CA2607720A1 - Novel aseptic drinks and puddings containing whey proteins and processes for the manufacture thereof - Google Patents

Abstract

A method of making an aseptic liquid or semi-solid food product comprising at least 2% whey wherein said method comprises mixing protein with water, heating same without pressure to effect denaturation, homogenizing same in two steps, cooling, adding flavor, heating to aseptic condition, and homogenizing a third time.

Description

NOVEL ASEPTIC DRINKS AND PUDDINGS CONTAINING WHEY PROTEINS
AND PROCESSES FOR THE MANUFACTURE THEREOF

This application claims the benefit of priority of U.S. Provisional No.
60/675,851, filed 29 April 2005, which is hereby incorporated by reference in its entirety.

Background of the Invention Field of the Invention [0001] The present invention relates to a process for the manufacture of high-protein aseptic drinks and puddings containing at least 2% by weight of whey protein, and to the novel products which are thereby obtained, whereby the products have a long shelf-life ("shelf-stable") and have acceptable organoleptic properties in that they have pleasant tastes and textures, in particular a smooth mouth feel.

Description of the Related Art [0002] The preservation of foods, in this case liquid or semi-solid foods ("drinks"
and "puddings" respectively), by heat serves to reduce the concentrations of micro-organisms in the foods and may also inactivate enzymes that are present in the foods. The heating operation may form only part of the preservation operation, for example, preservatives may be added to inhibit growth of any residual micro-organisms remaining after the heat treatment, and both the choice of the packaging and the defined storage conditions (that is, under refrigeration or at ambient temperature) also play a role. Typically, the shelf-life, meaning the period during which the product remains edible without significant change in organoleptic properties (taste, flavor, odor, texture) is related to the temperature to which the product is exposed during processing, the duration of the period during which the product is maintained at that temperature, and other factors such as the pH of the product, steps taken to ensure absence of micro-organisms in the equipment used to process, and the barrier function of the packaging used. In the most simple form, for products which do not require long shelf-lives, such as milk and dairy products that are distributed and consumed rapidly, the process known as pasteurization may suffice to give a shelf-life acceptable for the market. The heating process may in itself give rise to changes in organoleptic properties, thus it is customary in pasteurization to use the minimal conditions that will reduce the microbial content to an acceptable level for the shelf-life required.
Typically, pasteurization may consist of heating the product to a relatively high temperature of, say, 85 C for 2 seconds, followed by rapid cooling, or heating the product to 71 C - 74 C for 15 - 40 seconds, again followed by rapid cooling, or by holding the product at 62 C - 65 C for up to 30 minutes with stirring before cooling. Such processes may extend the shelf life of products such as milk from a few days to several weeks, which is adequate for such types of widely used consumer products but unacceptable for special nutritional products that may remain in distribution systems for several months and then be retained by the consumer for further periods of months before use.

[0003] Where an extension of shelf stability to 12 months or more is required, consumer products such as milk, and the nutrient-dense products such as those envisaged in the instant invention, may be processed by ultra high temperature (UHT) treatment. Typically in the UHT process, the product is indirectly heated to 135 C - 140 C by means of heating coils, and held at this temperature for 6 -seconds, or heated directly by live steam under pressure at 140 C - 150 C for 4 seconds, followed by aseptic packaging. Such a process allows an extension of shelf-life to 12 months or more, though at the cost of some change in organoleptic properties. A further possibility is the so-called retort process, where the product is completely sterilized by sealing in cans which are then heated in an autoclave at 110 C - 130 C for 10 - 20 minutes. However, as will be evident to the skilled artisan, the retort process can destroy, or cause heat damage to, sensitive ingredients and may result in unacceptable organoleptic changes.

[0004] There is presently an increasing demand for high-protein drinks and puddings, especially those with low carbohydrate contents. More particularly, this demand encompasses drinks and puddings containing whey protein. Whey protein is considered an excellent source of protein for bodybuilding and it is very popular in both weight loss nutrition and in sports nutrition. In addition to containing whey protein, high-protein drinks and puddings often contain many vitamins and minerals. Existing aseptic products that contain whey proteins usually contain only a very small quantity of this highly nutritional protein, because of the seemingly insurmountable problems caused by the whey proteins during a conventional aseptic manufacturing process. In the typical aseptic process, the components of the product are homogenized with water at about 2500 - 3000 psi (pounds per square inch), the pressure then being reduced to about 500 psi, whereupon the resultant homogenate is then heated to temperatures of 135 C -150 C, most often about 143 C, to which it is exposed for a period of time, which may be 6-12 seconds. Such processes are continuous processes, conducted in equipment which receives continuous feeds of the ingredients, and results in a continuous flow of finished product. Because of the high temperatures involved in this process, where the product envisaged is a drink, the resulting beverages tend to lose consistency, and protein may sediment out in the form of lumps or aggregates at the bottom of the container. A further problem is that the exposure of the proteins to heat may also cause gelation, resulting in increased viscosity such that drinks become almost pudding-like in consistency. Furthermore, in the case of whey proteins, presence of more than about 2% whey protein in an aseptic drink or pudding manufactured by this conventional process generally results in a short shelf life and unsatisfactory organoleptic properties characterized by unpalatable taste, gelation, sedimentation and grittiness or powdery texture in drinks, grittiness and powdery texture in puddings, and in the case of both drinks and puddings, a dry feeling in the mouth and throat when consumed. These defects have been attributed to the presence of free sulfhydryl groups in the whey protein, which may not only break down to give a sulfury taste, but may also contribute to cross-linkages both in the whey protein and with other proteins present, often involving calcium to give calcium bridges between protein chains.
Additionally, when such products are fortified with vitamins and minerals, they often suffer from a break down in such added vitamins and minerals, which results in a flavor that is at best unsatisfactory and at worst totally unpalatable.

[0005] The instant invention relates to processes for the manufacture of aseptic drinks and puddings ("aseptic products") provided in a "ready to use"
packaging and which contain whey protein, and to the resultant aseptic products, whereby the process comprises subjecting the ingredients of the aseptic products to heat and pressure. Theaseptic products may also contain other proteins. A typical utility for such aseptic products is as nutritional drinks or puddings which may be high or relatively high in total protein and which are suitable for use in weight loss programs or as convenient products for use as sports or energy drinks. The motivation to manufacture such products may be one or more of the following:
to provide convenient nutrient-dense products that can be readily consumed without the need for reconstitution of a powder, to provide a product in which the amino acid profile can be adjusted to the profile optimal for the intended use, or to act as a carrier for some ingredient of functional or nutritional importance where the ingredient for technical or organoleptic reasons might be unsuitable for use in other types of product.

[0006] High-protein aseptic products in the form of drinks and puddings, where the whey protein content exceeds 2% by weight of the finished product, are known, and processes for the manufacture of such high-protein products are likewise known, but the existing processes, and the products which result from the application of such processes to the manufacture of high-protein aseptic products containing 2% or more of whey protein suffer from numerous disadvantages, namely the processes result in the build-up and retention of protein and heat-damaged protein in the processing equipment "cook-on", and the resultant products suffer from poor organoleptic properties in that they have gritty textures, sediment on standing, may show increased viscosity and gelation, and suffer from off-flavors.

[0007] The disadvantages of using whey protein in amounts of more than 2% in aseptic products are known. For example, U.S. Patent 6,627,243 discloses a cream substitute, comprising from 5% to 40% by weight of butter, from about 0.25% to about 5% by weight of a thickening agent, and about 0.25% to about 4%
of a food protein, based on the total weight of the cream substitute, together with a sufficient amount of water to total 100% by weight, and, optionally, from about 0.05% to about 2% by weight of a food acceptable acid. Whereas the abstract of this patent discloses that the food protein content may be up to 4%, the specification discloses firstly that the food protein may be soy, rice, pea, and milk protein or a dairy protein, such as whey protein concentrate, whey protein isolate, or casein, and secondly that the food protein may be present in an amount of about 0.25% to about 2% by weight based on the total weight of the cream substitute. However, U.S. Patent 6,759,078 discloses that culinary cream substitutes that are prepared with standard whey protein concentrate display the undesired characteristic of forming strong aggregates or gelling when heated, and that a superior formulation can be obtained if microparticulated and denatured whey protein concentrate is used in place of the typical whey protein concentrate.
The '078 Patent relates to cream substitutes which contain 3% - 6% of a dry blend, whereby the dry blend comprises 50% - 90% of a microparticulated and denatured whey protein concentrate and 10% - 30% of a xanthan gum, whereby the preferred whey protein concentrate contains 53% - 55% protein. While these references illustrate some of the problems of the aseptic processing of materials containing whey proteins, neither of these Patents relate to aseptic drinks or puddings that are intended for direct consumption, but to aseptic cream substitutes intended for use as ingredients in the food service industry.

[0008] There is further disclosed in U.S. Patent 4,623,552 an aseptic pudding based on starch and carrageenans, which may comprise liquid milk in amounts of 50% - 80%. This Patent further discloses that a problem encountered as a consequence of the elevated temperatures required to sterilize the pudding composition prior to packaging is that there is an increased tendency of the formulation to "cook-on" the heating surfaces, leading to the undesirable presence of distinct cooked particles in the final product and frequent interruption of the production process to effect cleaning and scraping of heating surfaces. It is also revealed that the milk-solids-not-fat (MSNF) component of the milk employed in high quality pudding formulations (the use of fresh.milk as the bulk of a pudding formula being desirable for attainment of best flavors and texture) has the greatest tendency to cook-on heating surfaces, and that this problem may be alleviated, if not eliminated, if dairy cream or dairy cream and water is used to replace a portion of the whole milk which otherwise might be used in the formulation. Where dairy cream with or without water is used, the final pudding product retains the desired texture and flavor associated with use of whole milk, but has a significantly decreased tendency to cook on heating surfaces. Calculation indicates that liquid milk at 80% of the finished formulation would provide about 0.6% whey protein in the finished product, suggesting that the "cook-on" which causes the frequent interruption of the manufacturing process may be initiated by the whey protein which then further catalyses the deposition of other proteins on the hot equipment.

[0009] The problem of unpalatability caused by the aseptic processing of dairy materials containing whey protein is recognized, as illustrated by U.S. Patent 6,117,470, which discloses a process for the manufacture of an aseptic consumer milk of acceptable organoleptic properties by separating the whey proteins from the milk by micro-filtration. This results in a sterile liquid containing the whey proteins, and a retained fraction containing the casein and caseinates together with the fat. The retained fraction is then subjected to the high-temperature aseptic processing, and is afterwards recombined with the sterile liquid containing the whey proteins to give a milk that has a long shelf life and is acceptable to consumers.

[0010] The literature, and the empirical experience of skilled artisans, thus confirms that the aseptic processing of materials containing whey proteins to give products that are shelf-stable over long periods of time is problematical;
while it is indeed possible to aseptically process such materials, the resultant products, while they may be shelf-stable, taste bad and have unfortunate mouth feel.
Economically, since they also result in frequent interruptions of the manufacturing process for the purpose of cleaning off "cooked-on" protein, they are quite literally products which the manufacturers of aseptic products wish to avoid; they taste bad, and are expensive to produce. At a consumer level, products which taste bad or have a gritty and/or slimy mouth feel do not generate repeat sales irrespective of the merits of their nutritional profile.

Summary of the invention [0011] It has now surprisingly been found that such obstacles to the manufacture of protein drinks and puddings containing significant amounts of whey protein, which may optionally be partially hydrolysed or denatured, whereby significant means the whey protein comprises 2% or about 2% or more of the final product by weight, may be overcome by firstly preconditioning the proteins and homogenizing the ingredient blend without flavors, optional vitamins and minerals, and stabilizer, at lower pressures than in the conventional process, but at a higher temperature, cooling and adding a phosphate stabilizer blend in water at 55 C -60 C or about 55 C - about 60 C, together with flavors and optional vitamins, and minerals, processing the resultant liquid at 130 C - 150 C, or about 130 C to about 150 C but generally 143 C or about 143 C, for 2 - 40 or about 2- 40 seconds and finally homogenizing again at 300 - 500 psi or about 300 - about 500 psi.
Specifically, the mix without flavor, vitamin mix and stabilizer is preheated to 95 C -99 C or about 95 C to about 99 C, held at this temperature for 0 - 90 or about 90 seconds, and either homogenized at 1200 psi - 1500 psi or about 1200 psi -about 1500 psi in the first stage and at 300 psi - 500 psi or about 300 psi to about 500 psi in the second stage, or optionally homogenized in a single stage at 300 psi - 500 psi or about 300 psi to about 500 psi. It is then cooled to ambient temperature (< 25 C) or lower, preferably to 10 C or less. A sequestering agent, such as a phosphate stabilizer blend, sodium citrate, potassium citrate or ethylene diamine tetra acetic acid (EDTA) or any other sequestering agent know in the art, which can also be added at other stages, including the first step, is dissolved in water at about 35 C - 65 C, and added with the flavors and the optional vitamins and minerals to the cooled homogenizate a buffering agent may be added, and the whole is then processed at 143 C or about 143 C for 2 - 40 or about 2 to 40 seconds. Finally, the resultant aseptic product, if a drink, is homogenized once more at 300 - 500 psi or about 300 - about 500 psi using only one stage of homogenizing pressure, while if the product is a pudding it is optionally homogenized once more at 200 - 300 psi or about 200 to about 300 psi using only one stage of homogenizing pressure, and packed into aseptic containers, such as those known as TetraPaks. The resultant products, despite their high content of whey proteins, are smooth and lack the powdery, gritty mouth feel of whey-containing products manufactured by conventional processes, in part attributable to the prevention of interactions between sulfhydryl groups and the cross-linking of protein chains, and the preconditioning of the ingredients as described further prevents a build-up of protein in the processing equipment.

[0012] Thus, in one embodiment, the present invention relates to a method of making an aseptic liquid or semi-solid food product comprising at least 2%
whey, the method comprising:

a) mixing protein with water at a temperature that does not denature the proteins and forming a liquid homogenous dispersion, wherein at least 2% of the protein is whey protein;

b) heating the dispersion of step a) without pressure, to a temperature that denatures the proteins and maintaining such temperature, such as about 2 to 10 seconds, so as to ensure denaturation;

c) pumping the denatured mixture of b) first through a homogenizer at a pressure of about 1200 psi - 1500 psi and then through a homogenizer at a pressure to about 300 psi - 500 psi, so as to homogenize said mixture;

d) cooling the homogenized mixture of c) and forming a uniform or homogenous mixture;

e) adding one or more flavors, vitamins or minerals to the mixture;

f) heating the mixture of e) at a temperature from about 130 C to about 150 C for a period of time just long enough to render the mixture an aseptic liquid or semi-solid food product; and g) subjecting the product of f) to about 200 to about 500 psi so as to homogenize the aseptic liquid or semi-solid food product;

wherein the amount of whey protein is at least 2% of the aseptic liquid or semi-solid food product, wherein a sequestering agent, such as phosphate, with or without water is added to at least one of the above steps and wherein said product lacks grittiness and sedimentation, has pleasing organoleptic and textural properties and is ready to use.

[0013] The whey protein in the above process may be an integral part of another protein, such as a milk protein isolate or a milk protein concentrate.
In one embodiment, the liquid homogenous dispersion of part a) comprises 10 grams of milk protein isolate in 100 ml of water. The mixture of step a) also may comprise one or more of fats or carbohydrates.

[0014] The above method produces an aseptic liquid or semi-solid food product that has a shelf-life of six months or more, does not sediment on standing or storage during its shelf-life, does not exhibit gelation or significant changes in viscosity during its shelf-life, retains pleasing organoleptic and textural properties during its shelf-life and is ready to use, i.e. can be consumed directly, without further processing or mixing with other ingredients.

[0015] In one embodiment, the aseptic food product is a pudding; in another embodiment the food product is a beverage. The pudding may be cooled and then packaged in a container. The container may comprise a thermoplastic material.
In one embodiment, the pudding is packaged and stored in a single serving sized packages for ready consumption.

[0016] In another embodiment, the invention relates to a method of making an aseptic liquid or semi-solid food product comprising at least 2% whey, the method comprising:

a) mixing protein with water at a temperature that does not denature the proteins and forming a liquid homogenous dispersion, wherein at least 2% of the protein is whey protein;

b) heating the dispersion of step a) without pressure, to a temperature that denatures the proteins and maintaining such temperature so as to ensure denaturation;

c) pumping the denatured mixture of b) through a homogenizer at a pressure of from about 200 psi to 500 psi or pumping the denatured mixture of b) first through a homogenizer at a pressure of about 1200 psi - 1500 psi and then through a homogenizer at a pressure to about 300 psi - 500 psi, so as to homogenize said mixture;

d) cooling the homogenized mixture of c) and forming a uniform or homogenous mixture;

e) adding one or more flavors, vitamins or minerals to said mixture; and f) heating the mixture of e) at a temperature from about 130 C to about 150 C for a period of time just long enough to render the mixture an aseptic liquid or semi-solid food product; wherein the amount of whey protein is at least 2%
of the aseptic liquid or semi-solid food product, wherein a sequestering agent, such as phosphate, is added with or without water to at least one of the above steps and wherein said product lacks grittiness and sedimentation, has pleasing organoleptic properties and is ready to use. This food product may be a pudding having the properties described above.

[0017] In another embodiment, the invention relates to a method of directly delivering an aseptic liquid or semi-solid food product to a consumer, comprising a) preparing a aseptic liquid or semi-solid food product comprising at least 2% whey, the method comprising:

i) mixing protein with water at a temperature that does not denature the proteins and forming a liquid homogenous dispersion, wherein at least 2% of the protein is whey protein;

ii) heating the dispersion of step i) without pressure, to a temperature that denatures the proteins and maintaining such temperature, such as about 2 to 10 seconds, so as to ensure denaturation;

iii) pumping the denatured mixture of ii) first through a homogenizer at a pressure of about 1200 psi - 1500 psi and then through a homogenizer at a pressure to about 300 psi, so as to homogenize said mixture;

iv) cooling the homogenized mixture of iii) and forming a uniform or homogenous mixture;

v) adding one or more flavors, vitamins or minerals to the mixture;
vi) heating the mixture of v) at a temperature from about 130 C to about 150 C for a period of time just long enough to render the mixture an aseptic liquid or semi-solid food product; and vii) subjecting the product of vi) to about 200 to about 500 psi so as to homogenize the aseptic liquid or semi-solid food product; wherein the amount of whey protein is at least 2% of the aseptic liquid or semi-solid food product and wherein said product lacks grittiness and sedimentation, has pleasing organoleptic properties and is ready to use; wherein a sequestering agent, such as phosphate with or without water may be added to one or more of the above steps;

b) packaging the product of a); and c) opening the package of b) and delivering said product directly to the consumer.

In each of the aforementioned embodiments, many variations in the sequence of the disclosed method are possible, including, without limitation, that the addition of the sequestering agent, such as phosphate mixture with or without water may occur as the first step in the process or at another point in the process.

In each of the aforementioned embodiments, a buffering agent may be added prior to the final aseptic heating of mixture, in order to increase the shelf-life of the product.

Detailed Description of the Preferred Embodiments [0018] The invention provides a process for the manufacture of aseptic protein food products, such as beverages and puddings, containing at least 2% by weight of whey protein, whereby the food products may comprise other proteins, vitamins, minerals, carbohydrate and fat.

[0019] The invention further provides novel aseptic food products, which may optionally be low in carbohydrate, whereby at least 2% of the weight of the product comprises whey protein, and wherein the protein drinks and puddings are smooth and homogenous, free from grittiness, do not separate out to any significant extent on standing or sediment, and do not exhibit off-flavors that are organoleptically unacceptable to the consumer.

[0020] Whey protein is generally defined as that part of the milk protein which is present in the so-called milk serum, that is, the liquid part of the milk in which are suspended or dispersed fat globules (which are surrounded by membranes) and proteins of various sizes in micellar form, consisting mostly of calcium salts of casein molecules. Casein is the main protein of milk of bovine origin. The whey protein is a generic name applied to a heterogenous group of proteins which include a-lactalbumin, (3-lactoglobulin, serum albumin, immunoglobulins and proteose-peptones.

[0021] The whey protein may be used as a concentrated or isolated whey protein, such as are generally available in commerce, or it may be a component of another proteinaceous material of dairy origin in the broadest sense of the word.
Proteinaceous materials of dairy origin include, but are not limited to, dried milk, for example skim milk powder, partially defatted milk powder, or whole fat milk powder, milk protein concentrates, milk protein isolates and dried fermented milk products such as yoghurts. Such proteinaceous materials of dairy origin are generally available in commerce. Where the materials are of bovine origin, the whey protein content expressed as a percentage of the total protein is in the range of 15% - 22%, but generally less than 20%. The whey protein proportion of milks from other species of very limited commercial application may differ, for example buffalo milk protein is 14% whey, equine milk protein is 33% whey, goat milk protein is 22% whey, ovine milk protein is 15% whey.

[0022] The novel process of the instant invention thus provides nutritional options which have hitherto not been available, in that they permit the manufacture of novel aseptic drinks and puddings containing whey proteins which are devoid of gritty mouth feel and can take advantage of the benefits conferred by a significant content of whey protein.

[0023] The process of the instant invention may be realized using conventional equipment, such as that used by Tetrapak Industries and described in U.S.
Patent 4,944,132, which is hereby incorporated in its entirety by reference.

[0024] The present invention is thus directed to a process for the manufacture of aseptic protein drinks and puddings containing 2% or more of whey protein, that possess excellent organoleptic properties, are free from powdery and gritty mouth feel, and in the case of drinks show no gelation or sedimentation, and to the resultant novel aseptic drinks and puddings.

[0025] In one embodiment, the invention relates to an aseptic "ready to use"
nutritional drink containing at least 2% by weight of whey protein, whereby the drink may be consumed as is via a straw, in a glass, or directly from the container, though other methods of consumption that may be apparent to, or preferred by, the consumer are not excluded.

[0026] In another embodiment, the invention relates to an aseptic "ready to use" nutritional pudding containing at least 2% by weight of whey protein, whereby the pudding is in semi-solid form and intended to be consumed with a spoon or squeezed from a package or tube, though other methods of consumption that may be apparent to, or preferred by, the consumer are not excluded.

[0027] The drinks and puddings of the invention may also contain carbohydrate materials of digestible or indigestible nature, including, but not limited to, completely or partly sugar-based carbohydrates, mono-, di- and polysaccharides, such as fructose, glucose (dextrose), sucrose, maltose, lactose, galactose, tagatose, maltodextrins, starch, and/or soluble fibers, including, but not limited to, fructooligosaccharides, polydextrose, glucomannans and the like.
The carbohydrate materials may be used in the form of powders, crystals or of concentrated solutions otherwise referred to as syrups.

[0028] The drinks and puddings of the invention may also comprise carbohydrates that are partially or wholly sugar alcohols. That is, the sugar alcohol could be an alcohol of any sugar known to the skilled artisan.
Examples of such sugar alcohols include, but are not limited to, glycerine, sorbitol, maltitol, lactitol, hydrogenated starch hydrolysate, erythritol, xylitol, arabinitol, galactitol, isomaltitol, palatinit, mannitol, ribitol and mixtures thereof. The sugar alcohols may be used in the form of powders, crystals or of concentrated solutions otherwise referred to as syrups.

[0029] In another embodiment, the drinks and puddings of the invention comprise other proteins in addition to the whey protein. Suitable proteins include, but are not limited to, isolates or concentrates of milk proteins, casein, caseinates, rice, canola, soy, bean and pea protein, whereby the proteins may be partially hydrolysed.

[0030] In yet another embodiment, the drinks and puddings of the invention comprise an edible fat or oil, including, but not limited to, soya bean oil, corn oil, sunflower seed oil, canola oil, or any other oil or fat that is appropriate for human consumption.

[0031] In a further embodiment, the drinks and puddings of the invention comprise gums or thickening agents, including, but not limited to, xanthan gum, locust bean gum, guar gum, modified cellulose derivatives and the like.

[0032] The drinks and puddings of the invention may also comprise nutraceutical substances such as herbs, herbal extracts and free amino acids, vitamins, minerals, flavors, antioxidants, preservatives, coloring agents, acidulants, and other substances required for technical purposes, such as chelating agents, emulsifiers such as lecithin and mono- and diglycerides.

[0033] In one embodiment, the novel product is a beverage. In another embodiment, the product is a pudding.

[0034] In yet another embodiment, the invention relates to a method of making an aseptic protein drink, the method comprising a) mixing one or more proteinaceous materials that comprise whey protein, such as a milk protein concentrate or isolate, a whey protein concentrate or a whey protein isolate with other proteins, carbohydrates, optionally oil or fat and other ingredients, other than phosphates, flavors, and optional vitamins and minerals and water at a temperature of 35 C - 65 C;

b) either cooling the above mixture to 5 C - 10 C until required, whereupon it is heated to a temperature of 99 C, or directly heating the mixture to 99 C;

c) holding the mixture at a temperature of 95 C - 99 C for 0 - 90 seconds, then either homogenizing the mixture in a two-stage process under a pressure of 1200 psi - 1500 psi initially, reducing to 300 psi, or homogenizing the mixture in a single-stage process at 300 psi - 500 psi;

d) cooling the homogenized mixture to ambient temperature or below (<25 C), preferably less than 10 C;

e) solubilizing a blend of phosphates using water at a temperature of 35 C - 55 C;

f) adding the solution of phosphates to the cooled homogenate;

g) adding flavors and optional vitamins and minerals to the cooled homogenate;

h) processing the entire mixture by heating to 130 C - 150 C for 2- 10 seconds and rapidly cooling;

i) homogenizing the resultant aseptic product at 300 - 500 psi and packing into aseptic containers;

wherein at least 2% by weight of drink is whey protein.

[0035] In another embodiment, the phosphate mixture may be added at various steps in the process. For example, the phosphate mixture may be added prior to or following the first step of mixing the protein with water.

[0036] In another embodiment, a buffering agent may be added prior to the final heating of mixture, in order to increase the shelf-life of the product.

[0037] In yet another embodiment, the invention relates to a method of making an aseptic protein pudding, the method comprising a) mixing one or more proteinaceous materials that comprise whey protein, such as a milk protein concentrate or isolate, a whey protein concentrate or a whey protein isolate with other proteins, carbohydrates, optionally oil or fat and other ingredients, other than phosphates, flavors, and optional vitamins and minerals and water at a temperature of 35 C - 65 C;

b) either cooling the above mixture to 5 C -10 C until required, whereupon it is heated to a temperature of 99 C, or directly heating the mixture to 99 C;

c) holding the mixture at temperature for 0- 90 seconds, then eitherr homogenizing the mixture in a two-stage process under a pressure of 1200 psi -1500 psi initially, reducing to 300 psi, or homogenizing the mixture in a single-stage process at 300 psi - 500 psi;

d) cooling the homogenized mixture to ambient temperature or below (<25 C), preferably less than 10 C;

e) solubilizing a blend of phosphates using water at a temperature of 35 C - 55 C;

f) adding the solution of phosphates to the cooled homogenate;
g) adding flavors and optional vitamins and minerals to the cooled homogenate;

h) processing the entire mixture by heating to 130 C -150 C for 2- 40 seconds and rapidly cooling;

i) optionally homogenizing the mixture at a pressure of 200 psi - 300 psi and packing into aseptic containers;

wherein at least 2% by weight of the pudding is whey protein.

[0038] In another embodiment, the phosphate mixture may be added at various steps in the process. For example, the phosphate mixture may be added prior to or following the first step of mixing the protein with water.

[0039] In another embodiment, a buffering agent may be added prior to the final heating of mixture, in order to increase the shelf-life of the product.

[0040] The invention further provides novel aseptic protein drinks and puddings, which also comprise carbohydrate and are suitable for use as meal replacement drinks and puddings, whereby at least 2% of the weight of the product comprises whey protein as hereinbefore defined, and wherein the protein drinks and puddings are smooth and homogenous, free from grittiness, do not separate out to any significant extent on standing or sediment, and do not exhibit off-flavors that are organoleptically unacceptable to the consumer.

[0041] The novel products according to the invention are made by aseptic processing, whereby the products are sterilized by a heat process and packaged in aseptic and impermeable containers. Such containers may be thermoplastic containers, paper or any other type of container known to the skilled artisan.

[0042] In one embodiment of the present invention, there is provided an aseptic protein drink comprising at least 2% by weight of whey protein, whereby the viscosity of the drink does not change significantly after processing, the drink does not exhibit gelation, the drink does not exhibit sedimentation, and the drink does not contain particles created during processing that are perceptible to the human taste organs and palate.

[0043] In a further embodiment of the present invention there is provided an aseptic pudding or fiavored gelled mass, whereby the gelling may be based on various mechanisms which could include pectin, alginate(s), starch, agar-agar, gelatine, other functional proteins, and their activating agents, (or combinations thereof), which contains at least 2% whey protein by weight. This embodiment also provides a fruit or other flavored gelled mass, whereby the sugars present have been wholly or partially replaced by one or more sugar alcohols (including glycerine), or poorly digestible sugars such as tagatose, and digestible polysaccharides have been wholly or partially replaced by poorly digestible polysaccharides such as polydextrose.

[0044] In a further embodiment of the present invention there is provided a drink or pudding which contains elevated levels of protein, and made with or without the addition of digestible carbohydrates, poorly digestible carbohydrates, or sugar alcohols (including glycerine) which contains an elevated content of protein in the range of 5% to 25% by weight and which may optionally comprise added vitamins and minerals.

[0045] Yet another embodiment of the present invention also provides a method for manufacture of the novel drinks or puddings whereby the selected proteins and other ingredients in dry powder form are introduced with water into a continuous mixing device which provides a uniform dispersion of the ingredients, and which may be heated or cooled as required, whereafter the resultant liquid is homogenized, subjected to heat treatment, homogenized again, cooled, and packaged into sterile (aseptic) containers.

[0046] Another preferred embodiment of the present invention provides a method for manufacture of the novel drinks and puddings whereby a liquid blend of proteinaceous materials, comprising at least 2% whey protein, is first prepared by stirring the proteinaceous materials into water at 50 C - 55 C. At the same time, a further liquid blend is prepared by dissolving one or more of an inorganic phosphate, including, but not limited to, sodium polyphosphate, sodium hexametaphosphate, potassium mono-phosphate and potassium di-phosphate, in water at 50 C - 55 C. Once the phosphates have dissolved, other desirable ingredients such as carbohydrates, oils, emulsifiers, vitamins, sweeteners, minerals, electrolytes, fiavors and colors are thoroughly dispersed in the phosphate solution.

[0047] The two liquid blends thus obtained are then subjected to a continuous process, which consists, in order, of:

1) Pumping the liquid protein blend through a heat exchanger which increases the temperature of the blend to 95 C - 99 C and maintains it at this temperature for 0 - 60 seconds, after which the hot blend optionally passes either through a two-stage homogenizer, wherein the first stage operates at a pressure of 1200 psi - 1500 psi, and the second stage operates at a pressure of 500 psi, or through two consecutive in-line homogenizers, the first set to homogenize at a pressure of 1200 psi - 1500 psi, the second adjusted to homogenize at a pressure of 500 psi, or optionally passing the mixture through a single-stage homogenizer set at a pressure of 300 psi - 500 psi.

2) Adding the dispersion of the other ingredients in the phosphate solution to the resultant homogenized liquid protein blend and stirring vigorously until thoroughly homogenous.

3) Ensuring that the pH of the resultant blend is a minimum of 6.55, though in the case of puddings it may be preferable to utilize a minimum of pH 6.77 and above, which adjustment of pH if required may be brought about by the addition of disodium phosphate or other food-compatible pH adjusters which will be obvious to the skilled artisan to bring the pH up to the required minimum, again with stirring. It is also important to add an buffering agent to minimize the pH drop during aseptic processing.

4) Pumping the resultant liquid through a continuous heating system, which may optionally heat the liquid by means of a heat exchanger or by direct steam injection, such that the temperature is raised to 140 C - 150 C and maintained at this temperature for up to 15 seconds.

5) If the product is a drink, passing the heated product immediately through a homogenizer set at 300 psi - 500 psi, whereafter the homogenized material is rapidly cooled to room temperature (20 C - 28 C) by means of an in-line heat exchanger, and passed into an aseptic surge tank. If the product is a pudding, the final homogenization may be omitted and the product passed directly into the aseptic surge tank, or the homogenization may consist of homogenization at a pressure of 200 psi - 300 psi.

6) Pumping the product from the aseptic surge tank into the aseptic packaging equipment and packaging it in units of the desired size or volume.

[0048] In another embodiment, the phosphate mixture may be added at various steps in the process described above. For example, the phosphate mixture may be added prior to or following the first step of pumping the liquid blend.

[0049] As will be apparent to those skilled in the art, the process herein claimed has wide and varied application, and may be utilized with many ingredients in addition to those containing the whey proteins, subject only to the ability of the ingredient to withstand the heat applied during the process without undergoing significant degradation or damage. Such ingredients may include, but are not limited to, proteinaceous ingredients such as concentrates and isolates of plant, animal, avine and dairy proteins, whereby the concentrates and isolates may be hydrolyzed to a greater or lesser extent, proteinaceous ingredients derived from the milling or grinding of nuts, seeds or grains without further concentration, carbohydrate ingredients in the broadest sense of the word, including, but not limited to, digestible or indigestible mono-, di-, oligo- and polysaccharides, which category includes polysaccharides which are randomly linked, such as polydextrose, where the saccharide may denote a triose, tetrose, pentose or hexose moiety, the derivatives of mono-, di- and oligosaccharides which may be obtained through hydrogenation and are commonly known as sugar alcohols, where the saccharide may denote a triose, tetrose, pentose or hexose moiety, thus including glycerol as a hydrogenated triose sugar, oils and fats, including, but not limited to, mono-, di- and triglycerides of animal, vegetable or marine origin and phosphatides of like origin, including, but not limited to, the phosphatidylcholines, the phosphatidylethanolamines and the phosphatidyisphingosines, herbs, herbal extracts, vitamins, minerals, amino acids and other substances of value for human health.

[0050] In another embodiment, the invention relates to a method of directly delivering an aseptic liquid or semi-solid food product to a consumer, comprising a) preparing a aseptic liquid or semi-solid food product comprising at least 2% whey, the method comprising:

i) mixing protein with water at a temperature that does not denature the proteins and forming a liquid homogenous dispersion, wherein at least 2% of the protein is whey protein;

ii) heating the dispersion of step i) without pressure, to a temperature that denatures the proteins and maintaining such temperature, such as about 2 to 10 seconds, so as to ensure denaturation;

iii) pumping the denatured mixture of ii) first through a homogenizer at a pressure of about 1200 psi - 1500 psi and then through a homogenizer at a pressure to about 300 psi - 500 psi, so as to homogenize said mixture;

iv) cooling the homogenized mixture of iii) and then adding to the cooled, homogenized mixture a solution comprising phosphate and water so as to form a uniform or homogenous mixture;

v) adding one or more flavors, vitamins or minerals to the mixture;

vi) heating the mixture of v) at a temperature from about 130 C to about 150 C for a period of time just long enough to render the mixture an aseptic liquid or semi-solid food product; and vii) subjecting the product of vi) to about 200 to about 500 psi so as to homogenize the aseptic liquid or semi-solid food product; wherein the amount of whey protein is at least 2% of the aseptic liquid or semi-solid food product and wherein said product lacks grittiness and sedimentation, has pleasing organoleptic properties and is ready to use;

b) packaging the product of a); and c) opening the package of b) and delivering said product directly to the consumer.

[0051] In another embodiment, the phosphate mixture may be added at various steps in the process. For example, the phosphate mixture may be added prior to or following the first step of mixing the protein with water.

[0052] In another embodiment, a buffering agent may be added prior to the final heating of the mixture, in order to increase the shelf-life of the product.

[0053] Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of this invention. Accordingly, the scope of the present invention is intended to be defined only by reference to the appended claims.

[0054] The invention is further illustrated without limitation by the following examples.

EXAMPLE 1:

[0055] A liquid aseptic high protein drink containing a total of 4.12% of whey protein was prepared using the following ingredients:

Ingredients Per 100 kg Whe rotein content, %
Whey protein concentrate 4.27 3.27 Whe protein isolate 0.15 0.13 Milk protein isolate 4.25 0.72 Calcium caseinate 1.20 Sunflower seed oil 0.50 Datem* 0.13 Carrageenan 0.020 Cellulose gel 0.07 Salt 0.13 Sucralose 0.0133 Acesulfame K 0.010 (sweetener) Color 0.0004 Vanilla Flavor 0.30 Phosphate mixture** 0.29 Fructo- 0.20 oligosaccharides***
Water 88.46 * Datem: Diacetyltartaric acid esters of mono- and diglycerides.
** Phosphate mixture: Blends of sodium polyphosphate, sodium hexametaphosphate, potassium mono-phosphate and potassium di-phosphate.
*** Fructo-oligosaccharides: Oligofructoses of varying degrees of polymerization obtained from the roots of chicory or Jerusalem artichoke.

[0056] Figures are given as kg/100 kg, and may be scaled to suit the equipment used and the size of batch required.

[0057] Firstly, a liquid blend, A, of the sunflower seed oil, whey protein concentrate, whey protein isolate, milk protein isolate, calcium caseinate, Datem, carrageenan, microcrystalline cellulose, salt, sucralose, acesulfame K, color and fructo-oligosaccharides was prepared by stirring the weights of these ingredients shown above into 68 kg of the water at 35 C - 55 C until a homogenous dispersion is obtained.

[0058] The phosphate mixture was at the same time dissolved in the remaining 20.46 kg of water at 55 C. Once the phosphates had dissolved completely, the vanilla flavor was added with stirring until a homogenous dispersion was achieved, identified as blend B.

[0059] The two liquid blends thus obtained were then subjected to a continuous process, which consisted in order of:

1) Pumping the liquid blend A through a heat exchanger which increased the temperature of the blend to 95 C - 99 C and maintained it at this temperature for 47 seconds, after which the hot blend was passed through a two-stage homogenizer, the first stage set to homogenize at a pressure of 1200 psi, the second stage adjusted to homogenize at a pressure of 500 psi.
2) To the resultant homogenized liquid blend A was now added the dispersion of the vanilla flavor in the solution of phospates and the whole stirred until thoroughly homogenous. Care was taken to ensure that the pH
of the resultant blend was a minimum of 6.55; if it was below this pH, di-sodium phosphate or other food-compatible pH adjuster was added to bring the pH up to this minimum.

3) The resultant liquid was now pumped through a continuous heating system with direct steam injection such that the temperature was raised to 142 C - 143 C and maintained at this temperature for 8 seconds.

4) The product was then immediately passed through a homogenizer set at 300 psi - 500 psi, rapidly cooled to 10 C by means of an in-line heat exchanger, and held in an aseptic surge tank.

5) Product from the aseptic surge tank was pumped into the aseptic packaging equipment and packed in units of 200 mL.

[0060] The product which resulted was smooth and possessed excellent mouth feel, with no trace of grittiness. It remained fully liquid without any signs of gelation or sedimentation on storage at room temperature. The nutritional profile of the product thus obtained was:

Protein, total 16.205 of which whey protein 8.24 g Carbohydrate, total 2.245 of which Soluble fibre 0.396 Insoluble fibre 0.139 Sugars 1.089 Sugar alcohols 0.000 Other carbohydrate 0.621 Fat 2.095 g Kilocalories (Atwater) 91 Kcal Kilo'oules 383 Kj [0061] The amino acid score, corrected for protein digestibility, was 1.21:
ESSENTIAL AMINO ACID: UNCORRECTED CORRECTED:
T to han 1.26 1.21 Histidine 1.34 1.30 Phen lalanine/t rosine 1.46 1.42 Lysine 1.51 1.46 Leucine 1.56 1.51 Methionine/cystine 1.65 1.60 Threonine 1.74 1.68 Valine 1.76 1.70 Isoleucine 2.02 1.96 [0062] The amino acid profile, as free amino acids after hydrolysis, was:
AMINO-ACID: CONTENT rams/Unit :
Alanine (ALA) 0.662 Arginine (ARG) 0.566 g Aspartic acid (ASP) 1.483 g Cysteine/cystine 0.249 g (CYS) Glutamic acid 3.455 g (GLU) Glycine (GLY) 0.275 Histidine (HIS) 0.415 Isoleucine E (ILE) 0.921 Leucine E (LEU) 1.679 g Lysine s (LYS) 1.425 Methionine E (MET) 0.423 Phenylalanine E 0.732 g (PHE) Proline (PRO) 1.430 Serine (SER) 0.896 Threonine F_ (THR) 0.963 g Tryptophan E 0.225 g (TRY) Tyrosine (TYR) 0.766 Valine F_ (VAL) 0.998 g Ornithine (ORN) 0.000 Hydroxyproline 0.000 g (HYP) F_ = essential amino acid.

[0063] Total amino-acids: 17.563 g (reflecting the fact that the weight of free amino acids obtained is greater than the weight of protein hydrolysed due to incorporation of water during the hydrolysis).

EXAMPLE 2:

[0064] An aseptic high-protein chocolate-flavored pudding containing a total of 3.50% of whey protein was prepared using the following ingredients:

Ingredients Per 100 kg Whey protein content, %
Whey protein concentrate 2.50 1.87 Milk protein concentrate 4.71 0.75 Milk protein isolate 4.80 0.86 Calcium caseinate 1.00 Sunflower seed oil 0.70 Datem* 0.13 Carrageenan 0.020 Locust bean gum 0.032 Salt 0.14 Sucralose 0.0155 Acesulfame K 0.010 Cocoa powder 1.85 Chocolate flavor 0.24 Phosphate mixture** 0.30 Fructo- 0.25 oligosaccharides***
Water 83.30 * Datem: Diacetyltartaric acid esters of mono- and diglycerides.
** Phosphate mixture: Blends of sodium polyphosphate, sodium hexametaphosphate, potassium mono-phosphate and potassium di-phosphate.
*** Fructo-oligosaccharides: Oligofructoses of varying degrees of polymerization obtained from the roots of chicory or Jerusalem artichoke.

[0065] Figures are given as kg/100 kg, and may be scaled to suit the equipment used and the size of batch required.

[0066] Firstly, a liquid blend, A, of the sunflower seed oil, whey protein concentrate, milk protein concentrate, milk protein isolate, calcium caseinate, Datem, carrageenan, Locust bean gum, salt, sucralose, acesulfame K, cocoa powder and fructo-oligosaccharides is prepared by stirring the weights of these ingredients shown above into 63.30 kg of the water at 35 C - 55 C until a homogenous dispersion is obtained.

[0067] The phosphate mixture is at the same time dissolved in the remaining 20.00 kg of water at 55 C. Once the phosphates have dissolved completely, the chocolate flavor is added with stirring until a homogenous dispersion is achieved, identified as blend B.

[0068] The two liquid blends thus obtained are then subjected to a continuous process, which consists in order of:

1) Pumping the liquid blend A through a heat exchanger which increases the temperature of the blend to 95 C and maintains it at this temperature for 47 seconds, after which the hot blend passes through a two-stage homogenizer, the first stage set to homogenize at a pressure of 1200 psi, the second stage adjusted to homogenize at a pressure of 500 psi.

2) To the resultant homogenized liquid blend A is now added the dispersion of the flavor in the solution of phospates and the whole stirred until thoroughly homogenous. Care is taken to ensure that the pH of the resultant blend is a minimum of 6.77; if it is below this pH, di-sodium phosphate may be added to bring the pH up to this minimum.

3) The resultant liquid is now pumped through a tubular or scraped surface heat exchanger such that the temperature is rapidly raised to 142 C, and maintained at this temperature for 8 seconds.

4) The product is then rapidly cooled to 10 C by means of an in-line heat exchanger, and held in an aseptic surge tank.

5) Product from the aseptic surge tank is pumped into the aseptic packaging equipment and packed aseptically in plastic cups of 130 mL.

[0069] The product which resulted was smooth and possesed excellent mouth feel, with no trace of grittiness. It remained unchanged, retaining a pudding-like consistency, without any signs of further gelation or of sedimentation, on storage at room temperature.

[0070] The nutritional profile of the product thus obtained was:
Protein, total 14.412 of which whey protein 7.00 g Carbohydrate, total 2.579 of which Soluble fibre 0.510 Insoluble fibre 0.613 Sugars 0.840 Sugar alcohols 0.000 Other carbohydrate 0.616 Fat 1.863 g Kilocalories (Atwater) 80 Kcal Kilojoules 336 Kj EXAMPLE 3:

[0071] A batch of 5077 kg of a vanilla-flavored liquid aseptic high protein drink containing a total of 3.27% of whey protein was prepared using the following ingredients:

Ingredients Trade names Per batch Whey protein (kg) content, %
Whe protein concentrate Lacprodan 80 131.99 2.08 Milk protein isolate Kerry 9060 335.06 1.19 Gum arabic 71.07 Calcium caseinate Miprodan 40 55.84 Sunflower seed oil Trisun AS100 83.76 Datem Panodan 7.60 Carrageenan Danisco 0.61 Cellulose gel Avicel CL611 2.03 Salt 7.61 Sucralose Splenda 0.36 Granulated sugar 282.77 Polydextrose Litesse 41.63 Vanilla flavor 16.25 Annato/turmeric color 0.3 Potassium Brifisol K-1000 6.09 mono/diphosphates Sodium Joha C-New 5.58 hexametaphosphate Fructo-oligosaccharides Raftilose P95 39.09 Water 3989.72 [0072] The potassium mono- and diphosphate mixture and the sodium hexametaphosphate were first each dissolved in 10 kg hot water (55 C); these solutions were combined and cooled. The vanilla flavor and the annato/turmeric color were each dispersed in 10 kg cold water. The phosphate, vanilla and color solutions were then combined and a further 294.55 kg cold water added with stirring. The resultant solution was identified as blend B.

[0073] For the preparation of the batch, the sunflower seed oil and the datem were first added to a large mixing tank containing 3655.17 kg water at 60 C
and vigorously stirred for 2 - 3 minutes. Thereafter, the remaining ingredients (whey protein concentrate, milk protein isolate, gum arabic, calcium caseinate, carrageenan, microcrystalline cellulose, salt, sucralose, sugar, polydextrose and fructo-oligosaccharides) were consecutively added to the tank with stirring.
After addition was complete, the mixture was stirred vigorously for a further 15 minutes;
this mixture was identified as blend A.

[0074] The liquid blend A was then pumped through a heat exchanger which increased the temperature of the blend to 95 C and maintained it at this temperature for 15 seconds, after which the hot blend was passed through a two-stage homogenizer, the first stage set to homogenize at a pressure of 1500 psi, the second stage adjusted to homogenize at a pressure of 300 psi. The blend was then cooled to about 5 C and placed in a tank, whereupon the blend B was added with stirring. The resultant mixture was stirred until homogenous, and the pH
tested. Care was taken to ensure that the pH of the resultant blend was in the range of 6.60 - 6.80; di-sodium phosphate or other food-compatible pH adjuster was added if necessary to ensure the pH fell within this range.

[0075] The resultant liquid (combined blends A and B) was now pumped through a continuous heating system with direct steam injection such that the temperature was raised to 142 C - 143 C and maintained at this temperature for seconds. The product was then immediately passed through a homogenizer set at 300 psi - 500 psi, rapidly cooled to 10 C by means of an in-line heat exchanger, and held in an aseptic surge tank, from which it was then pumped into the aseptic packaging equipment and packed in units of 236 mL.

[0076] The nutritional composition of the resultant product, as expressed by a Canadian Nutrition Facts panel, was:

Nutrition Facts Valeur nutritive Serving size / Portion 236 mL (250 g) Servings per container / Portions par contenant 1 Amount per serving % Daily Value*
Teneur par portion %
valeur quotidienne*
Calories I Calories 210 Fat / Lipides 5 g 8%
Saturated / satures 1 g 5%
+ Trans / trans 0 Cholesterol / Cholesterol 0 mg 0%
Sodium I Sodium 220 mg 9%
Potassium / Potassium 240 mg 7%
Carbohydrate I Glucides 22 g 7%
Fibre / Fibres 7 g 28%
Sugars / Sucres 14 g Protein / Proteines 22 g Vitamin A / Vitamine A
0%
Vitamin C / Vitamine C
0%
Calcium / Calcium 35%
Iron / Fer 0%
Calories per gram: Fat 9 Carbohydrate 4 Protein 4 Calories par gramme : Lipides 9 Glucides 4 Proteines [0077] The product which resulted was smooth and possesed excellent mouth feel, with no trace of grittiness. It remained fully liquid without any signs of gelation or sedimentation on storage at room temperature.

EXAMPLE 4.

[0078] A batch of 6161 kg of a chocolate-flavored liquid aseptic high protein drink containing a total of 3.13% of whey protein was prepared using the following ingredients:

Ingredients Trade names Per batch Whey protein (kg) content, %
Whey protein concentrate Lacprodan 80 154.03 2.00 Milk protein isolate Kerry 9060 388.15 1.13 Gum arabic 81.33 Calcium caseinate Miprodan 40 67.77 Sunflower seed oil Trisun AS100 99.81 Datem Panodan 7.40 Carrageenan Danisco 0.74 Cellulose gel Avicel CL611 2.46 Salt 9.86 Sucralose Splenda 0.49 Granulated sugar 338.87 Polydextrose Litesse 30.81 Chocolate flavor 11.71 Cocoa powder 10/12 Sienna 58.53 Potassium Brifisol K-1000 6.78 mono/diphosphates Sodium Joha C-New 6.78 hexametap hosp hate Fructo-oligosaccharides Raftilose P95 32.65 Water 4863.08 [0079] The potassium mono- and diphosphate mixture and the sodium hexametaphosphate were first each dissolved in 10 kg hot water (55 C); these solutions were combined and cooled. The chocolate flavor was dispersed in 10 kg cold water. The phosphate and flavor solutions were then combined and a further 397.03 kg cold water added with stirring. This solution was identified as blend B.

[0080] For the preparation of the batch, the sunflower seed oil and the datem were first added to a large mixing tank containing 4436.05 kg water at 60 C
and vigorously stirred for 2 - 3 minutes. Thereafter, the remaining ingredients (whey protein concentrate, milk protein isolate, gum arabic, calcium caseinate, carrageenan, microcrystalline cellulose, salt, sucralose, sugar, polydextrose, cocoa powder and fructo-oligosaccharides) were consecutively added to the tank with stirring. After addition was complete, the mixture was stirred vigorously for a further 15 minutes; this mixture was identified as blend A.

[0081] The liquid blend A was then pumped through a heat exchanger which increased the temperature of the blend to 99 C and maintained it at this temperature for 28 seconds, after which the hot blend was passed through a two-stage homogenizer, the first stage set to homogenize at a pressure of 1500 psi, the second stage adjusted to homogenize at a pressure of 300 psi. The blend was then cooled to about 5 C and placed in a tank, whereupon the blend B was added with stirring. The resultant mixture was stirred until homogenous, and the pH
tested. Care was taken to ensure that the pH of the resultant blend was in the range of 6.60 - 6.90; di-sodium phosphate or other food-compatible pH adjuster was added if necessary to ensure the pH level fell within this range.

[0082] The resultant liquid (combined blends A and B) was now pumped through a continuous heating system with direct steam injection such that the temperature was raised to 142 C - 143 C and maintained at this temperature for seconds. The product was then immediately passed through a homogenizer set at 300 psi - 500 psi, rapidly cooled to 10 C by means of an in-line heat exchanger, and held in an aseptic surge tank, from which it was then pumped into the aseptic packaging equipment and packed in units of 236 mL.

[0083] The nutritional composition of the resultant product, as expressed by a Canadian Nutrition Facts panel, was:

Nutrition Facts Valeur nutritive Serving size / Portion 236 mL (250 g) Servings per container/Portions par contenant I
Amount per serving %
Daily Value*
Teneur par portion % valeur uotidienne*
Calories I Calories 210 Fat / Lipides 5 g 8%
Saturated / satures 1 g 5%
+ Trans / trans 0 g Cholesterol / Cholesterol 0 mg 0%
Sodium / Sodium 240 mg 10%
Potassium I Potassium 310 mg 9%
Carbohydrate / Glucides 22 g 7%
Fibre / Fibres 7 g 28 %
Sugars / Sucres 14 g Protein / Proteines 22 g Vitamin A / Vitamine A
0%
Vitamin C / Vitamine C
0%
Calcium I Calcium 30%
Iron / Fer 0%
Calories per gram: Fat 9 Carbohydrate 4 Protein Calories par gramme : Lipides 9 Glucides 4 Proteines 4 [0084] The product which resulted was smooth and possesed excellent mouth feel, with no trace of grittiness. It remained fully liquid without any signs of gelation or sedimentation on storage at room temperature.

EXAMPLE 5.

[0085] A chocolate-flavored liquid aseptic high protein drink containing a total of 2.91 % of whey protein was prepared using the following ingredients:

Ingredients Per 100 kg Whey protein content, %
Whey protein concentrate 2.590 2.07 Whe protein isolate 0.139 0.12 Milk protein isolate 3.984 0.72 Calcium caseinate 1.096 Sunflower seed oil 0.598 Datem* 0.139 Carrageenan 0.030 Cellulose gel 0.149 Salt 0.149 Sucralose 0.010 Acesulfame K (sweetener) 0.100 Cocoa powder 10/12 1.544 Chocolate flavor 0.189 Potassium 0.080 mono/diphosphates Sodium hexametaphosphate 0.129 ig osaccharides** 0.199 Water 88.873 ~ Datem: Diacetyltartaric acid esters of mono- and diglycerides.
** Fructo-oligosaccharides: Oligofructoses of varying degrees of polymerization obtained from the roots of chicory or Jerusalem artichoke.

[0086] Figures are given as kg/100 kg, and may be scaled to suit the equipment used and the size of batch required.

[0087] Firstly, a liquid blend, A, of the sunflower seed oil, whey protein concentrate, whey protein isolate, milk protein isolate, calcium caseinate, cocoa powder, Datem, carrageenan, cellulose gel, salt, sucralose, acesulfame K and fructo-oligosaccharides was prepared by stirring the weights of these ingredients shown above into 68 kg of the water at 35 C - 55 C until a homogenous dispersion is obtained.

[0088] The phosphates (potassium mono- and di-phosphate, sodium hexametaphosphate) were at the same time dissolved in the remaining 20.873 kg of water at 55 C. Once the phosphates had dissolved completely, the chocolate flavor was added with stirring until a homogenous dispersion was achieved, identified as blend B.

[0089] The two liquid blends thus obtained were then subjected to a continuous process, which consisted in order of:

1) Pumping the liquid blend A through a heat exchanger which increased the temperature of the blend to 95 C - 99 C and maintained it at this temperature for 47 seconds, after which the hot blend was passed through a two-stage homogenizer, the first stage set to homogenize at a pressure of 1200 psi, the second stage adjusted to homogenize at a pressure of 500 psi.
2) To the resultant homogenized liquid blend A was now added the dispersion of the vanilla flavor in the solution of phospates and the whole stirred until thoroughly homogenous. Care was taken to ensure that the pH
of the resultant blend was a minimum of 6.55; if it was below this pH, di-sodium phosphate or other food-compatible pH adjuster was added to bring the pH up to this minimum.

3) The resultant liquid was now pumped through a continuous heating system with direct steam injection such that the temperature was raised to 142 C -143 C and maintained at this temperature for 8 seconds.

4) The product was then immediately passed through a homogenizer set at 300 psi - 500 psi, rapidly cooled to 10 C by means of an in-line heat exchanger, and held in an aseptic surge tank.

5) Product from the aseptic surge tank was pumped into the aseptic packaging equipment and packed in units of 236 mL.

[0090] The product which resulted was smooth and possesed excellent mouth feel, with no trace of grittiness. It remained fully liquid without any signs of gelation or sedimentation on storage at room temperature. The nutritional profile of the product thus obtained was:

Protein, total 16.122 g of which whey protein 6.87 g Carbohydrate, total 3.815 of which Soluble fibre 0.723 Insoluble fibre 1.278 Sugars 0.897 Sugar alcohols 0.000 Other carbohydrate 0.917 Fat 2.794 g Kilocalories (Atwater) 97 Kcal Kilojoules 405 Kj EXAMPLE 6:

[0091] An aseptic high-protein chocolate-flavored pudding containing a total of 3.285% of whey protein was prepared using the following ingredients:

Ingredients Per 100 kg Whey protein content, %
Whey protein concentrate 1.50 1.20 Milk protein concentrate 5.85 1.03 Milk protein isolate 5.45 1.0355 Calcium caseinate 1.00 40% cream 4.50 Datem* 0.13 Tapioca Starch 2.00 Locust bean gum 0.040 Salt 0.15 Sucralose 0.016898 Acesulfame K 0.010 Cocoa powder 2.10 Chocolate flavor 0.82 Phosphate mixture" 0.30 Fructo- 0.25 oligosaccharides***
Water 75.783 * Datem: Diacetyltartaric acid esters of mono- and diglycerides.
Phosphate mixture: Blends of sodium polyphosphate, sodium hexametaphosphate, potassium mono-phosphate and potassium di-phosphate.
*** Fructo-oligosaccharides: Oligofructoses of varying degrees of polymerization obtained from the roots of chicory or Jerusalem artichoke.

[0092] Figures are given as kg/100 kg, and may be scaled to suit the equipment used and the size of batch required.

[0093] Firstly, a liquid blend, A, of phosphate and water is prepared;

[0094] Then, a liquid blend B, of the 40% cream, whey protein concentrate, milk protein concentrate, milk protein isolate, calcium caseinate, Datem, carrageenan, Locust bean gum, salt, sucralose, acesulfame K, cocoa powder and fructo-oligosaccharides is prepared by stirring the weights of these ingredients shown above into water at 35 C - 55 C until a homogenous dispersion is obtained. The percentage of solids of this blend will be around 22-25%.

[0095] Liquid Blend A and Liquid Blend B are combined in one tank;

[0096] This blend thus obtained is then subjected to a continuous process, which consists in order of:

1) Pumping the liquid blend through a heat exchanger which increases the temperature of the blend to 85C- 95 C and maintains it at this temperature for 30 seconds, after which the hot blend passes through a two-stage homogenizer, the first stage set to homogenize at a pressure of 1200 psi, the second stage adjusted to homogenize at a pressure of 500 psi.

2) To the resultant cooled( about 8-10C) homogenized liquid blend is transferred to another tank and the flavor and the starch slurry (starch and water) is added. Care is taken to ensure that the pH of the resultant blend is a minimum of 6.77. The Ph is adjusted with KOH or Sodium-hydroxide, if it is below 6.75. A buffering agent is added to minimize the drop in ph after the final aseptic heating. Drop in ph is normal in all the aseptically processed products The total solids at this stage should be 20.6-21.00%. If it is higher it is adjusted with water 3) The resultant liquid is now pumped through a tubular or scraped surface heat exchanger such that the temperature is rapidly raised to 142 C, and maintained at this temperature for 6-15 seconds or at 133 C for 30 - 40 seconds.

4) The product is then rapidly cooled to 20-28 C by means of an in-line heat exchanger, and held in an aseptic surge tank.

5) Product from the aseptic surge tank is pumped into the aseptic packaging equipment and packed aseptically in plastic cups of 125 mL or 142m1 .

[0097] The product which resulted was smooth and possessed excellent mouth feel, with no trace of grittiness. It remained unchanged, retaining a pudding-like consistency, without any signs of further gelation or of sedimentation, on storage at room temperature.

[0098] The nutritional profile of the product thus obtained was:
Protein, total 15-17* g of which whey protein 4.81 g Carbohydrate, total 5.20 of which Soluble fibre 0.510 Insoluble fibre 0.613 Sugar alcohols 0.000 Other carbohydrate 0.616 Fat 2.97 g Kilocalories (Atwater) 110 Kcal *17-18gms of protein where it is filled in 142gmslastic cup.
The above values are or 125gm plasic cups.

EXAMPLE 7.

[0099] A chocolate-flavored liquid aseptic meal replacement drink containing a total of 2.86% of whey protein was prepared using the following ingredients:

In redients Per 100 kg Whey protein content, %
Whe protein concentrate 2.700 2.16 Milk protein isolate 3.900 0.70 Calcium caseinate 1.100 Sunflower seed oil 1.900 Datem* 0.150 Carrageenan 0.030 Cellulose gel 0.090 Salt 0.160 Sugar 3.650 Sucralose 0.005 Gum arabic/acacia 1.300 Cocoa powder 10/12 0.980 Chocolate flavor 0.230 Potassium 0.100 mono/diphosphates Sodium hexametaphosphate 0.130 Vitamin/mineral premix 0.006 Polydextrose 0.700 Potassium citrate 0.008 Fructo-oIi osaccharides** 0.450 Water 82.411 * Datem: Diacetyltartaric acid esters of mono- and diglycerides.
** Fructo-oligosaccharides: Oligofructoses of varying degrees of polymerization obtained from the roots of chicory or Jerusalem artichoke.

[0100] Figures are given as kg/100 kg, and may be scaled to suit the equipment used and the size of batch required.

[0101] Firstly, a liquid blend, A, of the sunflower seed oil, whey protein concentrate, milk protein isolate, calcium caseinate, cocoa powder, Datem, carrageenan, cellulose gel, salt, sugar, sucralose, gum arabic/acacia, polydextrose and fructo-oligosaccharides was prepared by stirring the weights of these ingredients shown above into 62.411 kg of the water at 35 C - 55 C until a homogenous dispersion is obtained.

[0102] The phosphates (potassium mono- and di-phosphate, sodium hexametaphosphate) and potassium citrate were at the same time dissolved in the remaining 20.000 kg of water at 55 C. . Once the phosphates had dissolved completely, the chocolate flavor was added with stirring until a homogenous dispersion was achieved, and finally the vitamin and mineral premix was dispersed in this liquid, all with vigorous stirring. The liquid was identified as blend B.

[0103] The two liquid blends thus obtained were then subjected to a continuous process, which consisted in order of:

1) Pumping the liquid blend A through a heat exchanger which increased the temperature of the blend to 95 C - 99 C and maintained it at this temperature for 47 seconds, after which the hot blend was passed through a two-stage homogenizer, the first stage set to homogenize at a pressure of 1200 psi, the second stage adjusted to homogenize at a pressure of 500 psi.
2) To the resultant homogenized liquid blend A was now added the dispersion of the vanilla flavor in the solution of phospates and the whole stirred until thoroughly homogenous. Care was taken to ensure that the pH
of the resultant blend was a minimum of 6.55; if it was below this pH, di-sodium phosphate or other food-compatible pH adjuster was added to bring the pH up to this minimum.

3) The resultant liquid was now pumped through a continuous heating system with direct steam injection such that the temperature was raised to 142 C - 143 C and maintained at this temperature for 8 seconds.

4) The product was then immediately passed through a homogenizer set at 300 psi - 500 psi, rapidly cooled to 10 C by means of an in-line heat exchanger, and held in an aseptic surge tank.

5) Product from the aseptic surge tank was pumped into the aseptic packaging equipment and packed in units of 340 mL (12 oz).

[0104] The product which resulted was smooth and possesed excellent mouth feel, with no trace of grittiness. It remained fully liquid without any signs of gelation or sedimentation on storage at room temperature. The nutritional profile of the product thus obtained, per serving, was:

Protein 19.84 g (of which 9.72 g whey protein) Carbohydrate 21.39 Fat 8.14 g Kilocalories 226 [0105] In addition, each serving of the product provided 380 mg of potassium and the following percentages of the U.S. RDA for vitamins and minerals:

Vitamin A 15%
Vitamin C 15%
Calcium 30%
Iron 15%
Vitamin D 15%
Vitamin E 8%
Thiamin 20%
Riboflavin 25%
Niacin 30%
Vitamin B6 20%
Biotin 10%
Pantothenic acid 15%
Phosphorus 40%
Iodine 25%
Magnesium 20%
Zinc 20%
Selenium 15%
Copper 25%
Manganese 50%
Chromium 8%
Molybdenum 25%

Claims (37)

1. A method of making an aseptic liquid or semi-solid food product comprising at least 2% whey, said method comprising:

a) mixing protein with water at a temperature that does not denature said proteins and forming a liquid homogenous dispersion, wherein at least 2% of said protein is whey protein;

b) heating the dispersion of step a) without pressure, to a temperature that denatures said proteins and maintaining such temperature so as to ensure denaturation;

c) pumping the denatured mixture of b) first through a homogenizer at a pressure of about 1200 - 1500 psi and then through a homogenizer at a pressure to about 300 - 500 psi so as to homogenize said mixture;

d) cooling the homogenized mixture of c) and forming a uniform or homogenous mixture;

e) adding one or more flavors to said mixture;

f) heating the mixture of e) at a temperature from about 130° C to about 150° C for a period of time just long enough to render the mixture an aseptic liquid or semi-solid food product; and g) subjecting the product of f) to about 300 to about 500 psi so as to homogenize said aseptic liquid or semi-solid food product;

wherein the amount of whey protein is at least 2% of the aseptic liquid or semi-solid food product and wherein, after at least one of the above steps, phosphate with or without water is added to the mixture.

2. The method of claim 1, wherein said product lacks grittiness and sedimentation and has pleasing organoleptic properties.

3. The method of claim 1, wherein said whey protein is an integral part of another protein.

4. The method of claim 3, wherein said why protein is part of a milk protein isolate or a milk protein concentrate.

5. The method of claim 1, wherein the liquid homogenous dispersion of a) comprises 10 grams of milk protein isolate in 100 ml of water.

6. The method of claim 1, further comprising mixing in step a) one or more of carbohydrates or fats.

7. The method of claim 1, wherein said aseptic liquid or semi-solid food product has a shelf-life of 6 months or more, does not sediment on standing or storage during its shelf-life, does not exhibit gelation or significant changes in viscosity during its shelf-life, and retains pleasing organoleptic and textural properties during its shelf-life.

8. The method of claim 1, wherein said aseptic food product is a pudding.

9. The method of claim 8, further comprising the step of cooling the pudding and packaging cooled pudding in a container.

10. The method of claim 9, wherein said container comprises a thermoplastic material.

11. The method of claim 9, wherein said container is in single serving sized packages for ready consumption.

12. The method of claim 1, wherein the temperature in step f) is maintained from 2 to 40 seconds.

13. A packaged, aseptic pudding product produced according to the method of claim 8.

14. The method of claim 8, wherein said pudding has a shelf-life of 6 months or more, does not exhibit grittiness or sandy mouth feel on standing or storage during its shelf-life, does not exhibit gelation or significant changes in viscosity during its shelf-life, and retains pleasing organoleptic and textural properties during its shelf-life.

15. The method of claim 1, wherein a buffering agent is added prior to the final aseptic heating in order to increase shelf-life of product.

16. The method of claim 1, wherein vitamins or minerals are added to step (e).

17. A method of making an aseptic liquid or semi-solid food product comprising at least 2% whey, said method comprising:

a) mixing protein with water at a temperature that does not denature said proteins and forming a liquid homogenous dispersion, wherein at least 2% of said protein is whey protein;

b) heating the dispersion of step a) without pressure, to a temperature that denatures said proteins and maintaining such temperature so as to ensure denaturation;

c) pumping the denatured mixture of b) through a homogenizer at a pressure of from about 300 psi to 500 psi so as to homogenize said mixture; or alternatively, pumping the denatured mixture of c) first through a homogenizer at a pressure of about 1200 - 1500 psi and then through a homogenizer at a pressure to about 300 - 500 psi so as to homogenize said mixture;

d) cooling the homogenized mixture of c) and forming a uniform or homogenous mixture;

e) adding one or more flavors to said mixture;

f) heating the mixture of e) at a temperature from about 130° C to about 150° C for a period of time just long enough to render the mixture an aseptic liquid or semi-solid food product; wherein the amount of whey protein is at least 2%
of the aseptic liquid or semi-solid food product; and wherein phosphate with or without water is added to at least one of the above steps.

18. The method of claim 17, wherein said product lacks grittiness and sedimentation and has pleasing organoleptic properties.

19. The method of claim 17, wherein said whey protein is an integral part of another protein.

20. The method of claim 19, wherein said why protein is part of a milk protein isolate or a milk protein concentrate.

21. The method of claim 17, wherein the liquid homogenous dispersion of a) comprises 10 grams of milk protein isolate in 100 ml of water.

22. The method of claim 17, further comprising mixing in step a) one or more of carbohydrates or fats.

23. The method of claim 17, wherein said aseptic liquid or semi-solid food product has a shelf-life of 6 months or more, does not sediment on standing or storage during its shelf-life, does not exhibit gelation or significant changes in viscosity during its shelf-life, and retains pleasing organoleptic and textural properties during its shelf-life.

24. The method of claim 17, wherein said aseptic food product is a pudding.

25. The method of claim 24, further comprising the step of cooling the pudding and packaging cooled pudding in a container.

26. The method of claim 25, wherein said container comprises a thermoplastic material.

27. The method of claim 26, wherein said container is in single serving sized packages for ready consumption.

28. A packaged, aseptic pudding product produced according to the method of claim 24.

29. The method of claim 24, wherein said pudding has a shelf-life of 6 months or more, does not exhibit sandy or gritty mouth feel on standing or storage during its shelf-life, does not exhibit gelation or significant changes in viscosity during its shelf-life, and retains pleasing organoleptic and textural properties during its shelf-life.

30. The method of claim 17, wherein a buffering agent is added prior to the final heating in order to increase shelf-life of product.

31. The method of claim 17, wherein vitamins or minerals are added at step (e).

32. The method of claim 24, further comprising the step of adding a starch and water.

33. A method of directly delivering an aseptic liquid or semi-solid food product to a consumer, comprising:

a) preparing a aseptic liquid or semi-solid food product comprising at least 2% whey, the method comprising:

i) mixing protein with water at a temperature that does not denature the proteins and forming a liquid homogenous dispersion, wherein at least 2% of the protein is whey protein;

ii) heating the dispersion of step i) without pressure, to a temperature that denatures the proteins and maintaining such temperature, such as about 0 to 10 seconds, so as to ensure denaturation;

iii) pumping the denatured mixture of ii) first through a homogenizer at a pressure of about 1200 - 1500 psi and then through a homogenizer at a pressure to about 300 - 500 psi, so as to homogenize said mixture;

iv) cooling the homogenized mixture of iii) and forming a uniform or homogenous mixture;

v) adding one or more flavors to the mixture;

vi) heating the mixture of v) at a temperature from about 130° C to about 150° C for a period of time just long enough to render the mixture an aseptic liquid or semi-solid food product; and vii) subjecting the product of vi) to about 200 to about 500 psi so as to homogenize the aseptic liquid or semi-solid food product; wherein the amount of whey protein is at least 2% of the aseptic liquid or semi-solid food product and wherein said product lacks grittiness and sedimentation, has pleasing organoleptic properties and is ready to use; wherein, phosphate with or without water can be added at any of the above steps;

b) packaging the product of a); and c) opening the package of b) and delivering said product to the consumer.

34. The method of claim 33, wherein vitamins or minerals are added at step (v).

35. A method for preparing a protein mixture used in the manufacture of an aseptic liquid or semi-solid food product of at least 2% whey protein, comprising:

a) mixing protein with water at a temperature that does not denature said proteins and forming a liquid homogenous dispersion, wherein at least 2% of said protein is whey protein;

b) heating the dispersion of step a) without pressure, to a temperature that denatures said proteins and maintaining such temperature so as to ensure denaturation.

36. The method of claim 35, wherein the protein mixture is added to a solution of phosphate and water so as to form a uniform or homogenous mixture.

37. The method of claim 36, wherein a buffering agent is added to the protein mixture.