Whey Protein Powder Production via High Shear Heating

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Solution Overview

Problem

Denatured whey protein tends to coagulate and foul equipment during heating, leading to undesirable textures and increased costs due to the need for dilution to prevent coagulation, which affects the quality and cost of producing hydrophobic whey protein powders for food substitutes.

Innovation Solution

Heating a concentrated whey protein slurry to 140° F. to 300° F. while subjecting it to high shear conditions and subsequent drying to produce a powdered whey protein with improved hydrophobic properties and reduced coagulation, allowing for a more concentrated starting slurry without equipment fouling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If whey protein slurry is heated to denature the protein, then hydrophobic whey protein powder is produced with good organoleptic qualities, but the protein coagulates and fouls the heating equipment

Engineering Contradiction:

Improveequipment efficiencyVSAvoidcoagulation and fouling

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by subjecting the whey protein slurry to high shear mixing conditions before heating to denature the protein. This pre-shearing action prevents coagulation and fouling during the subsequent heating process by keeping the protein molecules dispersed and preventing them from forming large aggregates that would foul equipment surfaces.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs periodic action by applying intermittent high shear mixing pulses during the heating process. Rather than continuous mixing, periodic shear pulses are applied to maintain protein dispersion and prevent coagulation on heating surfaces, thereby reducing fouling while maintaining equipment efficiency.

Inventive Principle:

Principle #19Periodic action

2Object-generated harmful factors

If the whey protein slurry is diluted to prevent excessive coagulation during heating, then equipment fouling is reduced, but production costs increase due to additional water evaporation requirements

Engineering Contradiction:

ImprovecoagulationVSAvoidenergy for water evaporation

Core Design Contradiction:

Object-generated harmful factorsVSLoss of energy

Solution Approach 1:

The patent applies preliminary action by subjecting the concentrated whey protein slurry to high shear mixing conditions before heating to denature the protein. This pre-shearing action prevents coagulation and fouling during the subsequent heating process by keeping the protein molecules dispersed and preventing them from forming large aggregates that would foul equipment surfaces.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical parameters of the slurry by applying high shear stress, which fundamentally alters the flow and aggregation behavior of the protein molecules. This parameter change allows concentrated slurries to be heated without excessive coagulation, eliminating the need for dilution and the associated energy costs of evaporating excess water.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If additives are added to reduce particle size of denatured whey protein, then mean particle size is reduced, but the hydrophobic qualities of the protein are adversely impacted and water retention increases

Engineering Contradiction:

Improveparticle size controlVSAvoidhydrophobic properties

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces chemical additives with a mechanical approach to control particle size. Instead of using additives that chemically modify the protein, the patent uses high shear mixing to mechanically control the size and distribution of protein aggregates, thereby maintaining the natural hydrophobic properties of the denatured protein while achieving fine particle control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The method produces whey protein powders with superior organoleptic qualities, reducing water absorption and imparting a smooth, creamy texture, while maintaining equipment efficiency and reducing production costs by allowing a more concentrated slurry processing.

Implementation Method 1

heating a slurry comprising starting whey protein to a temperature of about 140° F. to about 300° F., where the heating converts at least a portion of the starting whey protein to denatured whey protein

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

subjecting the slurry to high shear conditions

Methodology Applied

Scientific EffectShear stress: Shear Stress

Implementation Method 3

drying the slurry to leave the powdered whey protein

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS7811620B2Method of making whey protein compounds

Publication Date: 2010.10.12 LEPRINO FOODS CO

AI summary

A method of making a powdered whey protein, where the method includes heating a slurry comprising starting whey protein to a temperature of about 140° F. to about 300° F. The heating converts at least a portion of the starting whey protein to denatured whey protein. The method also includes subjecting the slurry to high shear conditions, and drying the slurry to leave the powdered whey protein. Also, a system for producing a powdered whey protein. The system includes a cooker to heat a slurry comprising starting whey protein, and a shear pump to subject the slurry to high shear conditions.