROTEINS

ASSOCIATION INCREASE DYNAMIC RADIUS INCREASE INTERNAL FRICTION INCREASE VISCOSITY

HEAT

SHEAR

JM Gonzalez ©


PROCESS - VISCOSITY

r 1

m 1

r 3 m 3

HEAT

SHOCKWAVE

HIGH PROTEIN SYSTEM: SHOCKWAVE STEAM INJECTOR

• SHOCKWAVE MOMENTUM TRANSFER DISRUPTS CASEIN-WHEY PROTEINS INTERACTION

SMALLER INCREASE DYNAMIC RADIUS SMALLER INCREASE INTERNAL FRICTION SMALLER INCREASE VISCOSITY

JM Gonzalez ©

POWDER SURFACE PROPERTIES:

• HYDROPHILIC: “FISH-EYES”. GEL-LIKE LAYER ON POWDER

SURFACE HINDERS WATER PENETRATION.

• HYDROPHOBIC: REJECTS WATER PENETRATION.

POWDER RECONSTITUTION:

• WETTING: PENETRATION LIQUID INTO POWDER

• SINKING: IMMERSION OF THE POWDER INTO THE LIQUID

• DISPERSION: INDIVIDUAL POWDER PARTICLES INTO THE LIQUID

• DISSOLVING: SOLUBLE COMPONENT

Ref: Emulsifiers in food technology. R. J. Whitehurst. P pp. 30-33 2004 by Blackwell Publishing Ltd


PROCESS - AGGLOMERATION



RE-WETTING:

• POWDER PARTICLES ARE SUSPENDED IN AIR WHILE SMALL

LIQUID DROPLETS ARE SPRAYED.

• HYDROPHILIC SPOTS AT POWDER SURFACES RE-WET AND

FORM BRIDGES WITH OTHER POWDER PARTICLES.

• LOOSE AGGREGATES ARE FORMED WITH MULTIPLE

MICRO-CHANNELS FOR WATER TO PENETRATE.

JM Gonzalez ©

LECITHINATION:

• LECITHIN IS SPRAYED ONTO POWDER PARTICLES.

• POWDER SURFACE IS COATED WITH LECITHIN.

• HYDROPHILIC AND HYDROPHOBIC SURFACES ARE “EVEN-

OUT” BY THE AMPHIPHILIC PROPERTY OF PHOSPHOLIPIDS.

• AGGLOMERATION ALSO OCCURS.



JM Gonzalez ©


protein hydrolysates

RATIONALE FOR USE:

• MUSCLE RECOVERY

• ALLERGY MANAGEMENT

• DIGESTIVE DEFFICIENCIES

• BIOACTIVE PEPTIDES FUNCTIONALITY:

ANTI-OXIDANTS

ANTI-HYPERTENSIVE

ANTI-MICROBIAL

IMMUNO-MODULATORY

FAST DIGESTION RATE

ANTI-TUMOR

HYPOCHOLESTEROLEMIC

ANTI-THROMBOTIC

ENHANCES MUSCLE RECOVERY

ENHANCE MINERAL ABSORPTION

FORMULATION

MUSCLE FIBER GROWTH AND REPAIR.

• GERIATRIC FOODS

• SPORTS NUTRITION

WHEY PROTEIN HYDROLYZATE IS EFFICIENT

DELIVERING BRANCHED-CHAIN

AMINO ACIDS (BCAA) TO BLOOD

PLASMA.

Ref: Comparison of Different Sources and Degrees of Hydrolysis of Dietary Protein: Effect on Plasma Amino Acids,

Dipeptides, and Insulin Responses in Human Subjects. Morifuji et al. J. Agric. Food Chem. 2010, 58, 8788–8797



FORMULATION

POSSIBLE TO:

• FORMULATE AT HIGHER PROTEIN LEVELS

• IMPROVE PROTEIN SOLUBILITY

• REDUCE VISCOSITY

PENDING ON DEGREE OF HYDROLYSIS AND SOURCE OF PROTEINS:

• CONCERNS WITH FLAVOR PROFILE

• COLOR CHANGE INTENSIFIES

• INCREASE IN OSMOLALITY

• INCREASE IN LACTOSYLATION



PROCESSING

JM Gonzalez ©

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