Method for refining whey in order to prepare source material for milk product and a milk product with reduced casein content using whey as source material

Abstract

Heat treatment of whey or whey concentrate and separation (precipitation) of lean whey from the protein curd and partially reintroducing lean whey into it during pressure homogenisation of the resulting mixture produces a uniform, homogeneous, emulsion like liquid protein mass, which is the source material to produce different milk products.

Description

[0001] Method for refining whey in order to prepare source material for milk product and a milk product with reduced casein content using whey as source material

[0002] Technical field

[0003] The invention pertains to the dairy industry and involves a method for adding value to whey and producing a milk product with reduced casein content from whey, including acidified milk products.

[0004] Prior Art

[0005] The dairy industry generates significant quantities of whey as a by-product during cheese manufacture, which presents a challenge for economically viable repurposing. Whey (greenish-yellow liquid), is a by-product obtained when, during the manufacture of cheese, milk coagulates and casein (milk protein) is separated. For example, the production of one kilogram of cheese yields about 8 to 10 litres of (cheese) whey. Conventionally, excess whey is processed into whey powder (used as animal feed or also used as protein-rich food supplements (athletes use it in the form of so-called power powder)) or surplus lean whey may be used to produce biogas. The latter is not economically optimal for the recovery of whey and it makes sense to refine it more for food production.

[0006] Several methods for processing (adding value to) whey and utilising it in the dairy industry are known in the state of the art.

[0007] A known whey processing method (UA105893U, Nat Univ Food Technologies, published on 11.04.2016) enriches whey with biogenic metal, manganese, and particles to increase its biological value. This method includes receiving and quality control of raw materials, cooling and intermediate storage, heating to 35-40 °C, defatting of whey, pasteurisation of milk whey, cooling, and storage for further use. However, this approach has a drawback in that it requires the addition of metal to enrich the whey.

[0008] Known is a method for preparing a liquid milk mixture (WO2015197496A1 , Nestec SA, published on 30.12.2015) which comprises the following steps: mixing milk protein with whey and optionally adding water, fat, oil and / or emulsifiers to the mixture of milk protein and whey; adjusting the pH with organic acid to 5.8-6.2; homogenising the mixture; and heat treating it to 85-100 °C for one to three minutes. The disadvantage here is the use of components not related to the original raw material. In this invention, not only milk-related primary components are used to obtain the mixture.

[0009] A method for regulating the ratio of whey protein to casein in skim milk is known (WO9608155, New Zealand Dairy Board, Bhaskar Ganugapati Vijaya, et al., published on 21.03.1996). This invention uses microfiltration and ultrafiltration to separate casein and whey proteins from skim milk. The invention uses the possibility of microfiltration and ultrafiltration to separate casein and whey proteins from the source material of skim milk. The drawback is the high casein content in the final product.

[0010] Known is a method for processing whey protein (US2010047423, Tetra Kavk Holdings & Finance, published on 25.02.2010), involving the processing of whey protein using microparticles. Microparticles comprises heat treatment and mechanical processing of whey protein. The method includes the steps of passing the protein concentrate through a high-pressure pump and treating it at elevated pressure. This heat treatment of the protein concentrate is followed by mechanical treatment. The limitation is that it focuses only on processing the protein mass into starting material for milk products.

[0011] The closest method related to the method of the invention is steam processing of whey concentrate to form hard curd, which is separated from the whey and as a result of the method fatty substitutes are formed of the whey (US5 413 804 A, Rhodes Kenneth H, published on 09.05.1995). The characterization effect of this invention is improving flavouring properties of the end product with proteins and with the aim of replacing fat.

[0012] The closest related product to the milk product of this invention is a whey protein product (W02011 / 051557 A1 , Valio Ltd, published on 05.05.2011), which comprises whey protein and casein, with casein content between 5 and 50 wt%. In a preferred embodiment of the invention, a whey protein product (acidified drink) is prepared from skim milk, where the typical total protein content of the product is 2.5 to 8 wt%, casein making up 5 to 50 wt% of the protein, whey protein enriched with cr-lactalbumin and / 3- lactoglobulin making up 50 to 95 wt%, fat content usually between about 0.01 and 3.5 wt%, and lactose content less than 1 wt%. The drawback is that the product is made from skim milk, not whey, and casein is added to the product separately, which results in an increased casein content in the final product. Summary of the invention

[0013] The applicant investigated additional possibilities for refining whey to use whey as a source material for milk products, altering the ratio of milk proteins for casein and whey protein. The primary motivation for developing this invention was economic, aiming to refine whey, a production residue of the dairy industry, and increasing product selection made from it and for improving the nutritional value of the products. The proposed method for processing whey into a milk product is economically more advantageous than converting whey into whey powder or biogas.

[0014] Research revealed that heat treatment and high-pressure homogenisation of whey resulted in a uniform substance - a homogeneous emulsion-like liquid protein mass - with desirable properties to manufacture milk products, including acidified milk products (source material for milk products).

[0015] This homogeneous, emulsion-like liquid (protein) mass is obtained from whey or whey concentrate produced as a by-product during cheese manufacture (cheese whey). During the milk coagulation and cheese-making process, most of the casein is transferred to the cheese mass, while the whey proteins remain mostly in the (cheese) whey.

[0016] The method for refining whey, as per the invention, involves precipitating (separating) protein (dry matter) from the whey or whey concentrate, and following precipitation, the obtained (protein) mass ((whey) protein curd) is separated from liquid / lean whey (liquid separation is also accompanied by a reduction of lactose and minerals in the protein mass). Depending on technologies for producing different traditional milk (dairy) products, the separated liquid / lean whey is later partially (accordingly to the recipe) reintroduced into the precipitated (separated) protein mass (dry matter), and the normalised mixture is homogenised. The protein mass precipitated from whey is diluted with lean whey until the content of the dry matter of a traditional milk product is achieved in order to be similar on its flavour and consistence to a traditional yogurt, kefir, milk drinks etc product made from milk. Original ingredients of milk (for example minerals, lactose, milk fat, which were moved into lean whey during protein precipitation) are reintroduced into the (protein) mass by adding lean whey. As a result, a new homogeneous emulsion-like liquid (protein) mass is obtained, which serves as a source material for a milk product (by nature similar to natural milk, but its ratio of protein consistence is substantially different from milk and which is used to produce traditional milk products enriched with whey protein (including acidified ones) - protein composition of the milk products made from this emulsion like liquid (protein) mass is different from so called usual / traditional milk products and their protein concentration in a product is in turn amendable by adding lean whey to the (protein) mass. By this method, milk product’s source material with improved nutritional value is obtained. There is whey protein 95.1 to 99 wt%, in which the whey protein-casein ratio is 99:1 to 95.1 :4.9, in such a source material. Milk products with concentrated whey protein can be obtained from such a source material’s protein content having flavour, colour and fragrance properties to similar traditional milk products.

[0017] According to the invention, whey or whey concentrate is used to prepare a milk product, from which a homogeneous emulsion-like liquid protein mass is obtained as a result of adding value to the whey with the method of the invention. This mass (source material for milk product) is suitable for producing a milk product, including acidified milk products, with high whey protein content and additionally reduced casein content.

[0018] An preferred embodiment of the method of the invention includes the following steps: whey obtained during cheese manufacture is used, this whey is buffered / stored for a short time, heated to a temperature of 65 °C, pumped into a technological tank, heat- treated to form protein curd (with precipitation), preferably directly with steam at 83-90 °C, lean whey is separated from the protein curd that has formed (after the precipitation of protein), then the separated lean whey is partially added back to the protein curd precipitated (according to the recipe, until the correct dry matter of the resulted products produced) and the mixture of protein curd (coagulated protein) and lean whey is pumped into the mixer tank and mixed. The resulting mixture is homogenised at a pressure of 80 to 150 bar (on higher pressure if possible) and a temperature of 35 to 90 °C, and cooled. Homogenisation is optionally carried out in multiple stages. The final result is a homogeneous emulsion-like liquid (protein) mass, in which the protein mass comprises (whey) protein 95.1 to 99 wt%, in which the whey protein-casein ratio is 99:1 to 95.1 :4.9; this mass serves as the source material for a milk product, for preparing different milk products (including acidified milk products such as yogurt, kefir, skyr, Ayran or also non-acidified milk drink). Depending on the milk product, additives such as flavours and / or fragrances and / or sweeteners, e.g. syrups, jams, etc., may be optionally added to enhance / enrich the flavours.

[0019] According to one embodiment, whey concentrate is added to the buffered / stored whey according to the recipe. This makes it possible to prepare many more (in quantity) different milk products from a smaller amount of source material (as the mass extraction increases). Adding whey concentrate to whey improves the extraction of protein curd.

[0020] According to another embodiment, only whey concentrate obtained from whey during cheese manufacture is used to produce the protein mass and water is added to the buffered / stored whey concentrate according to the recipe, resulting in reconstituted whey. This embodiment makes it possible to gain economic savings and to increase the source material volume, for example if the protein mass is made only from concentrate and the concentrate is purchased from other dairy industries.

[0021] A milk product made from whey according to the invention comprises additionally partially added, when needed (accordingly to the recipe), lean whey, wherein protein composition of (protein) masses dry matter precipitated from whey dry matter has whey protein 95.1 to 99 wt%). Optionally flavours and / or fragrances and / or sweeteners (e.g. syrups, jams, etc.), lactose or enzyme (in lactose-free products), optionally sourdough (if the product is heated before packaging, then the composition of the final product does not contain active microflora from sourdough), fat, a small amount of casein, minerals, vitamins, (additional) water, proteins (cr-lactalbumins, / 3-lactoglobulins, serum albumins, immunoglobulins, lactoferrin, glycomacropeptides).

[0022] List of drawings

[0023] Fig 1 shows the technological diagram of the preferred embodiment of the method for producing the source material of the milk product from whey.

[0024] Fig 2 shows the technological diagram of one additional embodiment of the method for producing the source material for a milk product from whey to which whey concentrate is added.

[0025] Fig 3 shows the technological diagram of yet another additional embodiment of the method for producing the source material for a milk product from whey to which water is added in order to make the source material for the milk product. Embodiment of the invention

[0026] The technological diagram of the preferred embodiment of the invention for adding value to whey and producing a milk product with reduced casein content from whey is shown in Fig 1 , according to which:

[0027] 1. (cheese) whey obtained during cheese manufacture is used, which comprises: water >90%, lactose 4% to 5%; proteins: cr-lactalbumins, / 3-lactoglobulins, serum albumins, immunoglobulins, lactoferrin, glycomacropeptides, some casein residues; minerals: calcium, potassium, phosphorus, magnesium; vitamins: small amounts of vitamins B, vitamin D; fat <0.5%;

[0028] 2. whey is buffered / stored for a short time;

[0029] 3. whey is heated up to a temperature of 65 °C;

[0030] 4. heated whey is pumped into a technological tank;

[0031] 5. whey is heat-treated to a temperature of 83 to 90 °C (preferably directly with steam) to form a protein curd (for protein precipitation and separation of lean whey);

[0032] 5.1 lean whey is separated (after precipitation) from the protein curd;

[0033] 5.2 separated lean whey is partially reintroduced into the precipitation protein curd as needed (according to the recipe depending on technological features of different milk products);

[0034] 6. protein curd (coagulated protein) and a part of its lean whey (added according to the recipe) are pumped into a mixer tank and mixed; 7. the resulting mixture is homogenised at a pressure of 80 to 150 bar and at a temperature of 35 to 90 °C, and then cooled, optionally with a multi-step homogenisation step to obtain a more uniform mass;

[0035] 8. a homogeneous emulsion-like liquid protein mass is obtained, which is the source material for various milk products, in which the protein composition comprises whey protein 95.1 to 99 wt% and the whey protein-casein ratio is 99:1 to 95.1 :4.9 as a result of steps 1 to 7;

[0036] 9. the resulting homogeneous emulsion-like liquid protein mass is refined into a milk product, e.g., acidified milk product or some other milk product;

[0037] 9.1. depending on the milk product, additives such as flavours and / or fragrances and / or sweeteners, such as syrups, jams, etc., may be optionally added to bring out the flavours.

[0038] Fig 2 shows the technological diagram of one additional embodiment of the invention, which additionally includes step 2.1 , according to which whey concentrate is added to the buffered / stored whey (step 2) according to the recipe.

[0039] Fig 3 shows the technological diagram of another additional embodiment of the invention, according to which whey concentrate made from whey obtained during cheese manufacture is used and which additionally includes step 2.1, according to which water is added to the buffered / stored whey concentrate (step 2) according to the recipe, resulting in reconstituted whey.

[0040] Explanation that the pH of fresh whey is between 6.2 and 6.5. Whey concentrate has significantly the characteristics of fresh whey and its dry matter has been increased to a level of 19 to 25% (pH between 6.2 and 6.5). If fresh whey is mixed with whey concentrate, it also changes the pH, dry matter and other properties of the fresh whey.

[0041] A milk product made from whey comprises whey, optional flavourings (sweeteners and / or flavours and / or fragrances), lactose or added enzyme (in lactose-free product), optionally yeast (if the product is heated before packaging, the active microflora from yeast is not present in the composition of the final product), fat, a small amount of casein, minerals, vitamins, water, proteins (cr-lactalbumins, / 3-lactoglobulins, serum albumins, immunoglobulins, lactoferrin, glycomacropeptides), wherein the milk product comprises whey protein 95.1 to 99 wt% in the protein composition and the whey proteincasein ratio of the milk product is 99:1 to 95.1 :4.9.

[0042] In a preferred embodiment of the invention, the (unflavoured) milk product comprises 25 to 50 wt% of protein curd, in which the dry matter content is 20 to 24 wt% and that of lean whey is 50 to 75 wt%.

[0043] Lean whey separated from the whey during processing is accordingly to the recipe partially reintroduced into the protein curd depending on the technological properties of the milk product.

[0044] If the invention is desired to be used for the manufacture of an acidified milk product (in the preferred embodiment, e.g. yogurt), the homogenised and cooled mixture is pumped into a technological tank and yeast, lactase, etc. are added according to the recipe (not shown in the drawings). The resulting mixture is processed depending on the desired acidified milk product (it is acidified for different milk products at different temperatures and acidification times until the required pH is achieved) and optionally additional flavours and / or fragrances and / or sweeteners are added. The manufacture of the milk product (including acidified milk product) is carried out in a manner known from the art and is not separately described here.

[0045] The applicant made an exemplary product accordingly to the method of the invention (pasteurized yogurt drink) which casein and whey protein ratio in the protein composition was determined by muva kempten GmbH labor in Germany.

[0046] Example - pasteurized banana yogurt drink

[0047] Advantages of the invention:

[0048] - the production residue of the dairy industry is reduced, i.e. the whey is recovered; - the environmental footprint associated with further processing of lean whey is reduced (the need for clean drinking water is reduced);

[0049] - the method is also easier to apply in dairies with smaller production capacity, for which whey powder production is not affordable;

[0050] - it is a direct-line production method - a continuous production process that does not require unnecessary breaks in production and particularly expensive technological lines;

[0051] - the method uses only whey related to and obtained from milk, proteins and fats obtained from whey - this ensures the production of milk products with traditional properties (e.g. colour, smell, consistency and taste, which may arise when using whey powder), but which also have a different protein composition from conventional milk products (mostly whey proteins);

[0052] - when consuming a milk product with reduced casein content, consumers with the corresponding indication may experience fewer deficiencies.

[0053] Moreover, the product made according to the invention has significant benefits for the consumer, both related to health and nutritional intake. These days the deficiencies associated with lactose intolerance and milk allergy are acknowledged, casein may have an important effect on the latter. In conventional milk products, such as drinking milk, the casein content is about 80%. However, in the cheese making process almost all of the casein goes into the cheese, and the remaining whey is practically casein- free. Ricotta is made from whey, and pure ricotta, for example, has about 98 to 99% of whey protein and 1 to 2% of casein from whole protein content. If casein is reduced in a milk product, a consumer with the corresponding indication may experience fewer deficiencies when consuming such a milk product.

[0054] Furthermore, whey proteins, inter alia, (see https: / / www.healthline.com / nutrition / 10- health- benefits-of-whey-protein):

[0055] - are proteins of high nutritional value;

[0056] - support muscle growth;

[0057] - may reduce blood pressure;

[0058] - may reduce weight;

[0059] - may reduce the feeling of hunger.

Claims

Claims1. A method for refining whey to produce the source material for a milk product comprises steps: whey or whey concentrate obtained during cheese manufacture is buffered / stored, heated and heated whey is pumped into a technological tank to form (to precipitate) a protein curd during heat treatment, characterised in that additional steps are performed:- a lean whey is separated during the formation of the protein curd;- the separated lean whey is partially reintroduced into the precipitated protein curd;- the protein curd and the separated lean whey partially reintroduced into it are pumped into a mixer tank and mixed;- the resulting mixture is homogenised under pressure and cooled to an emulsionlike liquid protein mass, in which the protein mass composition comprises whey protein 95.1 to 99 wt% and the whey protein-casein ratio is 99:1 to 95.1 :4.9.

2. A method according to claim 1 , characterised in that a whey concentrate is added to the buffered / stored whey according to the recipe.

3. A method according to claim 1 , characterised in that a whey concentrate is prepared from the whey obtained during cheese manufacture.

4. A method according to claim 1 and 3, characterised in that water is added to the buffered / stored whey concentrate according to the recipe.

5. A method according to claims 1 to 4, characterised in that the whey is heated up to a temperature of 65 °C and pumped into a technological tank.

6. A method according to claims 1 to 5, characterised in that the whey is heat treated at a temperature of 83 to 90 °C.

7. A method according to claim 6, characterised in that the whey is heat treated with direct steam.

8. A method according to claims 1 to 7, characterised in that separated lean whey is reintroduced into the protein curd accordingly to the recipe depending on the technological properties of the milk product.

9. Method according to claims 1 to 8, characterised in that homogenisation of the resulted mixture is carried out at a pressure of 80 to 150 bar and at a temperature of 35 to 90 °C.

10. A method according to claims 1 to 9, characterised in that the homogenisation of the mixture is carried out in multiple stages.

11. A method according to claim 1 to 10, characterised in that a milk product is prepared from the formed homogeneous emulsion-like liquid protein mass, to which flavours and / or fragrances and / or sweeteners are optionally added.

12. A milk product with a reduced casein content made from whey as a source material, which is prepared according to the method of claims 1 to 11 and which comprises whey, water, lactose or enzyme, proteins, fat, casein, minerals, vitamins, optionally a leavening agent, optionally flavours and / or fragrances and / or sweeteners, characterised in that the milk product comprises 95.1 to 99 wt% whey protein of its protein composition, and the milk product has a whey protein to casein ratio of 99:1 to 95.1 :4.9.

13. A milk product according to claim 12, characterised in that the milk product comprises 25 to 50 wt% of protein curd, in which the dry matter content is 20 to 24 wt% and that of lean whey is 50 to 75 wt%.

14. A milk product according to claims 12 and 13, characterised in that the lean whey separated from the whey during its processing is partially reintroduced into the whey curd accordingly to the recipe depending on the technological properties of the milk product.

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