Solid Dairy Ingredient Production via Transglutaminase Cross-Linking
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Solution Overview
Problem
Current methods for producing dairy products using cross-linked micellar caseins with transglutaminases are lengthy, complex, and prone to altering the final product's properties, requiring extensive heat treatment and high enzyme doses, which complicates differentiation of cross-linking levels and increases production costs, while also posing challenges in maintaining organoleptic properties and nutritional recommendations for reduced fat and sugar content.
Innovation Solution
A method involving a liquid dairy composition with at least 50 wt% caseins and less than 20 wt% fat, where a transglutaminase is added at a dose of ≤3 units per gram of total nitrogenous matter, partially cross-linking the caseins, followed by thermal inactivation and transformation into a solid ingredient, which can be added to dairy products to improve texture and firmness without the need for additional cross-linking enzymes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transglutaminase is added to cross-link caseins in liquid dairy composition, then the stability and texture of the final product is improved, but the production time is lengthened due to extended treatment duration
Solution Approach 1:
The patent applies preliminary action by pre-cross-linking caseins in a concentrated liquid dairy composition before final product formulation. The cross-linking is performed on a concentrated substrate (at least 50 wt% caseins) where the enzyme acts more efficiently and rapidly, then the pre-cross-linked material is diluted or incorporated into the final product. This preliminary preparation step reduces the overall production time compared to cross-linking in the final diluted product formulation.
2Manufacturing precision
If high dose of transglutaminase is used to ensure adequate cross-linking, then the cross-linking effectiveness is improved, but the production cost increases and differentiation of cross-linking levels becomes difficult
Solution Approach 1:
The patent applies local quality by creating different cross-linking levels in different portions of the casein population. By using a moderate enzyme dose (≤3 units per gram of total nitrogenous matter) on a concentrated substrate, the patent achieves partial cross-linking where some casein molecules are cross-linked while others remain uncross-linked. This creates a heterogeneous mixture with varying cross-linking levels, allowing differentiation and providing a range of functional properties in the final product.
3Reliability
If thermal inactivation is applied to deactivate transglutaminase, then the enzyme is successfully inactivated as required by regulations, but additional processing steps and time are required
Solution Approach 1:
The patent applies merging by combining the thermal inactivation step with existing processing steps in the dairy product formulation. The pre-cross-linked liquid dairy composition undergoes thermal treatment as part of the standard pasteurization or sterilization process required for dairy products anyway. This integrates the enzyme inactivation requirement with mandatory food safety thermal processing, eliminating the need for a separate inactivation step and reducing overall process complexity.
4Ease of manufacture
If the liquid dairy composition is transformed into solid ingredient form, then the ingredient is more stable and easier to handle, but additional processing steps are required
Solution Approach 1:
The patent applies phase transitions by transforming the liquid dairy composition into solid ingredient form through drying or spray-drying processes. The pre-cross-linked liquid composition containing cross-linked caseins is converted into a powder or solid ingredient that is more stable, easier to store, and simpler to handle during formulation. This phase change from liquid to solid state improves manufacturability and logistics while the cross-linked structure maintains functional properties.
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 shortens production time, enhances reproducibility and organoleptic properties, allows for faster creaming, improved viscosity retention, and enables replacement of gelatine and emulsifying salts, while maintaining nutritional benefits and sensory qualities of dairy products.
Implementation Method 1
cross-linking the caseins of said liquid composition comprising the transglutaminase
Implementation Method 2
adding at least one transglutaminase to the composition of step i), at a dose less than or equal to 3 units per gram of total nitrogenous matter (TNM)
Implementation Method 3
inactivating, in particular thermally, said at least one transglutaminase
Data Source
AI summary
The present invention relates to a method for producing a solid food ingredient, comprising the steps:i) providing a liquid dairy composition comprising at least 50 wt % caseins relative to its total dry mass, and comprising at most 20 wt % fat(s) relative to its total dry mass;ii) adding at least one transglutaminase to the composition of step i), at a dose less than or equal to 3 units per gram of total nitrogenous matter (TNM);iii) at least partially cross-linking the caseins of the liquid composition comprising said at least one transglutaminase;iv) inactivating said at least one transglutaminase;v) transforming the liquid composition obtained after step iv) into a solid ingredient.