Formulating Dairy Protein Beverages PDF

# Formulating Dairy Protein Beverages ## Introduction This presentation is by Dr. Nancy Agnes, Head, Technical Operations, FoodResearchLab. FoodResearchLab's contact information is: - Group: www.foodresearchlab.com - Email: [email protected] ## The Shift Towards Healthier Beverages Histori...

# Formulating Dairy Protein Beverages ## Introduction This presentation is by Dr. Nancy Agnes, Head, Technical Operations, FoodResearchLab. FoodResearchLab's contact information is: - Group: www.foodresearchlab.com - Email: [email protected] ## The Shift Towards Healthier Beverages Historically, beverage companies focused on crafting products that were delicious and quenched thirst. Today, the industry is undergoing a transformation, with a growing shift towards healthier options that deliver more than just hydration. ## Dairy Protein Beverages: A Growing Trend Dairy protein beverages are gaining popularity for their exceptional nutritional benefits, driven by high-quality dairy proteins known for their excellent DIAAS scores ranging from 100 to 120. ## Innovative Dairy Protein Products The dairy industry is experiencing a surge in innovative, protein-enriched products. Examples include: - Fortified flavored milks - Meal replacement drinks - Yogurt-based smoothies - Protein-boosted sports drinks for post-exercise recovery These products are making a mark on the shelves. ## Consumer Recognition of Nutritional Enhancements Consumers are not only recognizing but also valuing the nutritional enhancements these beverages offer, including: - Added energy - Enhanced relaxation - Increased satiety ## Dairy Proteins: More Than Just Nutrition Incorporating dairy proteins into beverages isn't just about nutrition; these ingredients also contribute to the desired texture and viscosity of the drink, enhancing the overall consumer experience. ## Challenges of Creating Dairy-Based Beverages However, creating dairy-based beverages with a long shelf life presents its own set of challenges. These include: - Understanding of ingredient interactions - Specific formulation requirements - Processing techniques ## Food Research Lab's Expertise At Food Research Lab (FRL), we pride ourselves on leading the way in the development of dairy protein beverages. Our team is highly skilled in utilizing various dairy-based components, including milk and whey proteins, as well as supportive non-protein ingredients like permeate. ## Critical Factors in Developing Dairy Protein Beverages When developing these beverages, several critical factors must be considered: - **High or Low Acid:** What is high and low acid beverages? - **pH Levels:** What is the pH of the beverage? - **Ingredient Interactions:** How do various ingredients in the formula interact with the dairy components? - **Processing Conditions:** How will these affect the functionality and stability of the dairy ingredients? - **Packaging and Shelf Life:** What type of packaging is appropriate, and what shelf life is required? Understanding these elements is crucial for anyone looking to innovate within the space of dairy protein beverages. ## What is High Acid or Low Acid Beverages? In the beverage world, there are two categories - low acid and high acid. - A low acid beverage is typically anything above pH 4.6. - A high acid beverage is anything below pH 4.6. According to Dr Radhika Ganesan, R&D Head, when a company or entrepreneur works with FRL on a beverage, her first question is "What's the pH?" Selecting a pH is especially important when developing a beverage using dairy proteins. ## Impact of pH on Protein Functionality - **Generally speaking, whey protein ingredients work best in high acid beverages and milk protein ingredients have better functionality in low acid beverages.** ## Role of Stabilizers for Stability - **Depending on the pH, stabilizers may be needed to add stability to the dairy protein.** A table showing the protein type, stabilizer requirement, reason for the stabilizer, and common applications for each pH range is shown below: | pH Range | Protein Type | Stabilizer Requirement | Reason for Stabilizer | Common Applications | |-------------------| ------------------ | ------------------------ | ---------------------------------------------------------------------------------------------- | --------------------------------------------------------------------------------------- | | Below 3.5 (High Acid) | Whey Protein Isolate | None Typically Required | Protein is stable and far from its isoelectric point; low pH naturally inhibits protein aggregation. | Clear beverages like sports drinks, juice blends | | 3.5 to 4.5 (Mid-Range Acid) | Whey Protein Isolate | Pectin or Similar | Close to the isoelectric point of whey protein; stabilizers prevent protein aggregation during heat processing. | Flavored waters, enhanced protein beverages | | Above 4.5 (Low Acid) | Whey Protein Isolate | May Require Stabilizers | Protein stability might be compromised; specific stabilizers depend on other formulation aspects. | Dairy-based drinks, meal replacements | | Above 4.6 (Low Acid) | Milk Protein Concentrate | Gums, Carrageenan, or Pectin | Milk proteins are stable, but in beverage formulations, stabilizers may be needed for viscosity and texture. | Milk-based beverages, nutritional shakes, creamers | - **Milk Protein Concentrate in Low Acid Environments (pH Above 4.6):** In low acid conditions, milk protein concentrate is generally stable due to being far from its isoelectric point. - **However, stabilizers such as gums, carrageenan, or pectin may be added not necessarily to prevent aggregation (as with whey in mid-range pH) but to enhance texture, improve viscosity, and maintain a consistent suspension of the protein in the beverage.** This is particularly relevant in milk-based drinks, nutritional shakes, and creamers where mouthfeel and texture are crucial to consumer acceptance. ## Processing Conditions of Low and High Acid Beverages - **In addition to dictating what dairy protein ingredient to use, the pH of a beverage will also dictate the processing conditions.** - **Generally, low acid beverages that are shelf stable essentially have two processing options - ultra-high temperature (UHT) and retort processing.** - **Hot fill and basic pasteurization are the two common processing options for high acid beverages.** A table summarizing the processing options, temperatures, shelf stability, common uses for each method is below: | Processing Option | Temperature | Duration | Packaging | Shelf Stability | Common Uses | |--------------------|-------------------|----------|--------------------------|----------------|-------------------------------------------------------------------------------------| | Retort | 250°F - 300°F (High) | 20-40 min| Bottles, Cans | Shelf stable | Bottled beverages, canned drinks | | UHT | Above 275°F | 2-5 sec | Aseptically packaged cartons, Bottles | Shelf stable | Milk, juices, tea, coffee | | ESL | Same as UHT | 2-5 sec| Non-aseptically packaged containers | Requires refrigeration but has extended shelf life | Filtered milk products, coffee drinks | | Hot Fill (High Acid) | Above 180°F | Up to 2 min | Bottles | Shelf stable | Juices, teas, sports drinks | | Pasteurization | Above 180°F | Varies | Requires refrigerated containers | Requires refrigeration| Smoothies, some juice products | ## Explanation of Processing Methods - **Retort Processing:** Uses very high temperatures for a relatively long duration, making the product shelf stable. Suitable for containers that can withstand high temperatures like cans and bottles. - **Ultra-High Temperature (UHT) Processing:** Also involves high temperatures but for a very brief period. Products must be aseptically packaged to ensure shelf stability. Common for beverages like milk and juices. - **Extended Shelf Life (ESL):** Follows the UHT process but without aseptic packaging. These products have an extended shelf life compared to regular refrigerated products but still require refrigeration. Used for certain milk and coffee products. - **Hot Fill Process for High Acid Beverages:** This process involves heating the beverage above 180°F for up to 2 minutes. The beverage is then filled hot into the container and cooled, ensuring shelf stability due to the combination of high temperature and the acidity which inhibits pathogen growth. - **Basic Pasteurization for High Acid Beverages:** Similar to hot fill in terms of temperature but typically involves a different duration and potentially different temperature specifics, depending on the product. While this method effectively reduces microbial load, the products generally require refrigeration, especially if not filled aseptically. ## Which Ingredient to Use? Once the pH and processing conditions are established, selecting the appropriate dairy protein ingredient becomes crucial. It's essential to understand not only the functionality of each ingredient but also how they will interact during the processing phase. Dr. Radhika Ganesan explains, "For high acid beverages with a pH below 4.6, we typically recommend whey proteins due to their superior solubility and heat stability at lower pH levels. Conversely, for low acid beverages, which generally have a pH between 6 and 7, milk proteins are preferable. Milk proteins provide optimal solubility and heat stability in this pH range." The choice of protein source significantly influences the formulation, processing, and the challenges encountered during production and storage. ## Examples of Protein Sources - **Whey Proteins:** This category includes whey protein hydrolysate (WPH), whey protein concentrates (WPC), whey protein isolates (WPI), and milk-derived whey. - **Milk Proteins:** This group comprises milk protein concentrates (MPC), milk protein isolates (MPI), and micellar casein concentrate (MCC). In formulations with higher pH, milk protein concentrates (MPCs) are typically used as the primary protein source, whereas whey protein concentrates (WPCs) are favored in low-pH beverage formulations. This strategic selection ensures that the beverages are not only effective in meeting nutritional requirements but also stable and palatable throughout their shelf life. ## Specific Protein Source Characteristics - **Milk Protein Concentrate (MPC) and Milk Casein Concentrate (MCC)** are highly valued for their rapid digestive and absorptive properties, making them ideal for neutral pH protein-fortified beverages. - **MCC**, a relatively newer dairy protein, contains a higher ratio of casein compared to MPC. Both ingredients are excellent sources of essential amino acids and provide slowly digestible protein that promotes satiety. - **In contrast, whey proteins are more heat-sensitive during prolonged exposure to high temperatures, which can lead to denaturation, aggregation, and gel formation.** - **However, whey proteins are favored for their excellent solubility and ability to remain dissolved across a broad pH spectrum.** This makes them particularly useful for fortifying acidic beverages, typically with a pH range of 2.8 to 3.5. ## Protein Isolates vs. Concentrates A table outlining the key characteristics of protein isolates and concentrates is below: | Factor | Protein Concentrate | Protein Isolate | |----------------|---------------------|-----------------| | Cost | Lower | Higher | | Lactose Content | Higher | Lower | | Mineral Content | Higher | Lower | | Fat Content | Contains some fat | Minimal to no fat | | Product Clarity | Less clear | Higher clarity | | Overall Preference | Chosen for cost-efficiency | Preferred for lower sugar content and clarity| - **Micellar casein is a relatively new addition to the dairy protein market, distinct from isolates or concentrates due to its manufacturing process.** Unlike the common ultrafiltration method used for concentrates and isolates, micellar casein is produced through microfiltration (MF). - **This process effectively separates casein from whey proteins, resulting in a product that, while maintaining similar protein levels to concentrates and isolates, predominantly comprises casein.** In the U.S., approximately four companies produce micellar casein with a casein content typically ranging from 90-95%, compared to about 80% in Milk Protein Concentrate (MPC). - **The benefits of micellar casein include greater heat stability - attributable to its lower whey protein content - and a reduced sulfur aroma during ultra-high temperature (UHT) or retort processing.** - **Another innovative product is milk-derived whey, which stands out from the traditional cheese-derived whey as it bypasses the cheesemaking process.** Burrington Ganesan notes that milk-derived whey offers a notably clean and milky flavor, devoid of the additional flavors introduced by cheesemaking cultures or extended heat processing. - **Additionally, this form of whey is fat-free, as fats are removed during the microfiltration process, enhancing its clarity.** This makes milk-derived whey an excellent choice for clear beverages like protein waters, where a clean, unadulterated taste and appearance are desirable. ## Hydration is Essential for Dry Dairy Proteins Hydrating dairy proteins correctly is crucial in preventing solubility and heat stability issues in dairy protein beverages. According to Dr Radhika Ganesan R&D Director of FRL Lab, proper hydration of milk proteins, such as Milk Protein Concentrate (MPC), is particularly essential. - **For optimal hydration, these proteins should be subjected to shear and reconstituted at temperatures around 48.9°C to 50°C (120°F minimum) for about an hour.** - **Ganesan emphasizes that warmer temperatures are advisable for milk proteins due to their slow hydration properties.** Alternatively, using liquid MPC (also known as ultra-filtered skim milk) can circumvent hydration challenges associated with dried ingredients. ## Milk Protein Stabilization - **Milk proteins require stabilization in beverage formulations to prevent sedimentation during storage.** Selecting the correct stabilizers, sensitive to both pH and temperature, is vital. - **Incorrect stabilizers can destabilize the protein, negatively affecting the product's shelf life rather than enhancing it.** Carrageenan is effective at neutral pH, ideal for suspending cocoa solids in chocolate-flavored beverages. - **Guar gum, xanthan gum, and Carboxymethyl Cellulose (CMC)** are commonly used in neutral pH beverages, while high-methoxy pectin is preferred for whey protein-based beverages at low pH. - **The incorporation of stabilizers not only prevents age-related gelation with salts like sodium and potassium phosphate/polyphosphate but also improves the texture and viscosity of the drink.** - **Mineral ions such as calcium, potassium, and sodium influence the stability and clarity of acidified whey beverages.** Achieving the correct mineral balance is crucial for stability. - **The choice and level of mineral supplements, along with factors like color, sweetness, and flavor, significantly impact the final product.** There are numerous options available for sweeteners (both artificial and natural, low or high caloric), colors (natural or artificial), and flavors or flavor modifiers. - **Hydration of whey proteins, on the other hand, requires less time - approximately 20 to 30 minutes at temperatures not exceeding 54.4°C (130°F).** Exceeding this temperature could denature the whey proteins. Proper hydration is imperative, particularly as beverages with higher protein levels become more prevalent. - **Poor hydration of MPC or Milk Protein Isolate (MPI) can cause textural issues such as graininess or protein settling in the final product.** Here is a comparison in table format to illustrate the differences in hydration requirements between whey and milk proteins: | Protein Type | Hydration Time | Temperature | Hydration Importance | Common Issues if Poorly Hydrated | |--------------------|---------------|--------------------|-------------------------------------------------------|---------------------------------------------------| | Milk Protein (MPC/MPI) | About 1 hour | 48.9°C to 50°C (120°F minimum) | Crucial for avoiding solubility and stability issues | Grainy texture, sedimentation | | Whey Protein | 20 to 30 minutes| No higher than 54.4°C (130°F) | Essential to prevent denaturation | Protein denaturation, textural defects | ## Processing Aids - **When developing beverages, particularly those with low acidity, special considerations are necessary to ensure that the dairy proteins endure the heating process without degradation.** For low acid beverages, it's often crucial to incorporate a stabilizer such as carrageenan or gellan gum. These additives play a dual role: they protect the proteins and prevent them from interacting with each other, which can lead to instability. - **Another important aspect to consider during the high heat processing typical of Ultra-High Temperature (UHT) methods is the Maillard reaction.** This reaction can lower the pH of the beverage, potentially leading to protein instability. To counteract this effect, adding buffer salts (such as mono-, di-, or polyphosphates) is a common practice. These buffers help maintain a stable pH and can also chelate calcium, which might otherwise destabilize the proteins. While buffer salts are effective in stabilizing the beverage, they are often not considered clean label by some consumers, yet they are essential for enhancing the stability of the product. A table summarizing the problems, solutions, and purpose/effect of each processing aide is below: | Consideration | Detail | Solution | Purpose/Effect | |----------------------|---------------------------------------------------------|----------------------------------------------------------------|-----------------------------------------------------------------------------------| | Stabilizers Needed | Low acid beverages often require the addition of stabilizers. | Carrageenan, Gellan Gum | Protect proteins, prevent interaction and instability. | | High Heat Processing | Ultra-High Temperature (UHT) processing involves high heat that can trigger the Maillard reaction. | Monitor and control processing temperatures. | Prevent undesirable reactions that can lower pH and lead to protein instability. | | pH Instability from Maillard Reaction | The Maillard reaction during UHT can decrease pH, leading to instability in proteins. | Addition of buffer salts (mono-, di-, or polyphosphates). | Maintain a stable pH, chelate calcium to prevent protein destabilization. | | Consumer Perception of Additives | Buffer salts, while effective, may not align with consumer preferences for 'clean label' products. | Educate on the necessity, explore cleaner alternatives. | Enhance stability while trying to meet consumer expectations for clean label products. | ## Custom Dairy Ingredients - **Reducing the activity of calcium ions in Milk Protein Concentrate (MPC) by using calcium chelators or partially demineralizing during ultrafiltration can significantly enhance the heat and storage stability of beverages.** - **Studies have shown that beverages with MPC reduced by 20% in calcium content demonstrate superior storage stability compared to both the standard MPC and those reduced by 30%.** In response, several U.S. companies have started producing MPC with lower calcium levels, eliminating the need for buffers and achieving a cleaner label. - **These specially formulated MPCs offer greater heat stability and are an excellent choice for low acid dairy protein beverages.** - **Another strategy when working with whey proteins is the use of pre-acidified whey protein isolate.** This approach addresses the common challenge of needing to lower the pH of beverage formulations—sometimes to as low as pH 3.0—by adding acids such as phosphoric, citric, or malic acid. - **The level of acid required can be substantial, depending on the protein content of the beverage.** To simplify the process and reduce the astringency of the final product, several companies in the U.S. have developed pre-acidified whey protein isolate. Food Research lab can assist you to source the right ingredients from these manufacturers. ## The Future of Dairy Protein Beverages As noted earlier, the dairy protein beverage sector is rapidly evolving and expanding, primarily focusing on muscle health—whether it's for sports recovery, weight management, or healthy aging. Dr. Radhika Ganesan of FRL points out that there is particularly untapped potential in the healthy aging segment, where few products currently exist. This is an area she actively encourages companies to explore further. FRL is committed to supporting companies and entrepreneurs in developing new dairy protein beverages. For more information or technical support, please reach out to the FRL's Beverages staff.