Process and systems for preparing nutritional compositions

Abstract

The present invention relates to a process for preparing a nutritional composition comprising the steps of: a) providing an aqueous composition comprising, by weight of said aqueous composition, at least 0.5 wt.% protein and at least 10 wt.% of a carbohydrate; b) providing a lipid composition; c) transferring the aqueous and lipid compositions of steps a) and b) to a combination point for forming a combined composition, wherein the aqueous composition of step a) is transferred to the combination point using a pump; d) mixing the combined composition in a mixing device to provide a mixed composition; e) drying the mixed composition to obtain a dried composition with a total solid of at least 85%, wherein the process does not comprise the use of a pump between step d) and the obtaining of the dried composition of step e). The present invention further relates to an industrial system suitable for carrying out the process according to the invention.

Description

[0001] PROCESS AND SYSTEMS FOR PREPARING NUTRITIONAL COMPOSITIONS

[0002] Technical Field of the invention

[0003] The present invention pertains to the field of food processing. In particular, the present invention relates to a process for manufacturing powdered nutritional compositions, such infant formula products, and to a system for performing the process according to the invention.

[0004] Background of the Invention

[0005] Powdered nutritional compositions containing a protein component, a fat component and a carbohydrate component are well known. They are intended to be reconstituted in a liquid prior to consumption with a liquid. Powdered nutritional compositions include infant formulae, growing-up milks and compositions used in clinical nutrition, for example for enteral feeding. Manufacture of said food products involves multi-step, complex, often continuous processes which require the highest sanitary and quality control standards in the production line.

[0006] Conventionally, such products are manufactured by mixing all the ingredients in optionally sterilized liquid phases, homogenising / emulsifying the mixture and subjecting the emulsion to drying techniques, such as spray-drying. The flows of the liquid phases, their mixtures and emulsions are commonly operated and controlled by multiple pumps in different steps of the process.

[0007] WO2015036464 describes a process of obtaining spray-dried infant formula compositions with large, phospholipid coated lipid globules. The process comprises adding a vegetable oil blend to a water phase in a w / w ratio of between 15 to 30 by injection and a centrifugal booster pump, feeding it into an inline mixer where the aqueous and fat phase were mixed with a tip speed of 20 to 50 m / s and thereafter pumped with a positive displacement pump, a mono pump, with a pressure of about 8 bar to the heater. The oil in water mixture was then fed via the concentrate heater to the spray dryer driven by the pump used downstream of the inline mixer (Fig. 1).

[0008] WO2015036466 describes processes of preparing infant formulae products with large, phospholipid coated lipid globules. The process described therein involves mixing a fat phase into an aqueous phase, premixing with a Typhoon propeller mixer, transferring the pre-emulsion to a static mixer where the aqueous and fat phase were thoroughly mixed by pumping the preblended mixture through the static mixer with different flows in order to emulsify the lipid phase into the aqueous phase (Fig. 1). Figure 2 discloses that the obtained emulsion may be subsequently spray dried.

[0009] WO2016146496 relates to a process of preparing an infant formula using a 2-step emulsification process. The process comprises pumping an aqueous phase and an oil phase, premixing with a Typhoon propeller mixer, feeding the pre-emulsion into a stator rotor machine having a tip speed of 7 to 15 m / s and a slit width of less than 1 mm. After the first emulsification step, the product was pumped into a second emulsification step using pneumatic atomizers (2F) at 3 to 4 bar of air pressure, followed by spray-drying (Figure).

[0010] There remains a need for improved, simplified, yet robust processes and systems that allow meeting the required quality standards of medical and infant nutrition production, while reducing the amount of machinery in the production line.

[0011] Summary of the Invention

[0012] The present inventors have developed a process for the manufacture of powdered nutritional compositions, such as infant formulae, which requires less machinery, thereby representing a more efficient and robust alternative manufacture, without any impact in the processing efficiency and quality of the final product.

[0013] Accordingly, in a first aspect, the invention relates to a process for preparing a nutritional composition comprising the steps of: a) providing an aqueous composition comprising, by weight of said aqueous composition, at least 0.5 wt.% protein and at least 10 wt.% of a carbohydrate; b) providing a lipid composition; c) transferring the aqueous and lipid compositions of steps a) and b) to a combination point for forming a combined composition, wherein the aqueous composition of step a) is transferred to the combination point using a pump; d) mixing the combined composition in a mixing device to provide a mixed composition; e) drying the mixed composition to obtain a dried composition with a total solid of at least 85%, wherein the process does not comprise the use of a pump between step d) and the obtaining of the dried composition of step e).

[0014] Surprisingly, it has been observed that the product features are unchanged as compared to a reference process. Also, the flow rate of the product throughout the whole process and hence the production per time unit appears to be totally unaffected. Another benefit of the present invention lies in the precise control of the water entering the drying steps. Removing the pump(s) between the combination point of the aqueous and lipid compositions and the homogenization step, and further removing the pump(s) from the homogenization towards the drying steps effectively enables a precise operation and direct control of the amount of water into the system assuming constant dry matter content in the aqueous phase. Controlling the amount of water into the system is particularly beneficial in the drying step because matching the evaporation capacity - removing the water fed to the dryer - is a key parameter to achieve a stable dryer operation resulting also in constant product properties.

[0015] Advantageously, the processes and systems according to the invention enable to control the preparation of the compositions of high sanitary standards in an optimized way, by reducing the number of machines, without compromising the quality, therefore representing a robust alternative to equivalent processes and systems of the art. More equipment means more points of introduction of undesired contaminations, and more points where an operator needs to adjust and to perform maintenance activities. Since the use of certain type of energy-consuming pumps is rendered redundant, the invention further enables a more economical and environmental-conscious production of food compositions.

[0016] The presence of pumps as a last element priorto the dryer, as described in the state of the art, is alleged to ensure the control of the feed into the dryer. The present inventors however have developed a robust process wherein the pump to control the feed into the dryer has become obsolete, whereas the process runs in the same parameters and the obtained composition retains the same features as when the pump is used. In addition to reducing the number of pumps required in the manufacturing line, which has self- evident benefits, the process and the system are not restricted to any type of pump used upstream the injection point. For instance, when using pumps with viscosity dependent slip, less variation is achieved and better control of feed to dryer, related to varying viscosity being dependent on e.g. fat globule size, being in turn dependent on flow through inline mixer (residence time / shear).

[0017] In the absence of pumps as a last element prior to the dryer, in some instances one or more pumps are introduced more upstream in the process before the combination point, e.g. for pumping the aqueous composition towards the combination point. This is advantageous, as the handling of the mixed composition requires gentle processing to keep the 3D structure (i.e. the lipid globule size and the lipid globule coating) of the combined or mixed composition intact, while this does not apply to the handling of the aqueous phase. This offers more freedom to choose any type of pump for the processing of the aqueous phase.

[0018] The invention further relates to an industrial system configured to prepare dried nutritional compositions, the system comprising: at least a first and a second device for providing a first and a second nutritional composition, respectively, wherein the first and the second devices have at least one outlet for transferring the first and the second nutritional compositions from the devices towards a combination point; at least a first pump between the first device and the combination point and at least a second pump between the second device and the combination point; a combination point for receiving the first and the second nutritional compositions for providing a combined nutritional composition; a mixing device for mixing the combined nutritional composition, the mixing device comprising at least one inlet for receiving the combined nutritional composition and an outlet for providing the mixed nutritional combination to a dryer; and a dryer for drying the mixed nutritional composition into a dried nutritional composition, wherein no pump is present in the system between the mixing device and the outlet of the dryer. Detailed Description of the Invention

[0019] In a first aspect, the present invention relates to a process for preparing a nutritional composition comprising the steps of: a) providing an aqueous composition comprising, by weight of said aqueous composition, at least 0.5 wt.% protein and at least 10 wt.% of a carbohydrate; b) providing a lipid composition; c) transferring the aqueous and lipid compositions of steps a) and b) to a combination point for forming a combined composition, wherein the aqueous composition of step a) is transferred to the combination point using a pump; d) mixing the combined composition in a mixing device to provide a mixed composition; e) drying the mixed composition to obtain a dried composition with a total solid of at least 85%, wherein the process does not comprise the use of a pump between step d) and the obtaining of the dried composition of step e).

[0020] Nutritional compositions prepared by the process of the invention are selected from infant formula, follow-on formula, growing up milk, fortified milk, food supplements, maternal supplements, protein powders / supplements, milk-based nutritional supplements, meal replacements (such as, shakes), compositions for clinical and medical nutrition (e.g., enteral compositions or tube feeding compositions upon reconstitution) and the like. Preferably, the nutritional composition is selected from infant formula, follow-on formula or growing up milk.

[0021] In the context of the present invention, the term “protein” refers to proteinaceous matter in general, which includes proteins, peptides, free amino acids but also compositions comprising proteins, peptides and / or free amino acids, i.e. sources of protein. Proteins based on cow's milk proteins such as whey protein, casein and mixtures thereof and proteins based on soy, rice, rapeseed, potato or pea are herein preferred. In case whey proteins are used, the protein is preferably based on acid whey or sweet whey, whey protein isolate or mixtures thereof and may include a-lactalbumin and p-lactoglobulin.

[0022] “Carbohydrate”, as used herein, includes at least one of digestible carbohydrates, non-digestible carbohydrates, vitamins, in particular water-soluble vitamins, trace elements and minerals. Preferred digestible carbohydrate sources are lactose, glucose, sucrose, fructose, galactose, maltose, starch and maltodextrin. Lactose is the main digestible carbohydrate present in human milk. Lactose advantageously has a low glycaemic index. The digestible carbohydrate component preferably comprises lactose. Preferred non-digestible carbohydrates include inulin, oligofructose, galactooligosaccharides, fructooligossacharides, and the like.

[0023] The term “lipid” or “total lipid” as used herein refers to one or more selected from the group consisting of triglycerides, polar lipids (such as phospholipids, glycosphingolipids and cholesterol), free fatty acids, monoglycerides and diglycerides. “Lipid” or “fat” as used herein are synonyms and used interchangeably. The terms “globules” and “droplets” as used herein are synonyms and used interchangeably. Fats (animal fats, e.g. milk fat) and oils (e.g. vegetable oils, such as sunflower oil) are thus herein considered encompassed by the term lipid.

[0024] As used herein, “combination point” refers to a point in the manufacturing process where the aqueous and the lipid compositions are combined. For instance, the combination point may be an intermediate vessel, device, apparatus, piping, tube, transfer line or the like configured to receive the aqueous and the lipid composition and, after which, the aqueous and the lipid compositions are transferred into further process steps as a combined, single composition, irrespective of the homogeneity of its phases. Accordingly, the combination point may be a point in e.g., the piping of the aqueous composition in which the lipid composition is added, or vice-versa. Alternatively, the aqueous and / or the lipid compositions may be transferred from their respective piping towards a combination point that is located in a piping suitable to receive the aqueous and the lipid compositions and transfer the combined composition to the subsequent process steps, e.g. the mixing step.

[0025] As used herein, a “pump” is an equipment that transforms the mechanical energy it absorbs from an electric, thermal or other kinds of motor, and transfers it to a fluid as hydraulic energy. This allows the fluid to be transported from one place to another, on one level or different levels.

[0026] Assemblies and devices as described herein but not otherwise specified may be used in combination with one or more fluid processing passageways including one or more elements, for example, one or more of a channel, a branch channel, a valve, a flow splitter, a vent, a port, an access area, a via, or any combinations thereof. Any element may be in fluid communication with another element.

[0027] As used herein, “fluid communication” means either direct fluid communication, for example, two regions can be in fluid communication with each other via an unobstructed fluid processing passageway connecting the two regions or indirect fluid communication. Indirect fluid communication refers to fluid processing passageway which is capable of being in fluid communication, for example, two regions can be capable of fluid communication with each other when they are connected via a fluid processing passageway that can comprise a valve disposed therein, wherein fluid communication can be established between the two regions upon actuating the valve, for example, by dissolving a dissolvable valve, bursting a burstable valve, or otherwise opening a valve disposed in the fluid processing passageway.

[0028] Process steps

[0029] The process comprises the step a) of providing an aqueous composition comprising, by weight of the aqueous composition, at least 0.5 wt.% protein and at least 10 wt.% carbohydrate. To prepare the aqueous composition, also called “compounding of the aqueous phase”, protein(s) and carbohydrate(s) and optional further components are compounded in an aqueous phase, in particular an aqueous medium, preferably water. For this, protein and carbohydrates as well as all other optional components may be in a dry state or present as solutions or suspensions. The aqueous composition of step a) may be provided from an assembly or device suitable for preparing and / or holding the aqueous composition to be provided to the combination point of step c). Suitable assemblies or devices include vessels, pipes, tanks, and the like. Preferably, the assembly or device is connected to a pump for providing the aqueous composition of step a) to the combination point of step c).

[0030] In a preferred embodiment, the aqueous composition is transferred towards the combination point using a pump. Advantageously, the process according to the invention allows full flexibility as to the selection of the type of pump. Suitable pumps according to the invention include, but are not limited to, centrifugal pump, positive displacement pump, such as high pressure pump, gear pump, membrane pump, piston pump, helical pump, liquid ring vacuum pump, peristaltic pump, lobe pump, Mohno pump, flexible impeller pump, rotary pump, etc. In some embodiments, the pump is a low shear pump. In other embodiments, the pump is a high shear pump.

[0031] In a preferred embodiment, the aqueous composition comprises, by weight of the aqueous composition, at least 0.5 wt.% protein, more preferably 0.8 wt.% protein, even more preferably, at least 1 wt.% protein. The amount of protein added in the aqueous composition preferably represents at least 50 wt.% of the total protein in the nutritional composition obtained by the present process, more preferably at least 80 wt.%, even more preferably 100 wt.% of the total protein in the nutritional composition obtained by the process of the invention.

[0032] Based on dry weight, the nutritional composition obtained by the process of the invention in step e) preferably comprises less than 12 wt.% protein, more preferably between 9 and 12 wt.%, most preferably between 9.5 and 11 wt.% protein.

[0033] The amount of carbohydrates added in the aqueous composition preferably represents at least 20 wt.% of the total carbohydrates in the nutritional composition obtained by the present process, more preferably at least 40 wt.%, even more preferably at least 80 wt.% of the total carbohydrates in the nutritional composition obtained by the process of the invention.

[0034] The nutritional composition of the invention preferably comprises digestible carbohydrates. Based on dry weight, the nutritional composition obtained by the process of the invention in step e) preferably comprises 20 to 80 wt.%, more preferably 40 to 65 wt.% digestible carbohydrates.

[0035] In some embodiments, part of the carbohydrates are added in the aqueous composition and part of the carbohydrates are added in the dry blending step after the obtaining of the dried composition from the drying step of the process of the invention (step e). Accordingly, in one preferred embodiment, carbohydrates are partly dry blended into the dried composition. In some embodiments, the aqueous composition comprises, by total weight of the aqueous composition, 5-75 wt.% total solids, more preferably 10-60 wt.%, even more preferably 15-55 wt.%, most preferably 20-50 wt.% total solids.

[0036] The process comprises step b) of providing a lipid composition. The lipid composition of step b) may be provided from an assembly or device suitable for preparing and / or holding the lipid composition to be provided to the combination point of step c). Suitable assemblies or devices include vessels, pipes, tanks, and the like. Preferably, the assembly or device comprises or can be connected to, preferably is connected to, a pump for providing the lipid composition of step b) to the combination point of step c).

[0037] In a preferred embodiment, the lipid composition is transferred towards the combination point using a pump as herein defined. Preferably, the pump is selected from a dosing pump, Mohno pump or a lobe pump.

[0038] In one preferred embodiment, the lipid composition of step b) is transferred into the aqueous composition of step a), more preferred the lipid composition of step b) is injected into the aqueous composition of step a).

[0039] In a preferred embodiment of the present invention the lipid composition is added into the aqueous composition using low pressure, preferably at most 10 bar, more preferably at most 8 bar. Preferably, a dosing pump is used and low pressure is applied, in particular the pressure is lower than the pressure drop applied by the subsequent mixing step d).

[0040] The lipid composition may comprise at least a vegetable lipid, at least an animal lipid or the combination thereof. Preferably part of the animal fat, that means lipid, is milk fat, more preferably anhydrous milk fat, MFGM and / or butter oil. Commercially available lipids, preferably vegetable lipids, for use in the present invention preferably are in the form of a continuous oil phase. Preferably, the lipid composition comprises further components such as fat-soluble vitamins.

[0041] In a preferred embodiment, the lipid composition comprises 30 to 100 wt.% vegetable lipids based on total lipids, more preferably 50 to 100 wt.% based on total lipids. Preferably, the lipid composition comprises at least 75 wt.%, more preferably at least 85 wt.% triglycerides based on total lipids.

[0042] In some embodiments, the lipid composition comprises polar lipids, preferably phospholipids, in particular comprises added polar lipids. In a preferred embodiment, the polar lipids are added into the aqueous or the lipid composition or both provided in steps a) or b) of the present process. Polar lipids may alternatively or additionally be added during process step c) during mixing of the lipid and the aqueous phase.

[0043] Preferably, a phospholipid-delivering material is added to the aqueous composition of step a) or lipid composition of step b), preferably in an amount such that the amount of phospholipids is between 0.5 and 20 wt.% on total lipid weight of the nutritional composition. The phospholipid-delivering material is selected from MFGM, lecithin, whey protein concentrate, butter serum, milk fat, butter oil, etc.

[0044] According to the present invention, it is preferred that the lipid composition is liquid at the temperature(s) used during the process. However, if the lipid composition is solid due to its composition it is preferably heated to above the melting temperature of the at least one lipid, preferably vegetable lipid, contained in the lipid phase. In a particularly preferred embodiment of the present invention, the lipid composition is heated to a temperature above its melting point, preferably to a temperature of 40 to 80 °C, preferably 50 to 70 °C, more preferably to 55 to 60 °C thereby resulting in a liquid lipid composition. Most preferably, the lipid composition is heated to a temperature of at least 40 °C, preferably at least 45 °C, more preferably at least 50 °C, most preferably to at least 55 °C. If required, the lipid composition is preferably filtered by appropriate filtration devices prior to the next step, preferably step c), to prevent foreign bodies, for instance impurities or pathogens, from entering the production process.

[0045] The nutritional composition obtained by the present process preferably comprises 2.1 to 6.5 g lipids per 100 ml, more preferably 3.0 to 4.0 g per 100 ml, when in liquid form, for instance as a ready-to-feed liquid or, if spray-dried, reconstituted with water. Based on dry weight, the composition obtained by the present process preferably comprises 10 to 50 wt.%, more preferably 12.5 to 40 wt.%, preferably 19 to 30 wt.% lipids.

[0046] In some embodiments, the process according to the invention comprises a concentration step, preferably a concentration step wherein the aqueous composition is concentrated, more preferably a falling film evaporator is used in the concentration step. In a preferred embodiment, the concentration step is carried out before the combination point, more preferably between compounding of the aqueous composition as herein defined and the combination point.

[0047] Heating may be required for better dissolution of the ingredients of the aqueous, lipid or combined compositions. Accordingly, in some embodiments, the process according to the invention comprises a heating treatment. Preferably, the heating treatment is carried out before the combination point, more preferably between compounding of the aqueous composition and the combination point. Additional or alternative heating treatment may be carried out downstream the process, such as between the mixing and the drying steps.

[0048] The process comprises the step c) of transferring the aqueous and lipid compositions of steps a) and b) to a combination point, wherein the aqueous and the lipid compositions obtained in steps a) and b) are combined thereby forming a combined composition and wherein one or both compositions obtained in steps a) and b) are pumped to said combination point. The aqueous composition of step a) is transferred to the combination point using a pump. The aqueous and the lipid compositions are individually transferred towards the combination point. Accordingly, in a preferred embodiment, at least one of the aqueous and the lipid composition of steps a) and b) are in fluid communication with the combination point of step c). Fluid communication as herein defined may be direct or indirect fluid communication. Examples of indirect fluid communication include batch production of the aqueous and / or lipid compositions of steps a) and / or b) with subsequent transfer towards the combination point of step c). In some embodiments, at least one of the aqueous and the lipid composition of steps a) and b) are in direct fluid communication with the combination point of step c).

[0049] Preferably, the aqueous composition of step a) and the lipid composition of step b) are individually transferred to the combination point using a pump. The pumps used in the individual transfer of the aqueous composition of step a) and the lipid composition of step b) to the combination point may be the same or different. Preferably, at least one of the pumps in step c) comprises a dosing pump or an injector pump.

[0050] In some embodiments, the combination point is an injection point. Accordingly, in one embodiment, the lipid composition is combined with the aqueous composition via an injection point of the lipid composition into the aqueous composition.

[0051] In the process according to the invention, no pump is used downstream the mixing device, i.e., the mixed composition is not pumped from the mixing device to the subsequent process steps such as the drying step.

[0052] The lipid and the aqueous compositions are combined in the combination point, preferably at a weight ratio between 0.1 :1 to 2:1 , such as at least 0.1 :1 , preferably 0.3:1 , more preferably 0.5:1 , even more preferably 0.8:1 , most preferably 1 :1. In some embodiments, the combined composition comprises based on dry matter, 5 - 55 wt.% lipid, preferably 8-50 wt.% lipid, more preferably 10-45 wt.% lipid.

[0053] The process comprises the step d) of mixing the combined composition, i.e., the compositions formed by the combination of the aqueous and the lipid compositions in the combination point, in a mixing device to provide a nutritional composition.

[0054] In a preferred embodiment, the aqueous composition, the lipid composition or most preferably the combined composition are heated to a temperature from 40°C to 90°C, preferably 50°C to 80°C, most preferably to about 70°C, prior to the mixing step, and optionally prior to the pre-homogenization step preceding the mixing step d).

[0055] The mixing step d), also referred to homogenization or emulsification step, is performed in a mixing device. The mixing step d) may be a single step or a series of at least 2 sequential mixing steps. In one preferred embodiment, the process comprises subjecting the aqueous composition, the lipid composition and / or the combined composition to a pre-homogenization step followed by the mixing step d), preferably the combined composition. The pre-homogenization step is preferably carried out under low shear force and / or at least a shear force that is at least 10%, more preferably at least 30% lower than the shear force applied during the mixing step d).

[0056] Any mixing devices may be suitably used in the optional pre-homogenization step and in the mixing step d). Preferred mixing devices for the process according to the invention include a batch mixer, an inline mixer, a rotor stator machine, a cavitator, a membrane emulsification system, a static mixer, more preferably mixing devices for the process include static mixer, inline mixer and / or a rotor stator machine. In a preferred embodiment, the mixing device of the mixing step d) comprises a rotor stator machine, more preferably an in-line mixer. In some embodiments, the mixing device comprising a rotor stator machine is typically operated at a tip speed of 8-30 m / s and having a slit width of less than 1 mm.

[0057] As used herein, “inline mixer” can refer to a mixer, which comprises a housing, an inlet, an outlet and at least one mixing head comprising at least one stator and at least one rotor, wherein the housing is configured and formed in a way to force substantially all, preferably all, of the fluid to be mixed through the at least one mixing head. Preferably, the lipid composition is added or injected into the aqueous composition shortly before entering the inline mixer, i.e., the combination point is located shortly before the inline mixer.

[0058] In some embodiments, no pre-homogenization is applied. Pre-homogenization may thus be limited to the combination point, where the aqueous and the lipid compositions are combined without a pre-mixer or pre-homogenizer.

[0059] According to some embodiments, the combined composition is mixed in process step d) in a very mild and controlled way so as to obtain lipid globules with a particle size larger, particularly slightly larger than the desired particle size to be finally obtained in the composition to be prepared by the overall process. Accordingly, in one embodiment of the invention, the process is for preparing a composition comprising lipid globules, wherein less than 10 vol.% of the lipid globules have a diameter of >12 pm and / or wherein the lipid globules have a volume-weighted mode diameter from 2.5 - 7 pm.

[0060] In the process according to the invention, the nutritional composition is transferred from the mixing step to the drying step preferably at a total target flow of at least 300 l / h, more preferably at least 400 l / h, for instance, 450 - 800 l / h. The total target flow of the nutritional composition transferred from the mixing step to the drying step is of at least 1 ton / hour, more preferably at least 5 ton / hour, even more preferably at least 10 ton / hour, for instance preferably from 15 ton / hour. In one embodiment, the total target flow of the nutritional composition transferred from the mixing step to the drying step is 1 to 35 ton / hour. The process comprises the step e) of drying the nutritional composition to obtain a dried composition with a total solid of at least 85%, preferably at least 90%, more preferably at least 95%, wherein preferably no pump is employed downstream the combination point of step c) to the obtaining of the dried composition of step e), more preferably wherein no pump is employed between step d) and the obtaining of the dried composition of step e) and most preferably wherein no pump is employed between step d) and step e). Accordingly, in the process according to the invention, no pump is used to control the feed of the nutritional composition obtained in step d) to the drying step e), in particular, to the dryer of the drying step e).

[0061] The drying step is preferably a spray-drying step or a belt-drying step, more preferably a spray-drying step. Preferably, the inlet temperature employed in the atomizer, preferably the spray dryer, is from 150 to 230 °C, preferably from 160 to 220°C and preferably 170 to 210 °C.

[0062] The combined composition, i.e., before the mixing step, or the mixed composition is typically a solution, slurry, emulsion, gel or paste.

[0063] Preferably, drying is performed with a rotary atomizer, also called a wheel or a disc atomizer. The atomizer may be a high shear or low shear atomizer. In some embodiments, the atomizer is a low shear atomizer suitable for preserving large lipid globules of the lipids in the nutritional composition.

[0064] In one preferred embodiment, spray drying is performed using a rotary atomizer, also called wheel atomizer, or a pneumatic atomizer, preferably a two-fluid atomizer. Two-fluid atomizers (2F atomizer) are commercially available. According to one embodiment, spray-drying is carried out using a pressure of at least 100 bar, more preferably at least 150 bar, even more preferably at least 200 bar. In another embodiment, spray-drying is carried out using a pressure of at most 10 bar, preferably at most 8 bar.

[0065] In a preferred embodiment, the nutritional composition of step d) is dried using a spray drying, preferably using a pneumatic atomizer, more preferably using a two-fluid pneumatic atomizer.

[0066] In one embodiment, drying is performed using a rotary atomizer having a wheel diameter of 100 to 250 mm, preferably of 100 to 150 mm, more preferably of 120 mm. In a furthermore preferred embodiment of the present invention the rotary atomizer is operated with a tip speed of the wheel from 50 to 120 m / s, preferably from 60 to 100 m / s, more preferably from 65 to 95 m / s, most preferred from 70 to 90 m / s. In a preferred embodiment of present invention, the rotational speed employed in the rotary atomizer, hereinafter also termed wheel speed, is from 10000 to 15000 rpm (rotations per min), preferably 11000 to 14000, preferably 1 1000 or 14000 rpm.

[0067] In some embodiments, the dried nutritional composition comprises lipid globules having a volume- weighted mode diameter of at least 1 .0 urn, and / or wherein at least 40 vol% of the lipid globules has a diameter of between 2 and 12 urn. A second aspect of the invention relates to an industrial system configured to prepare dried nutritional compositions, the system comprising: at least a first and a second device for providing a first and a second nutritional composition, respectively, wherein the first and the second devices have at least one outlet for transferring the first and the second nutritional compositions from the devices towards a combination point; at least a first pump between the first device and the combination point and at least a second pump between the second device and the combination point; a combination point for receiving the first and the second nutritional compositions for providing a combined nutritional composition; a mixing device for mixing the combined nutritional composition, the mixing device comprising at least one inlet for receiving the combined nutritional composition and an outlet for providing the mixed nutritional combination to a dryer; and a dryer for drying the mixed nutritional composition into a dried nutritional composition, wherein no pump is present in the system between the mixing device and the outlet of the dryer.

[0068] An alternative preferred embodiment is an industrial system for preparing dried nutritional compositions, the system comprising: at least a first and a second device for providing a first and a second composition, respectively, wherein the first and the second devices have at least one outlet for transferring the first and the second compositions from the devices towards a combination point; a combination point for receiving the first and the second compositions for providing a combined composition; a mixing device to mix the combined composition, the mixing device comprising at least one inlet for receiving the combined composition and an outlet for providing the mixed combination to a dryer; and a dryer for drying the mixed composition into a dried nutritional composition, wherein no pump is present in the system between the combination point and the outlet of the dryer.

[0069] Preferably, the system is suitably configured to carrying out the process according to the invention. Accordingly, the first and the second compositions are preferably the aqueous and the lipid compositions as herein defined. All definitions and embodiments apply mutatis mutandis.

[0070] The nutritional compositions preferably have a caloric density of at least 200 kcal per 100 gram dry matter, more preferably a caloric density of 300-1000 kcal per 100 gram dry matter and most preferably 350 kcal-900 kcal per 100 gram dry matter.

[0071] In a preferred embodiment, the mixing device is a low shear device, more preferably a rotor-stator- system and most preferably an in-line mixer. Preferably, the outlets of the first and the second devices are in fluid communication with the combination point. Preferably, the combination point is in fluid communication with the mixing device, more preferably direct fluid communication. The mixing device may also be in fluid communication, preferably direct fluid communication, with the dryer.

[0072] In a preferred embodiment, the dryer is a spray dryer, more preferably a spray dryer comprising a low shear atomizer. A suitable example of a low shear atomizer is a pneumatic or rotary atomizer. The spray dryer preferably comprises at least one inlet for receiving the mixed nutritional composition and at least one outlet for providing the dried nutritional composition.

[0073] EXAMPLES

[0074] Reference Example 1 (not according to the invention)

[0075] An infant formula was prepared in line with the process described in WO2016146496. The final infant formula was a powder comprising, per kg of final product, about 4910 kcal, about 260 g lipid, about 510 g digestible carbohydrates, about 40 g non-digestible oligosaccharides and about 120 g protein. The composition was prepared using whey protein concentrate, skim milk powder, lactose, a vegetable oil blend (fat) and non-digestible oligosaccharides. Also vitamins, minerals, trace elements as known in the art were used.

[0076] An aqueous phase comprising protein, digestible carbohydrates and the other ingredients, except the fat and fat-soluble vitamins, was prepared by state of the art techniques. The dry matter content of the aqueous phase was around 44 wt.%. The aqueous phase was pasteurized for 30 seconds at 85 °C.

[0077] A fat phase was prepared by state of the art techniques, heated to 60 °C and added to the aqueous phase in a w / w ratio of around 13 / 87 and premixed with a Typhoon propeller mixer. The total solid content of the fat and aqueous phase mixture was around 52 wt.%. The pre-emulsion was fed by a pump to a rotor stator machine (IKA) operating a tip speed of 14.5 m / s and having a slit width of less than 1 mm. The resulting emulsion was collected in a tank.

[0078] Subsequently, the emulsion was fed to a pneumatic atomizer (2F) operating at 4 bar air pressure using a Mohno pump (1A). In a second experiment, the emulsion was fed to the pneumatic atomizer (2F) operating at 4 bar air pressure using a lobe pump (1 B). In either case, target flow was 620 l / h. The setup is illustrated in Figure 1 .

[0079] Fat globule size distribution was measured for samples collected after atomization. Measurements were executed using a Malvern Mastersizer 2000 (Table 1 below). Example 2

[0080] An infant formula was prepared according to the process of the invention. The final infant formula was a powder comprising per kg final product about 4910 kcal, about 260 g lipid, about 510 g digestible carbohydrates, about 40 g non-digestible oligosaccharides and about 120 g protein. The composition was prepared using whey protein concentrate, skim milk powder, lactose, a vegetable oil blend (fat) and non-digestible oligosaccharides. Also vitamins, minerals, trace elements as known in the art were used.

[0081] An aqueous phase comprising protein, digestible carbohydrates and the other ingredients, except the fat and fat-soluble vitamins, was prepared by state of the art techniques. The dry matter content of the aqueous phase was around 45 wt.%. The aqueous phase was pasteurized for 30 seconds at 85 °C.

[0082] A fat phase was prepared by state of the art techniques, heated to 60 °C and injected into the flow of the aqueous phase at a w / w ratio of around 13 / 87. The total solid content of the fat and aqueous phase mixture was around 52 wt.%. The two phases were individually pumped towards the injection point and conveyed into a rotor stator machine. The aqueous phase is pumped towards the injection point by a Mohno pump in one experiment (2A) or using a lobe pump in another (2B). No pump was employed between the injection point and the inlet of the rotor stator machine. The rotor stator machine (IKA) was operated at a tip speed of 14.5 m / s and had a slit width of less than 1 mm. The resulting emulsion was fed at a total target flow of 620 l / h to a pneumatic atomizer (2F) operating at 4 bar air pressure. Pressure of the feed flow to the pneumatic atomizer was also recorded. No pump is located between the homogenizer (i.e. the rotor-stator machine) and the dryer. The set-up is illustrated in Figure 2.

[0083] Fat globule size distribution was measured for samples collected after atomization. Measurements were executed using a Malvern Mastersizer 2000 (Table 1).

[0084] Table 1

[0085] Comparing the reference examples (Ex. 1A and 1 B) with the processes according to the invention (Ex. 2A and 2B), it is observed that the processes according to the invention without a Mohno pump (MP) or the lobe pump (LP) between the combination point and the drying step allows obtaining of an identical product.

[0086] For both (ex. 1 A-B and 2A-B), industrial scale production led to similar results (data not shown). Example 3

[0087] Nutritional composition in powder form. After reconstitution of 14.8 g powder with water to 100 ml to form a ready to drink formula, a composition obtainable by the process according to the invention, comprises per 100 ml: - 67 kcal

[0088] 1 .3 g protein (milk protein)

[0089] 3.4 g lipids (mainly vegetable lipids)

[0090] 7.3 g digestible carbohydrates (mainly lactose)

[0091] 1.15 g mixture of non-digestible saccharides, comprising GOS (source VivinalGOS) and inulin (source RaftilinHP) about 108cfu probiotics vitamins, minerals as known in the art for the provision of infant formulae.

Claims

CLAIMS1 . A process for preparing a nutritional composition comprising the steps of: a) providing an aqueous composition comprising, by weight of said aqueous composition, at least 0.5 wt.% protein and at least 10 wt.% of a carbohydrate; b) providing a lipid composition; c) transferring the aqueous and lipid compositions of steps a) and b) to a combination point for forming a combined composition, wherein the aqueous composition of step a) is transferred to the combination point using a pump; d) mixing the combined composition in a mixing device to provide a mixed composition; e) drying the mixed composition to obtain a dried composition with a total solid of at least 85%, wherein the process does not comprise the use of a pump between step d) and the obtaining of the dried composition of step e).

2. The process of claim 1 , wherein the aqueous composition of step a) and the lipid composition of step b) are provided from an assembly or device suitable for preparing and / or holding the compositions, preferably wherein the assembly or device is in fluid communication with the combination point.

3. The process of claim 1 or 2, wherein the aqueous composition of step a) and the lipid composition of step b) are individually transferred to the combination point using a pump.

4. The process of any one of the preceding claims, wherein the lipid composition of step b) is added into the aqueous composition of step a).

5. The process of any one of claims 3 or 4, wherein the lipid composition of step b) is added into the aqueous composition of step a) using a pump, preferably wherein the pump comprises a dosing pump or an injector pump.

6. The process of any one of the preceding claims, wherein the mixing device comprises a rotor- stator-machine, preferably an in-line mixer.

7. The process of any one of the preceding claims, wherein the mixed composition of step d) is dried using a spray dryer.

8. Process of any one of the preceding claims, wherein the process comprises subjecting the combined composition to a pre-homogenization step followed by the mixing step d).

9. The process of any one of the preceding claims, wherein the process comprises a concentration step, preferably wherein the concentration step is carried out before the combination point.

10. The process of any one of the preceding claims, wherein the process comprises a heating treatment, preferably before the combination point.11 . Process of any one of the preceding claims, wherein a phospholipid-delivering material is added to the aqueous composition of step a) or lipid composition of step b), preferably in an amount such that the amount of phospholipids is between 0.5 and 20 wt.% based on total lipid weight.

12. Process of any one of the preceding claims, wherein the dried nutritional composition comprises lipid globules having a volume-weighted mode diameter of at least 1 .0 urn, and / or wherein at least 40 vol% of the lipid globules has a diameter of between 2 and 12 urn.

13. An industrial system configured to prepare dried nutritional compositions, the system comprising: at least a first and a second device for providing a first and a second nutritional composition, respectively, wherein the first and the second devices have at least one outlet for transferring the first and the second nutritional compositions from the devices towards a combination point; at least a first pump between the first device and the combination point and at least a second pump between the second device and the combination point; a combination point for receiving the first and the second nutritional compositions for providing a combined nutritional composition; a mixing device for mixing the combined nutritional composition, the mixing device comprising at least one inlet for receiving the combined nutritional composition and an outlet for providing the mixed nutritional combination to a dryer; and a dryer for drying the mixed nutritional composition into a dried nutritional composition, wherein no pump is present in the system between the mixing device and the outlet of the dryer.

14. The system according to claim 13, wherein the nutritional compositions have a caloric density of at least 200 kcal per 100 gram dry matter.

15. The system according to claim 13 or 14, wherein the system is configured to perform the process according to any one of claims 1-12.

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