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LECTURE 1

WHEY FRACTIONS TO INNOVATIVE FOODS PRODUCTS

using membrane technologies

Marta Henriques

2017

ESAC – IPC

College of Agriculture – Polytechnic Institute of Coimbra

Department of Food Science and Technology

Poznan University – PolandFaculty of Food Science and TechnologyErasmus mission

outlinePart A. Introduction

Part B. Whey protein concentratesProduction and characterization of whey proteins concentrates

motivation and scopemain objective

Part C. Conventional applications

LWPC on fresh cheese and set yogurts

Part D. Nonconventional applications

Ovine and bovine LWPC in set yogurts

LWPC as primary raw material for dairy gelsWPC-based coatings with antimicrobial

activity

WPC-based films produced by UV modification

LWPC WPC

Part E. Final remarksConclusionsSuggestions for future research

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≈ 9 L≈ 1 kg

Part A. Introduction

motivation and scope

Whey

• recognized high nutritional value

• main effluent of the cheese industries

• production (per year)

• 171 billion L (worldwide)

• 83 billion L (EU)

• high environmental impact

• no efficient biological treatment

• common practice: drying processes• scale size; technological and economical

resources

ELV - 40 mg/L

BOD - 40 000 mg/L

a b

MicroSmallMediumLarge

9%

69%

20%

2%

61%

30%

7%

2%

scale size volume of business

Portuguese scenario- 690 million L whey/year- only a little more than 50% have a known destination

Part A. Introduction

motivation and scope

LactogalBelInsulacPronicol

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main objectivedevelop process solution alternatives for whey valorisation in small/medium-sized cheese factories

• particularly for the whey protein fraction

Part A. Introduction

Part B. Production and characterization of LWPC and WPC

membrane technology

batch ultrafiltration (UF)batch diafiltration (DF)

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whey

process

ultrafiltration

(UF)

diafiltration (DF)

sdm vrm

ovine bovine

LWPCs

WPC

biochemical composition

protein profile, thermal stability

ultrafiltration

(UF)

diafiltration (DF)

sdm vrm

Part B. production and characterization of LWPC and WPC

biochemical composition

process

Whey UF DFsdm DFvrm

total protein(%, wet basis)

LWPC

7.4

12.4

3.7

5.5

3.0

8.9

0.751.43

Part B. Production and characterization of LWPC and WPC

LWPC

process

Whey UF DFsdm DFvrm

dry matter(%, wet basis)

bovine ovine

13.9

LWPC

12.9

20.2

7.6

4.5

8.58.0

6.8

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Whey UF DFsdm DFvrm

total protein(%, dry basis)

bovine ovine

WPC

61.5

50.2

68.371.1

83.7

11.1

17.8

49.9

UF DFsdm DFvrm UFRP DFsdm DFvrm

ovine

-Lg

-La

SAIgG

-La

-Lg

-Lg/-La

bovine

-Lg/-La8.7

5.1 5.2 7.4 6.7 6.1

IgG SA

Part B. Production and characterization of LWPC and WPC

WPC – protein profile

Part C. conventional applications

• nutritional properties

• high biological value

• essencial aminoacids

LWPC fresh cheese set yogurt dairy gels

• functional properties

– solubility, swelling, viscosity, gelation, water retention

– foaming, emulsification

– denaturation

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medium-fat full-fat

biochemical composition, colour, texture, sensorial properties

yield

spontaneous syneresis

25% 50% 30%

set yogurts

innovative

conventional

(C)

syneresis

viscosity

15%

fresh cheese

innovative

(I)conventional

(C) LWPC

use of LWPC instead WPCwhat is new…

Part C. LWPC in fresh cheese and set yogurts

LWPC (C)

(I)

LWPC

30%

using LWPC

• decrease cheese darkening during storage - better product appearance

• no significantly differences were found in texture between conventional and innovative products.

• texture parameters decreased during storage

C 25LWPC 50LWPC

(%) spontaneous syneresis(%) WRC

0

20

40

60

80

100

C 25LWPC 50LWPC

(%) yield

0

10

20

30

40

50

601st7th

Part C. LWPC in fresh cheese and set yogurts

fresh cheese - yield, syneresis, colour, texture

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Part C. LWPC in fresh cheese and set yogurts

set yogurts – syneresis, viscosity

C 15 LWPC 30 LWPC

0

5

10

15

20

25

1st10 th20 nd

syneresis

viscosity

C 30 LWPC

medium-fat full-fat

C 15 LWPC 30 LWPC

0

50

100

150

200

C 30 LWPC

Part C. LWPC in fresh cheese and set yogurts

Teststriangular test preference test

(preference percentage)right answers result (p < 0.05)

fresh cheeseC & 25LWPC 21/31 differ 25LWPC (52%)

C & 50LWPC 24/31 differ C (68%)

set yogurt medium-fat

C & 15LWPC 4/35 do not differ C (74%)

C & 30LWPC 13/35 do not differ C (83%)

set yogurt full-fat

C & 30LWPC3th day 7/20

10th day 10/15

do not differ

differC (63%)

reasons for preference: smoother texture (fresh cheese); softer (set yogurt)

sensorial evaluation

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biochemical composition, colour, rheological properties, WRC

non defatted

(ND)

thermal gels

defatted (D)

SMP 0% and 5%pH 4 and 7

acid gels

diafiltrated (DF)

chemical acidification (dessert type)

fermentation (yogurt type)

non defatted (ND)

protein 5% and 7%

microstructure texture, complex viscosity

use LWPC as raw material not as coadjuvant what is new…

Part C. LWPC as raw material for dairy gels

Part C. LWPC as raw material for dairy gels

pH 4 7

protein (%) 5 7 5 7

Geltype

ND

97.720.89 99.500.47

nd

98.801.59

D

94.610.80 96.210.64

nd

96.060.51

DF

92.600.92 98.240.73

nd

97.920.35

thermal gels – appearance, WRC (%)

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Part C. LWPC as raw material for dairy gels

pH 4 7

protein (%) 5 7 5 7

Geltype

ND nd

D

DF nd

thermal gels – microstructure

Yogurt type - 1stday

G' G

'' (P

a)

0,1

1

10

100

1000

100000% G'0% G''5% G'5% G''

Yogurt type - 21stday

Dessert type- 1stday

[rad/s]0,1 1 10

G' G

'' (P

a)

0,1

1

10

100

1000

10000

Dessert type - 21stday

[rad/s]0,1 1 10

Part C. LWPC as raw material for dairy gels

acid gels – rheological properties G’ and G’’ (Pa)

SMP

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Yogurt type - 1st day

|*|

(P

a.s)

0,1

1

10

100

1000

100000%5%

Dessert type- 1st day

0,1 1 10

|*|

(P

a.s

)

0,1

1

10

100

1000

10000Dessert type - 21th day

0,1 1 10

Yogurt type - 21th day

[rad/s] [rad/s]

Part C. LWPC as raw material for dairy gels

acid gels – rheological properties complex viscosity |*| (Pa.s)

SMP

• batch UF/DF solve the environmental problem of bovine/ovine whey in medium/small cheese industries

• incorporating LWPC into dairy products, such fresh cheese and set yogurts, increase the overall process yield and their functional properties

• depending on the gelation process and manufacture conditions, innovative products based on LWPC can be produce according to the desired food application

conclusionsPart E. Final Remarks

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Current work

USE OF LWPC and CUFP AS MAIN INGREDIENTS IN:

• KEFIR & PROBIOTIC DRINKS• Bovine origin

• Ovine origin

CUFP (concentrate ultrafiltration permeate)

Our approach

(liquid whey protein concentrate) (concentrated ultrafiltration permeate)

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(%)

LWPC

CUFP

Our approach

Input Outputs

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Our approachfermented drinks

* fresh or frozen

* with or without

fresh orfrozen-thawed

Products Analyses

LWPCKefir (k)(Patent: WO 2011005128 20110113)

Probiotics (p)L. acidophilus, L. casei and L. rhamnosus (1:1:1)

Kefir+Probiotics (k+p)

PhysicochemicalpH T. acidity Total solidsFatViscosity

Microbiological (during fermentation and storage – 0, 12, 24, 48 and 168 h)

Lactococus sppLactobacillus sppYeasts

Sensorial(at the end of the storage time)

Triangular testsPreference tests

CUFPKefir (k)

Probiotics (p)

Kefir+Probiotics (k+p)

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Fermented drinks_kefirpH and T Acidity (during fermentation and storage)

T im e (h o u rs )

0 2 0 4 0 6 0 8 0 1 0 0 1 2 0 1 4 0 1 6 0 1 8 0

pH

3

4

5

6

7

p H _ C U F Pp H _ L W P C

T im e (h o u rs )

0 2 0 4 0 6 0 8 0 1 0 0 1 2 0 1 4 0 1 6 0 1 8 0

TA

(ºT

horn

er)

4

6

8

1 0

1 2

1 4

1 6

1 8

2 0

2 2

T A _ C U F P T A _ L W P C

(5 ºC )(2 5 ºC )

Fro

zen

-th

aw

ed

kefi

r in

ocu

lum

Fre

shkefi

r in

ocu

lum

CUFP

Time (hours)

0 20 40 60 80 100 120 140 160 1804

5

6

7

8

9

10

Lactococcus sppLactobacillus spp Yeasts

LWPC

Time (hours)

0 20 40 60 80 100 120 140 160 180

Log

10(f

cu/m

L)

4

5

6

7

8

9

10

Lactococcus sppLactobacillus spp Yeasts

(5ºC)(5ºC)(25ºC) (25ºC)

CUFP

Time (hours)

0 20 40 60 80 100 120 140 160 1804

5

6

7

8

9

10

Lactococcus sppLactobacillus spp Yeasts

LWPC

Time (hours)

0 20 40 60 80 100 120 140 160 180

Log

10(

fcu

/mL

)

4

5

6

7

8

9

10

Lactococcus sppLactobacillus spp Yeasts

(5ºC)(5ºC)(25ºC) (25ºC)

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LWPC

k p k+p

14_ (5ºC)

CUFP

k p k+p

visc

osity

(cP

)

0

300

400

500 1_(25ºC)7_(5ºC)14_(5ºC)

10

5

Fermented drinks (without fruit pulp) viscosity (during fermentation and storage)

Time (hours)

0 10 20 30 40

pH

T A

cid

ity (

ºTho

rne

r)

1

2

3

4

5

6

7

8pHT Acidity (ºThorner)

Time (hours)

0 5 10 15 20 25 30 35 40

conv

erte

d la

cto

se (

%)

0

10

20

30

40

50

60

% converted lactose

Fermented drink_CUFP_kefirconverted lactose, pH and T Acidity (during fermentation)

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• Preference test (untrained panelists n=31)

LWPC_kefir vs CUFP_kefir• LWPC_kefir (74.2%)• CUFP_kefir (25.8%)

• Triangular test (untrained panelists n=45)

LWPC_kefir vs LWPC_probiotic vs LWPC_k+p

(Differences between fermented drinks were detected at a confidence level of 95%)

Sensorial analyses

Conclusions

• LWPC and CUFP are (chemical, microbial and sensorial) stable and attractiveto produce fermented drinks • LWPC_fermented drinks looks like a liquid yogurt• CUFP_fermented drinks looks like a fruit juice

• Frozen-thawed kefir inoculums' penalize fermentation• Frozen LWPC or CUFP does not influence the fermentation

• In CUFP_fermented drinks (about 45% lactose conversion)

• LWPC_fermented drinks are preferred to CUFP_fermented drinks• For LWPC products - LWPC_kefir is the preferred• For CUFP products - CUFP_probiotic is the preferred