AU6326200A - Reduced fat whey protein concentrate and method of manufacture - Google Patents

Description

WO 01/08502 PCT/NZOO/00140 REDUCED FAT WHEY PROTEIN CONCENTRATE AND METHOD OF MANUFACTURE TECHNICAL FIELD 5 This invention relates to reduced fat whey protein concentrate (WPC) and a method of producing such a product, preferably, although not exclusively, from a sweet whey. 10 BACKGROUND Whey Protein Concentrates (WPC) and Whey Protein Isolates (WPI) are two of the major whey protein product categories. WPC typically contains > 35% protein and > 4% fat, while WPI contains > 80% protein 15 and < 2% fat. The high protein and low fat content of WPI imparts greater functional attributes and a preferred composition as compared to WPC. As a result, WPI commands a higher market value. However, the processes used to manufacture WPI are very expensive and the yield is low (generally 50-60% for ion exchange WPI, 50-75% for microfiltration WPI). 20 WPC have many different uses. Those uses may broadly be divided into two categories, one being nutritional- based uses and the second being functional-based uses. The nutritional-based uses would include, for example, infant formulae, enteral formulae, and sports drinks. The 25 functional-based uses include, for example, for gelling, whipping, emulsification and other valuable properties for baking products. Functionality has been defined by Pour-El, A. (1981, "Protein Functionality: classification, definition, and methodology", Protein 30 Functionality in Foods, USA) as 'any property of a food or food ingredient WO 01/08502 PCT/NZOO/00140 2 except its nutritional ones that affect its utilisation'. Functional properties of a protein ingredient are influenced by the composition of the ingredient, the composition of the food system it is to be used in, and by the processing conditions required to manufacture this food system. The 5 majority of functional characteristics of ingredients can be categorised into hydration related (dispersibility, solubility, swelling, viscosity, gelation) and surface related (emulsification, foaming, adsorption at air-water and oil water interfaces) properties. 10 Traditionally, WPC is derived from whey which is the by-product of either acid (mineral acid or lactic whey) or sweet (cheese or rennet whey) coagulation of milk protein from milk in the manufacture of cheese or casein. The standard methods for producing WPC from acid or sweet whey are well known and are discussed, for example in United States 15 patent specification US 4,200,662. Acidification of milk to a pH of about 4.6 causes casein to become insolubilised and to coagulate as in, for example, casein (mineral acid casein or lactic casein) or certain cheese types (cottage cheese). The by-product 20 removal of the casein curd, cheese curd, is known as acid whey. The alternative method of producing whey is by the addition of rennin and/or pepsin, proteolytic enzymes, to cause coagulation of casein. The resulting whey, after removal of the coagulated casein, is known as sweet or cheese whey. 25 To produce a WPC the acid or sweet whey is concentrated to produce a product having nominally 35% whey protein solids. The process of concentration may involve delactosing, electrodialysis, reverse osmosis, gel filtration or ultrafiltration. 30 WO 01/08502 PCT/NZOO/00140 3 In several applications, WPC has a lower functional performance than WPI. However, in some applications, acid WPC has a superior functionality as compared to WPI. Typically, cheese WPC has an inferior functional performance as compared to acid WPC. This is thought to be 5 due to the difference in fat content, where cheese WPC typically has a higher fat content as compared to acid WPC. Cheese WPC has a lower market value than acid WPC and WPI. An improvement in functionality is expected to increase the market returns for cheese WPC. In addition, improved functional characteristics may also be achieved for acid WPC if 10 the fat content could be reduced to a level similar to that for WPI. Thus, it is an object of the present invention to provide a WPC and/or method of its manufacture which reduces or overcomes at least some of the abovementioned problems, or which at least provides the 15 public with a useful alternative. Other objects of the invention may become apparent from the following description which is given by way of example only. 20 STATEMENT OF THE INVENTION According to one aspect of the present invention there is provided a method for producing a WPC having a fat content of no greater than 4%, from whey, the method including the steps of: 25 - concentrating the solids content of whey to produce an intermediate WPC, - diluting the intermediate WPC with water to reduce the ionic strength, WO 01/08502 PCT/NZOO/00140 4 - adjusting the pH of the diluted intermediate WPC to within the range substantially 3.8 to 5.0, - holding the pH at that level for a period to optimise formation of a floc, and 5 - removing the floc to leave a reduced fat WPC supernatant. One preferred form of the process of the invention may further include controlling the temperature of the diluted intermediate WPC prior to pH adjustment. 10 Preferably, the temperature may be increased to substantially 50*C. Alternatively, it may be reduced to substantially 10"C. In one preferred form of the process of the invention the pH may be 15 adjusted to substantially 4.2 to 4.4. Preferably, the pH may be adjusted by the addition of a mineral or organic acid, preferably citric acid. 20 Preferably, the temperature may be increased to substantially 50 0 C and the removal of floc may be by a clarifier. In a further preferred form the whey may be concentrated to a solids concentration in the range substantially 12 to 30% total solids, more 25 preferably > 18% and in one preferred form substantially 23%. Preferably, the solids concentration may involve ultrafiltration. Preferably, the intermediate WPC may be diluted with water at a 30 ratio in the range substantially 1:3 to 1:20, retentate:water.

WO 01/08502 PCT/NZOO/00140 5 Preferably, the intermediate WPC having a solids content of > 18% total solids may be diluted in the ratio substantially one part retentate to nine parts water. Preferably, that water is demineralised water. Preferably, the starting whey for use in the process of the invention 5 is sweet whey. In a further preferred form the process of the invention may include further processing of the reduced fat WPC supernatant to concentrate the solids content and thereafter prepare a dry powder product by conventional 10 means. According to a further aspect of the present invention there is provided a WPC derived from a sweet whey, having functional characteristics at least equivalent to those of a WPC derived from acid 15 whey by conventional means. According to a further aspect of the present invention there is provided a WPC derived from acid or sweet whey having functional characteristics substantially equivalent to those of a conventional WPI. 20 Other aspects of the present invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings and/or Examples. 25 BRIEF DESCRIPTION OF THE DRAWINGS Figure 1: is a flow diagram of the general features of the process of the invention, in one preferred form; WO 01/08502 PCT/NZOO/00140 6 Figure 2: is a flow diagram of one specific embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION 5 The process of the invention is broadly identified in Figure 1, and involves the processing of whey (preferably sweet whey) to produce a reduced fat WPC. As indicated in Figure 1 the process, in broad terms, involves concentrating the solids component of the whey, preferably by an 10 ultrafiltration process, to produce an intermediate WPC with a solids content in the range 12% to 30% total solids. The solids content is preferably > 18%, and 30% is a maximum practical content. The intermediate WPC is then diluted with water to produce a WPC retentate with a lower ionic strength. The dilution ratio will vary depending on the 15 solids content of the intermediate WPC, but will be in the range 1:3 to 1:20, retentate:water. With a preferred solids content > 18% a ratio of about 1:9 is appropriate. The pH of the diluted retentate is then adjusted to a selected level in the range 3.8 to 5.0, the diluted retentate is held under those conditions for a specified period during which a floc forms and 20 the floc, which contains a high proportion of fat, is then separated to leave a low fat supernatant which can subsequently be processed to produce, for example, a dried, powder, reduced fat WPC. The end product has a reduced lactose content, as well as a reduced 25 fat content, and this combination results in an increase in protein content. Starting with a sweet whey the fat content may be reduced to 1 % or lower. Conventional sweet WPC has a fat content of 6 to 7% and conventional acid WPC has a fat content of generally above 4%. Thus, reductions in fat content of a sweet WPC produced from the process of the 30 invention to 4% or less provides at least functional equivalence to a WO 01/08502 PCT/NZOO/00140 7 conventional acid WPC product. Reductions below 4% offer functional advantages which, as the fat content is reduced to 1 % or less, approach the functional performance of WPI. It will be appreciated, therefore, that the functional characteristics of an acid WPC may also be improved by the 5 process of the invention. Specific details of the process of the invention, and the product resulting therefrom, in one preferred embodiment, are now provided by way of example. 10 Example Figure 2 summarises the process employed in a pilot plant trial. 15 Sweet whey was dosed with citric acid to reduce the pH to 6.00. The whey was then thermalised by heating indirectly to 73"C and holding for 15 seconds, before cooling regeneratively to 55"C. The thermalised sweet whey was stored prior to ultrafiltration (UF). UF was used to increase the total solids (TS) (brix) of the whey from about 6% to 23% 20 using 13 loops of 1 OkD spiral wound membranes. Diafiltration (DF - the addition of demineralised water to allow a high concentration ratio to be used) was used after loop 8. After UF, the retentate was chilled to about 4'C, for microbial control, prior to storage. 25 100 L of this sweet whey retentate (at 23% brix) was then diluted using 900 L of demineralised water at about 500C; an approximate ratio of 10% retentate to 90% water. This mixture, having a preferred ionic strength for the process, was agitated to ensure a homogenous solution. Once mixed, the dilute retentate was heated to 500C using indirect heating. 30 WO 01/08502 PCT/NZOO/00140 8 The heated dilute retentate was then acidified. Citric acid was dosed in-line, to reduce the pH from approximately 6.00 to approximately 4.30. The solution was then held for about 15 minutes prior to clarification using a pilot clarifier (GEA-Westfalia model KNA3). This was run at 750 5 L/hr, 4-4.5 bar back pressure, with continuous discharge, and two 0.5mm nozzles to separate the floc from the supernatant. It will be appreciated that other acids or acid combinations may be employed in the acidification step. Furthermore, whilst the preferred pH 10 may be about 4.30, floc formation may be achieved, although perhaps less effectively, with a pH in the range 3.8 to 5.0. Adjustment of the time the solution is held may be appropriate to optimise floc formation for removal. The supernatant was then heated to 50 0 C prior to UF through 5kD 15 spiral wound membranes. This second UF step concentrated the product to about 20% TS (brix). The volume concentration fraction (VCF) used was approximately 10. No diafiltration water was added. The retentate was then pH adjusted to about 6.8 (to give a pH in 20 the final powder of 6.8 - 7.0) using a mix of KOH and NaOH prior to spray drying. It will be appreciated by those skilled in the art that different processes may be involved in the initial solids concentration of sweet 25 whey, resulting in higher or lower proportions of solids than described in this example. To produce the required ionic strength of the WPC retentate will then require a greater or lesser rate of dilution.

WO 01/08502 PCT/NZO0/00140 9 It will also be appreciate by those skilled in the art that alternative methods may be employed for separating the floc from the supernatant, for example gravity settling, filtration or hydrocyclones. 5 Whilst the process described in the example includes the step of heating the diluted WPC retentate to about 50 0 C, the optimum temperature for the process will depend on a number of variables, including the holding time and the method of separation used. The process may, for example, involve chilling of the diluted WPC retentate to about 10"C prior to 10 acidification, rather than heating, where the separation method is other than by clarification. Product Composition 15 Table 1 provides compositional data for product manufactured using the process of the invention in a pilot plant. Table 1 Dried WPC (end-product) Dried Floc (by-product) Fat 1.00 12.9 Protein 87.30 74.0 Moisture 3.60 3.00 Lactose 1.02 1.20 Ash 4.40 1.50 20 The table shows that the by-product floc has a fat content of about 13%. The dried WPC end-product has a protein content of about 87% and a fat content of only 1 %.

WO 01/08502 PCT/NZOO/00140 10 Functional Testinq End-product from the pilot plant trial was assessed for functional characteristics (solubility, viscosity, gelation (aqueous and brine), foaming 5 (with sugar and without sugar), and performance in an acid beverage rapid test) and in model food systems (meringues, infant formula and yoghurt). The results were as follows. 1. Functional Test Systems 10 a) Solubility. It is desirable for products to have good solubility over a wide pH range to avoid sediment forming in final product applications, particularly beverages. Table 2 illustrates the solubility of each sample over a range of pH's. The pilot plant sample had a much greater degree of solubility than 15 that of an acid WPC. This is shown by the narrow pH range over which sediment formed, and also by the small amount of sediment which formed in comparison to the Acid WPC. Table 2. Solubility results - amount of sediment formed at varying pH 20 values for Pilot Plant Sample and Acid WPC. Sediment volume (cm 3 ) pH Acid WPC Pilot Plant Sample Natural (6.91) <0.1 (7.23) < 0.1 pH 2.0 0.15 < 0.1 3.0 2.5 < 0.1 3.5 2.4 < 0.1 WO 01/08502 PCT/NZO0/00140 11 4.0 2.9 < 0.1 4.5 2.5 0.6 5.0 1.6 0.6 5.5 0.1 < 0.1 6.0 < 0.1 < 0.1 6.5 < 0.1 < 0.1 7.0 < 0.1 < 0.1 8.0 <0.1 <0.1 b) Viscosity. 5 The relationship between viscosity and total solids for the pilot plant trial sample as compared to Acid WPC is shown below. Viscosity is a measure of rheological properties and is important in applications for example, sauces, gravies and salad dressings. The viscosity characteristic for the pilot plant sample is equivalent to acid WPC. 250 o 200 -- 150 [ 10% TS 20% TS UO 030% TS M100 - - 40% TS Ca, 50 U) 00 A Acid WPC Pilot Plant Sample WO 01/08502 PCT/NZOO/00140 12 C) Foaming. Foaming is important for applications such as, for example, cakes and meringues. Table 3 shows that the pilot plant sample has a maximum 5 overrun greater than that of the target product for the application (WPI) in the foaming system without sugar. In both systems, the pilot plant sample has greater foam stability than WPI. Table 3. Functional results for a pilot plant sample and a WPI in 10 a foaming test system. With Sugar Without Sugar WPI Pilot Plant WPI Pilot Plant Sample Sample Overrun @ 15 minutes 1 280% 1 280 % 2 030% 1 900 % Max. Overrun 2 280% 1 280 % 2 030% 2 150 % Foam Stability 25.11 28.09 15.11 19 minutes (time for first serum minutes minutes minutes drop) d) Gelation. 15 Gelation is a functional characteristic important in systems, for example, yoghurts and restructured meats. Table 4 illustrates the similarity between the pilot plant sample and Acid WPC (target product) in 0% NaCI gels. No data was available for comparison in 0.4% NaCl systems, and it 20 can be seen that the pilot plant sample does not perform as well overall in the 2% NaCl system.

WO 01/08502 PCT/NZ0O/00140 13 Table 4. Functional results for a pilot plant sample and Acid WPC in gelation test systems. 0 % NaCl Added 0.4% NaCl Added 2% NaCl Added Acid WPC Pilot Plant Acid WPC Pilot Plant Acid WPC Pilot Plant Sample Sample Sample Syneresis (%) 3.6 3.9 (no data) 11.8 25.3 46 Fudoh 1234 1257 (no data) 1626 783 665 Rheometer (g/cm 3 ) TA-XT2 44.47 34.22 (no data) 54.52 25.38 16.68 Stress (kPa) TA-XT2 1.18 1.05 (no data) 0.96 0.86 0.96 Strain (kPa) TA-XT2 29.38 32.59 (no data) 17.34 29.38 17.34 Rigidity 5 e) Acid Beverage Rapid Stability Test Absorbance of pilot plant sample and WPI over range of pH's after heating at 80*C for 20 minutes is shown below. For acid beverages, pH 3.8 is the most relevant. It can be seen that the two products, where WPI 10 is the target product for the application, are very similar in absorbance over the pH range.

WO 01/08502 PCT/NZOO/00140 14 3.5 3 E .5 c 2 5- H . 2 ~pH40O *pH3.8 1.5 0 0 WP Pilot Plant Sample Sediment is undesirable and was observed in the pilot plant sample only at pH 4.0 (14.5 ml sediment), compared to the WPI which had 2ml sediment at pH 4.0 and 1ml sediment at pH 3.8. 5 2. Model Food Systems. a) Set Yoghurt. Table 5 shows the similarity between the pilot plant sample and acid WPC in a set yoghurt system.

WO 01/08502 PCT/NZOO/00140 15 Table 5. Free whey, total solids content (TS) and Texture Analyser results for set yoghurt samples. Sample Day Texture Profile Results Free TS Peak 1 Peak 2 Positive Area Whey (%) (g) (g) (g.s) (%) Acid WPC 1 21 22 361 0 9.55 Pilot Plant 1 22 25 408 0 9.63 Sample 5 Peak 1 - represents elasticity / brittleness Area - calculated from the area between Peak 1 and Peak 2, represents mouthfeel / body b) Stirred Yoghurt 10 Table 6 shows the similarity between the pilot plant sample and Acid WPC in a stirred yoghurt system. Table 6. Viscosity, drained syneresis and total solids (TS) results for stirred yoghurts. 15 Viscosity (mPas) Level of TS Sample Shear Rate Whey (%) 50s' 100s1 Drainage Acid WPC 230 130 31 9.38 Pilot Plant 250 140 33 9.23 Sample WO 01/08502 PCT/NZOO/00140 16 c) Infant Formula. The following results show the similarity between the pilot plant sample and Acid WPC in a model infant formula system. 5 Acid WPC Pilot Plant Sample Heat Coagulation Time 7.5 minutes 7.5 minutes Mean particle diameter 11 (d 0.9) 15 (d 0.9) (Malvern Mastersizer) Table 7. Particle Size distribution of pilot plant sample and Acid WPC 10 as determined using the Malvern Mastersizer. Peak One Peak Two 0.28-0.35pm 0.35-0.43 m 6.52-8.04ptm 8.04-9.91 Vtm (%) (%) (%) (%) Acid WPC 7.11 6.17 14.81 17.86 Pilot Plant 5.41 5.64 8.07 9.98 Sample Thus, it can be seen that the process of the present invention enables the processing of a whey (preferably a sweet whey) in a manner which produces a readily removable floc containing a substantial portion of 15 the fat, leaving a WPC end-product having a high protein and reduced fat content, and with improved functional performance. The resulting product, when derived from a sweet whey may have a functional performance at least equivalent to that of a conventional acid WPC, and a similar composition. Furthermore, a WPC product, whether derived from sweet or 20 acid whey, may be produced with functional performance substantially equivalent to that of a WPI.

WO 01/08502 PCT/NZOO/00140 17 Where in the foregoing description reference has been made to specific components or integers of the invention having known equivalents then such equivalents are herein incorporated as if individually set forth. 5 Although this invention has been described by way of example and with reference to possible embodiments thereof it is to be understood that modifications or improvements may be made thereto without departing from the scope or spirit of the invention. 10

Claims (21)

1. A method for producing a WPC having a fat content of no greater than 4%, from whey, the method including the steps of: 5 - concentrating the solids content of whey to produce an intermediate WPC, - diluting the intermediate WPC with water to reduce the ionic 10 strength, - adjusting the pH of the diluted intermediate WPC to within the range substantially 3.8 to 5.0, 15 - holding the pH at that level for a period to optimise formation of a floc, and - removing the floc to leave a reduced fat WPC supernatant. 20

2. A method according to claim 1 wherein the pH is adjusted to within the range substantially 4.2 to 4.4.

3. A method according to claim 2 wherein the pH is adjusted by the addition of a mineral or organic acid. 25

4. A method according to claim 3 wherein the pH is adjusted by the addition of citric acid.

5. A method according to any one of the preceding claims wherein the 30 solids content of the whey is concentrated by ultrafiltration. WO 01/08502 PCT/NZOO/00140 19

6. A method according to any one of the preceding claims wherein the whey is concentrated to a solids concentration of in the range substantially 12 to 30% total solids. 5

7. A method according to claim 6 wherein the solids concentration is > 18% total solids.

8. A method according to claim 7 wherein the solids concentration is substantially 23% total solids. 10

9. A method according to any one of claims 6 to 8 wherein the intermediate WPC is diluted with water at a ratio in the range substantially 1:3 to 1:20, retentate:water. 15

10. A method according to claim 8 wherein the intermediate WPC is diluted with water in a ratio of substantially 1 part retentate to 9 parts water.

11. A method according to either claim 9 or claim 10 wherein the water 20 is demineralised water.

12. A method according to any one of the preceding claims wherein the starting whey is sweet whey. 25

13. A method according to claim 1 further including the step of controlling the temperature of the diluted intermediate WPC prior to pH adjustment by increasing the temperature to substantially 50'C. WO 01/08502 PCT/NZOO/00140 20

14. A method according to claim 1 further including the step of controlling the temperature of the diluted intermediate WPC prior to pH adjustment, by reducing the temperature to substantially 10 C. 5

15. A method according to claim 13 wherein the floc is removed by a clarifier.

16. A method according to any one of the preceding claims further including the step of processing the reduced fat WPC supernatant to 10 concentrate the solids content, and thereafter prepare a dry powder product.

17. A reduced fat WPC having a fat content 4% and manufactured in accordance with a method of any one of claims 1 to 16. 15

18. A reduced fat WPC manufactured according to a method of claim 12 and having functional characteristics at least equivalent to those of a conventional WPC derived from acid whey by conventional means. 20

19. A reduced fat WPC manufactured according to a method of any one of claims 1 to 11, derived from an acid whey and having functional characteristics substantially equivalent to those of a conventional WPI. 25

20. A method of producing a reduced fat WPC substantially as herein described and with reference to the accompanying figures and/or examples.

21. A reduced fat WPC substantially as herein described and with 30 reference to the accompanying figures and/or examples.