Lactase-Treated Milk-Based Products for Rapid Lactose Reduction
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Solution Overview
Problem
Existing methods for producing lactose-free milk-based products face challenges such as prolonged incubation times, microbial growth, increased Maillard reactions, high capital costs, and operational complexities in aseptic dosing systems, without a cost-effective and hassle-free solution.
Innovation Solution
A method involving the addition of lactase to a milk-based substrate followed by a high-temperature heat treatment of at least 120°C for at least 1 second, followed by storage at ambient temperatures to achieve lactose reduction without preincubation or aseptic dosing, using enzymes with a temperature optimum of 30-60°C for residual activity during storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If batch process with prolonged incubation is used to reduce lactose, then lactose content is reduced, but incubation time becomes too long (up to 24 h) and capital investment increases
Solution Approach 1:
The patent applies parameter changes by using high temperature heat treatment (120-140°C for 2-10 seconds) to inactivate psychotropic microbes and their enzymes, and by controlling storage temperature (2-40°C) to optimize residual lactase activity. These parameter changes enable rapid lactose reduction without prolonged incubation, resolving the contradiction between lactose reduction and time loss.
2Quantity of substance
If batch process with prolonged incubation is used, then lactose is hydrolyzed, but psychotropic microbes grow and secrete heat-stable proteases that deteriorate product quality
Solution Approach 1:
The patent applies preliminary action by performing high-temperature heat treatment (120-140°C for 2-10 seconds) before lactose hydrolysis to inactivate psychotropic microbes and their heat-stable proteases. This preliminary inactivation prevents microbial growth and enzyme secretion during the subsequent lactose hydrolysis process, eliminating the harmful effects while maintaining lactose reduction.
3Quantity of substance
If lactose is hydrolyzed followed by severe heat treatment, then lactose-free product is obtained, but Maillard reaction is accelerated due to doubled reducing sugar concentration
Solution Approach 1:
The patent applies preliminary action by performing high-temperature heat treatment (120-140°C for 2-10 seconds) before lactose hydrolysis to inactivate psychotropic microbes and their heat-stable proteases. This preliminary inactivation prevents microbial growth and enzyme secretion during the subsequent lactose hydrolysis process, eliminating the harmful effects while maintaining lactose reduction.
Solution Approach 2:
The patent applies parameter changes by using high temperature heat treatment (120-140°C for 2-10 seconds) to inactivate psychotropic microbes and their enzymes, and by controlling storage temperature (2-40°C) to optimize residual lactase activity. These parameter changes enable rapid lactose reduction without prolonged incubation, resolving the contradiction between lactose reduction and time loss.
4Object-generated harmful factors
If aseptic dosing systems are used to add lactase after heat treatment, then Maillard reaction is decreased, but device complexity and capital cost increase substantially
Solution Approach 1:
The patent applies preliminary action by performing high-temperature heat treatment (120-140°C for 2-10 seconds) before lactose hydrolysis to inactivate psychotropic microbes and their heat-stable proteases. This preliminary inactivation prevents microbial growth and enzyme secretion during the subsequent lactose hydrolysis process, eliminating the harmful effects while maintaining lactose reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces lactose levels to less than 0.2% efficiently, minimizes Maillard reactions, and eliminates the need for aseptic dosing equipment, offering improved product quality and operational simplicity with reduced costs and time.
Implementation Method 1
adding a lactase to the milk-based substrate
Implementation Method 2
Lactose hydrolysis followed by severe heat treatment
Implementation Method 3
performing a heat treatment of at least 120°C for at least 1 second
Implementation Method 4
Lactose hydrolysis followed by severe heat treatment, such as in UHT applications, will result in Maillard reaction being propagated at an accelerated rate
Data Source
AI summary
The present invention relates to a method of producing a lactose-reduced heat-treated milk-based product which comprises treatment of a milk-based substrate with a lactase and performing a heat treatment.