Post on 08-Feb-2017
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 ©
MPC WMP SMP WPC, WPI CASEIN WHEY + CASEIN HYDROLYZATES
technology challenges
TARGET PROTEIN LEVEL
AMINO ACID PROFILE
PROTEIN INGREDIENT SELECTION
INGREDIENT HISTORY
FORMULATION
DEGREE OF HYDROLYSIS
PEPTIDE PROFILE
JM Gonzalez ©
technology challenges
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 ©
technology challenges
• 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
technology challenges
STABILITY & SENSORY EXPERIENCE
DENATURATION
AGGREGATION
GELATION
COAGULATION
PRECIPITATION
FOULING (BURN ON)
technology challenges
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
technology challenges
PROCESS - THERMAL & pH BEHAVIOR
~ 1.6 moles lactose / b-lg mole
technology challenges
PROCESS - THERMAL & pH BEHAVIOR
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
technology challenges
PROCESS - THERMAL & pH BEHAVIOR
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
technology challenges
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
technology challenges
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
technology challenges
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
technology challenges
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.
technology challenges
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 ©
technology challenges
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
technology challenges
PROCESS - AGGLOMERATION
technology challenges
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.
technology challenges
PROCESS - AGGLOMERATION
JM Gonzalez ©
technology challenges
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
technology challenges
protein hydrolysates
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
technology challenges
protein hydrolysates
PROCESSING
JM Gonzalez ©