Whey Protein Particle Blend for High-Protein Yoghurt Processing

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Solution Overview

Problem

The production of high protein whey protein-based yoghurt products is challenging due to strong gel formation during heat-treatment, leading to equipment clogging, reduced operation cycles, and poor sensory quality, such as low viscosity and sedimentation issues.

Innovation Solution

A combination of microparticulated whey protein particles (type A) and acid-gellable whey protein aggregates (type B) is used, with type A particles having a size of 1-10 microns and type B particles having a size of 0.02-0.5 microns, to reduce gel formation during heat-treatment and enhance viscosity and gel strength during acidification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If high concentrations of whey protein are used in yoghurt production, then protein content is improved, but gel formation during heat-treatment increases causing equipment clogging and reduced productivity

Engineering Contradiction:

Improveprotein contentVSAvoidoperation cycles

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The invention changes the particle size parameter of whey protein from conventional sizes to microparticulated form (1-10 microns for type A, 0.02-0.5 microns for type B). This parameter change fundamentally alters the gelation behavior during heat-treatment, allowing high protein concentrations to be used without equipment clogging, thus resolving the contradiction between improving protein content and maintaining productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite mixture of two different types of microparticulated whey protein (type A and type B particles with different size ranges and properties). This composite approach combines the benefits of both particle types to achieve optimal gel formation control, enabling high protein content while preventing equipment clogging and maintaining continuous operation

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If high concentrations of whey protein are used in yoghurt production, then protein content is improved, but gel formation during heat-treatment leads to equipment clogging and cleaning requirements

Engineering Contradiction:

Improveprotein contentVSAvoidequipment operation

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

By changing the particle size parameter to microparticulated range (1-10 microns and 0.02-0.5 microns), the invention prevents excessive gel formation that would cause equipment clogging. This allows high protein concentrations to be processed smoothly through heat-treatment equipment without stopping for cleaning, thus improving ease of manufacture while maintaining high protein content

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If whey protein gel is broken up by homogenisation, then equipment clogging is prevented, but sensory quality deteriorates with low viscosity and watery consistency

Engineering Contradiction:

Improveequipment operationVSAvoidsensory quality

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The invention performs preliminary microparticulation of whey protein before yoghurt production. This preliminary action creates particles with controlled size distribution that inherently resist excessive gelation during heat-treatment, eliminating the need for subsequent homogenisation to prevent clogging. The product maintains strong gel structure and high viscosity without requiring breaking up, thus preserving sensory quality while ensuring smooth equipment operation

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If conventional whey protein is used, then production is simple, but gel formation during acidification is weak resulting in poor product quality

Engineering Contradiction:

Improveproduction simplicityVSAvoidgel strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention changes the particle size parameter to microparticulated range (1-10 microns for type A, 0.02-0.5 microns for type B), which fundamentally improves gel strength during acidification. The microparticulated structure provides much stronger gel formation compared to conventional whey protein, resulting in superior product quality while maintaining production simplicity through direct use of the microparticulated ingredient

Inventive Principle:

Principle #35Parameter changes

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 results in high viscosity and reduced sedimentation, producing a desirable yoghurt-like product with improved sensory quality.

Implementation Method 1

acid-gellable whey protein aggregates (referred to as type B particles)

Methodology Applied

Scientific EffectAcid-gelling: Gel

Data Source

PatentUS12490754B2Whey protein-based, high protein, yoghurt-like product, ingredient suitable for its production, and method of production

Publication Date: 2025.12.09 ARLA FOODS AMBA

AI summary

The present invention pertains to a new type of food ingredient containing a combination of insoluble whey protein particles having a particle size in the range of 1-10 micron (referred to as type A particles) and acid-gellable whey protein aggregates (referred to as type B particles). The invention furthermore pertains to whey protein-based, yoghurt-like products containing the combination of type A and type B particles and to methods of producing the food ingredient and the whey protein-based, yoghurt-like products.