Physical and rehydration properties of milk protein concentrates: comparison of spray-dried and extrusion-porosified powders

Exploring conventional and emerging dehydration technologies for slurry/liquid food matrices and their impact on porosity of powders: A comprehensive review

The contribution of dehydration to the growing market of food powders from slurry/liquid matrices is inevitable. To overcome the challenges posed by conventional drying technologies, several innovative approaches have emerged. However, industrial implementation is limited due to insufficient information on the best-suited drying technologies for targeted products. Therefore, this review aimed to compare various conventional and emerging dehydration technologies (such as active freeze, supercritical, agitated thin-film, and vortex chamber drying) based on their fundamental principles, potential applications, and limitations. Additionally, this article reviewed the effects of drying technologies on porosity, which greatly influence the solubility, rehydration, and stability of powder. The comparison between different drying technologies enables informed decision-making in selecting the appropriate one. It was found that active freeze drying is effective in producing free-flowing powders, unlike conventional freeze drying. Vortex chamber drying could be considered a viable alternative to spray drying, requiring a compact chamber than the large tower needed for spray drying. Freeze-dried, spray freeze-dried, and foam mat-dried powders exhibit higher porosity than spray-dried ones, whereas supercritical drying produces nano-porous interconnected powders. Notably, several factors like glass transition temperature, drying technologies, particle aggregation, agglomeration, and sintering impact powder porosity. However, some binders, such as maltodextrin, sucrose, and lactose, could be applied in controlled agglomeration to enhance powder porosity. Further investigation on the effect of emerging technologies on powder properties and their commercial feasibility is required to discover their potential in liquid drying. Moreover, utilizing clean-label drying ingredients like dietary fibers, derived from agricultural waste, presents promising opportunities.

Influence of Bulk Nanobubbles Generated by Acoustic Cavitation on Powder Microstructure and Rehydration Characteristics of Spray-Dried Milk Protein Concentrate Powders

Bulk nanobubbles (BNBs) have widespread applications in various fields of science due to numerous peculiar characteristics. Despite significant applications, only limited investigations are available on the application of BNBs in food processing. In the present study, a continuous acoustic cavitation technique was used to generate bulk nanobubbles (BNBs). The aim of this study was to evaluate the influence of BNB incorporation on the processability and spray drying of milk protein concentrate (MPC) dispersions. MPC powders were reconstituted to the desired total solids and incorporated with BNBs using acoustic cavitation as per the experimental design. The control MPC (C-MPC) and BNB-incorporated MPC (BNB-MPC) dispersions were analyzed for rheological, functional, and microstructural properties. The viscosity significantly decreased (p < 0.05) at all the amplitudes studied. The microscopic observations of BNB-MPC dispersions showed less aggregated microstructures and greater structural differences compared with C-MPC dispersions, therefore lowering the viscosity. The viscosity of BNB incorporated (90% amplitude) MPC dispersions at 19% total solids at a shear rate of 100 s^-1 significantly decreased to 15.43 mPa·s (C-MPC: 201 mPa·s), a net decrease in viscosity by ~90% with the BNB treatment. The control and BNB incorporated MPC dispersions were spray-dried, and the resultant powders were characterized in terms of powder microstructure and rehydration characteristics. Focused beam reflectance measurement of the BNB-MPC powders indicated higher counts of fine particles (<10 μm) during dissolution, signifying that BNB-MPC powders exhibited better rehydration properties than the C-MPC powders. The enhanced powder rehydration with the BNB incorporation was attributed to the powder microstructure. Overall, reducing the viscosity of feed by BNB incorporation can enhance the performance of the evaporator. This study, therefore, recommends the possibility of using BNB treatment for more efficient drying while improving the functional properties of the resultant MPC powders.

Influence of micro- and nano-bubble treatment on morphological characteristics and flow properties of spray-dried milk protein concentrate powders

This study investigated the morphological and bulk handling properties of milk protein concentrate (MPC) powders manufactured from incorporating micro- and nano-bubbles (MNB) before spray drying. Control MPC powders (C-MPC; no MNB treatment) and MNB-treated MPC powders (MNB-MPC; MPC dispersions passed through the MNB system and subsequently spray dried) were characterized in terms of particle size, shape factors, stability, variable flow rate, shear cell tests, compressibility, and wall friction. The MPC powders produced after the MNB injection process had better flowability and lower basic flow energy. Shear tests showed that C-MPC powders were more cohesive than MNB-MPC powders. The MNB-MPC powders had lower flow rate index values, lower wall friction angles, more rounded shape, and significant differences in powder compressibility compared with C-MPC powders. Overall, the results demonstrated that MNB incorporation during spray drying can produce ingredients with comparable morphological characteristics while improving the bulk powder properties.

The Effect of High Protein Powder Structure on Hydration, Glass Transition, Water Sorption, and Thermomechanical Properties

Poor solubility of high protein milk powders can be an issue during the production of nutritional formulations, as well as for end-users. One possible way to improve powder solubility is through the creation of vacuoles and pores in the particle structure using high pressure gas injection during spray drying. The aim of this study was to determine whether changes in particle morphology effect physical properties, such as hydration, water sorption, structural strength, glass transition temperature, and α-relaxation temperatures. Four milk protein concentrate powders (MPC, 80%, w/w, protein) were produced, i.e., regular (R) and agglomerated (A) without nitrogen injection and regular (RN) and agglomerated (AN) with nitrogen injection. Electron microscopy confirmed that nitrogen injection increased powder particles' sphericity and created fractured structures with pores in both regular and agglomerated systems. Environmental scanning electron microscopy (ESEM) showed that nitrogen injection enhanced the moisture uptake and solubility properties of RN and AN as compared with non-nitrogen-injected powders (R and A). In particular, at the final swelling at over 100% relative humidity (RH), R, A, AN, and RN powders showed an increase in particle size of 25, 20, 40, and 97% respectively. The injection of nitrogen gas (NI) did not influence calorimetric glass transition temperature (Tg), which could be expected as there was no change to the powder composition, however, the agglomeration of powders did effect Tg. Interestingly, the creation of porous powder particles by NI did alter the α-relaxation temperatures (up to ~16 °C difference between R and AN powders at 44% RH) and the structural strength (up to ~11 °C difference between R and AN powders at 44% RH). The results of this study provide an in-depth understanding of the changes in the morphology and physical-mechanical properties of nitrogen gas-injected MPC powders.

Enhanced rehydration behaviors of micellar casein powder: The effects of high hydrostatic pressure treatments on micelle structures

Natural micellar casein is generally dried into powdered forms for commercial transportation and storage. However, the poor rehydration ability of micellar casein powder critically limited the potential applications due to its dense cross-linked structures caused by colloidal calcium phosphate (CCP). In this study, micellar casein solutions were exposed to a high hydrostatic pressure (HHP) ranging from 100 to 500 MPa and were then freeze dried to produce powders. The effects on the casein micelle structures and the rehydration characteristics including wetting, dispersion and dissolving were comprehensively investigated. The results showed that HHP could induce smaller micelle sizes and significantly increase the free calcium in the reconstituted solution. It demonstrated that the majority of CCP bridges in casein micelles were dissociated, which produced porous powders with loose structures and thus significantly improved rehydration behaviors. 300 MPa was the pressure level that caused the quickest dispersion process and best solubility. Consequently, HHP has potential to be a novel physical technique to potentially modify the protein higher-order structures as well as improve the corresponding functionalities.

Investigation of the influence of powder characteristics on the breakage of dairy powders

Dairy powder breakage occurs in many processes and deteriorates powder properties and functionalities. This study investigated the influence of powder and particle characteristics on the dynamic breakage of dairy powders during the dispersion and conveying in a powder venturi feeder to provide information on assessing and reducing powder breakage during production and transportation. Four kinds of dairy powders (fifteen samples) were analysed: lactose crystals, agglomerates, commercial and lab-scale non-agglomerates. During the dispersion and conveying, breakage degree increased with increasing particle size and decreasing particle structural strength. Considering particle structure, the strength of crystals was the highest, followed by the continuum solids, followed by particles with numerous small holes throughout the particle, followed by particles with a small number of randomly distributed internal holes, followed by the hollow sphere particle with a very thin shell. The breakage behaviour of crystals during conveying was different from the other powders due to the difference in particle structures. Besides, the fat in particles might decrease the breakage of powders.

Influence of Glycomacropeptide on Rehydration Characteristics of Micellar Casein Concentrate Powder

Glycomacropeptide (GMP) shows potential for enhancing the rehydration properties of high-protein dairy powders due to its hydrophilic nature. This study involved formulating micellar casein concentrate (MCC) solutions (8.6% final protein content) with 0, 10, and 20% GMP as a percentage of total protein, and investigated the physicochemical and rehydration properties of the resultant freeze-dried powders (P-MCC-0G, P-MCC-10G, and P-MCC-20G, respectively). The surface charges of caseins in the control MCC and 10 or 20% GMP blended solutions were −25.8, −29.6, and −31.5 mV, respectively. Tablets prepared from P-MCC-10G or P-MCC-20G powders displayed enhanced wettability with contact angle values of 80.6° and 79.5°, respectively, compared with 85.5° for P-MCC-0G. Moreover, blending of GMP with MCC resulted in faster disintegration of powder particles during rehydration (i.e., dispersibility) compared to P-MCC-0G. Faster and more extensive release of caseins from powder particles into solution was evident with the increasing proportion of GMP, with the majority of GMP released within the first 15 min of rehydration. The results of this study will contribute to further development of formulation science for achieving enhanced solubility characteristics of high-protein dairy powder ingredients, such as MCC.

Functionality of MC88- and MPC85-Enriched Skim Milk: Impact of Shear Conditions in Rotor/Stator Systems and High-Pressure Homogenizers on Powder Solubility and Rennet Gelation Behavior

Milk protein concentrate (MPC) and micellar casein (MC) powders are commonly used to increase the protein concentration of cheese milk. However, highly-concentrated milk protein powders are challenging in terms of solubility. The research question was whether and how incompletely dissolved agglomerates affect the protein functionality in terms of rennet gelation behavior. For the experiments, skim milk was enriched with either MC88 or MPC85 to a casein concentration of 4.5% (w/w) and sheared on a laboratory and pilot scale in rotor/stator systems (colloid mill and shear pump, respectively) and high-pressure homogenizers. The assessment criteria were on the one hand particle sizes as a function of shear rate, and on the other hand, the rennet gelation properties meaning gelling time, gel strength, structure loss upon deformation, and serum loss. Furthermore, the casein, whey protein, and casein macropeptide (CMP) recovery in the sweet whey was determined to evaluate the shear-, and hence, the particle size-dependent protein accessibility. We showed that insufficient powder rehydration prolongs the rennet gelation time, leading to softer, weaker gels, and to lower amounts of CMP and whey protein in the sweet whey.

Effect of sodium triphosphate and sodium hexametaphosphate on properties of buffalo milk protein concentrate 60 (BMPC60) powder

Milk protein concentrate (MPC) powders are high-protein, innovative dairy ingredients. Buffalo milk naturally contains higher concentrations of casein and calcium, which have adverse effect on solubility of MPC powders. Therefore, this study was undertaken to investigate the effect of Sodium triphosphate (STP) and Sodium hexametaphosphate (SHMP) addition in ultrafiltered retentate on physicochemical, functional and reconstitution properties, morphological characteristics and rheological behaviour of the resultant powder. Pasteurized buffalo skim milk (PBSM) was concentrated by ultrafiltration (UF) process to obtain 2.53 × UF retentate (2.53 × UFR) with 0.61 protein to total solids (TS) ratio. Compared to PBSM, ultrafiltration significantly increased (p < 0.05) calcium, protein and TS contents of 2.53 × UFR, but significantly decreased (p < 0.05) its heat stability. Addition of STP-SHMP mixture in 2.53 × UFR noticeably improved the solubility, flowability, water binding, oil binding, foaming capacity, foam and thermal stability and, viscosity of treated MPC60 powder over control powder. The DeBroukere (D₄₃) mean, d₅₀, specific surface area, span and water activity values of treated MPC60 powder were 94.96 ± 0.05, 78.33 ± 0.04 µm, 715.93 ± 0.29 m² kg^-1, 1.97 ± 0.01 and, 0.26 ± 0.01, respectively. Scanning electron micrograph showed the presence of different size powder particles without clustering. Rheological modelling of the reconstituted solution of treated MPC60 was very well described by Herschel-Bulkley model. Overall, this study established that addition of STP-SHMP salts mixer in 2.53 × UFR could improve the solubility of resultant buffalo milk based MPC60 powder.

The Influence of Composition and Manufacturing Approach on the Physical and Rehydration Properties of Milk Protein Concentrate Powders

This study investigated the physical and rehydration properties of milk protein concentrate (MPC) powders with five different protein contents (i.e., 38.9, 53.7, 63.6, 74.1, and 84.7%, w/w) prepared by recombining the ultrafiltration (UF) retentate and UF permeate of skim milk. Powder density and flowability increased, while the powder particle size decreased with decreasing powder protein content. The amount of non-wetting MPC powder decreased with decreasing protein content, demonstrating greater wettability for lower protein powders. At protein contents >65% (w/w), the dispersibility and solubility of the powders decreased significantly, likely due to the greater hydrophobic interactions between casein proteins and a lower concentration of lactose. Therefore, as the protein content of the MPC powders was decreased, their rehydration properties improved. The results obtained in this study provide novel insights into the relationship between the composition of recombined UF retentate and UF permeate streams on the subsequent powder particle size, density, and rehydration properties, and demonstrate that such powders possess similar properties to those prepared using conventional direct membrane filtration.

Effect of change in pH, heat treatment and diafiltration on properties of medium protein buffalo milk protein concentrate

The demand of milk protein concentrate (MPC) powders is continuously increasing as high protein dairy ingredients. Presence of higher calcium and casein contents; heating, ultrafiltration (UF), diafiltration (DF) and spray drying of buffalo skim milk induces undesirable changes in milk proteins that causes problem of poor solubility in MPC powders. Therefore, this investigation was aimed to study the effect of change in pH (6.8-native, 7.0-neutral), heat treatments (74 ± 1 °C/15 s, 80 ± 1 °C/5 min, 85 ± 1 °C/5 min, 90 ± 1 °C/5 min) and DF on physicochemical, functional, reconstitution and rheological properties of medium protein buffalo milk protein concentrate (MP-BMPC) powder. Based on maximum ζ-potential and heat stability, UF retentate was selected, diafiltered and spray dried to obtain MP-BMPC powder. Despite having higher protein content, MP-BMPC powder exhibited markedly better functional (solubility, wettability, viscosity and emulsion stability) properties than buffalo milk protein concentrate 60. The interstitial air content, occluded air content, loose bulk density, packed bulk density, particle density and porosity values of MP-BMPC powder were 145.97 and 112.92 mL 100 g^-1 of powder, 0.21 g mL^-1, 0.30 g mL^-1, 0.55 g mL^-1 and 65.09%. Further, its specific surface area; particle size distribution (d₁₀, d₅₀, d₉₀); Sauter (D₃₂) and DeBroukere (D₄₃) mean values were 97.93 m² kg^-1; 34.32, 104.42, 218.58 µm; 61.27 µm and 117.99 µm. The storage modulus (G') and loss modulus (G″) crossover temperature of UF and DF retentates were ~ 57.16 °C and 55.10 °C, respectively. Rheological behaviour of UF, DF retentates and MP-BMPC solution were best explained by Herschel-Bulkley model. Fourier-transform infrared spectroscopy best described amide I, II and III regions in 1700-1400 cm^-1 and 1350-1200 cm^-1 wavenumber range.

Effect of change in pH of skim milk and ultrafiltered/diafiltered retentates on milk protein concentrate (MPC70) powder properties

Poor solubility of milk protein concentrate (MPC) powders are attributed to their high protein and calcium contents. Concentration of skim milk in ultrafiltration (UF) and diafiltration (DF) increased total solids, protein and mineral contents and changed pH and ζ-potential values of the retentates that leads to milk proteins destabilization in 7× UF/DF retentates. Hence, this investigation was aimed to study the effect of change in pH of skim milk (no change; native pH maintained) and DF retentates (5.85 and 7.10) with KOH, NaOH and NaH₂PO₄∙2H₂O on physicochemical, reconstitution, functional and rheological properties of fresh MPC70 powders. MPC70-7.10 powder had significantly higher (P < 0.05) solubility, but MPC70-NaOH and MPC70-5.85 showed significantly lower solubility than control. However, after two months storage at 25 ± 1 °C, control powder had significantly lower solubility (27.78% decrease) than treated powders. These changes in pH, significantly decreased calcium content and specific surface area; significantly improved viscosity, water binding, oil binding, emulsifying, foaming and buffering capacities, L*, a*, flowability, pH (except MPC70-5.85) and packed bulk density (except MPC70-NaOH) of treated powders over control. However, rennet coagulation time of all reconstituted powder solutions was similar. Hershel Bulkley, a best fit model, efficiently explained the pseudoplastic rheological behavior of all reconstituted MPC70 powders. This investigation had established that change in pH could improve the functional properties of MPC70 powders and is a simple, cheap, compatible and easy to use approach. Treated MPC70 powders could replace control in several food formulations owing to their improved functional properties.

Physico-chemical, functional and rheological properties of milk protein concentrate 60 as affected by disodium phosphate addition, diafiltration and homogenization

Ultrafiltration and diafiltration of skim milk altered delicate salt equilibrium and composition of 5× UF retentate (5× UFR), and thus adversely affected the reconstitutional and functional properties of milk protein concentrate (MPC) powders. It might be due to interaction and aggregation of proteins during spray drying. Therefore, this study was envisaged to investigate the effect of disodium phosphate (DSP) addition, diafiltration and homogenization of retentates on physico-chemical, functional and rheological properties of MPC60 powders. Solubility of fresh control powder was significantly lower than MPC60-H powder; at par with that of MPC60-DSP and MPC60-Na-K, but remained minimum after 60 days of storage at 25 ± 1 °C. The pH (6.6) adjustment of 5× UFR with DSP, significantly enhanced the dispersability, wettability, specific surface area (SSA), heat coagulation time (HCT), emulsification capacity and stability; buffer index of MPC60-DSP powder over control. Diafiltration of 5× UFR with NaCl and KCl, significantly (P < 0.05) decreased calcium content, but enhanced pH and mineral content of MPC60-Na-K powder. This treatment led to significant improvement in dispersability, SSA, emulsification capacity and stability, HCT and oil binding properties. Flowability, wettability, dispersability, HCT, foaming capacity, emulsification capacity and stability were also improved significantly in MPC60-H powder made from homogenized 5× UFR. Rheological behavior of reconstituted powder samples exhibited pseudoplastic behavior, best explained by Hershel Bulkley model. These MPC60 powders with improved functional properties can be used for the improvement of quality attributes of various food formulations.

Particle Size of Milk Protein Concentrate Powder Affects the Texture of High-Protein Nutrition Bars During Storage

Milk protein concentrate powder with 85% protein (MPC85) was jet-milled to give 2 particle size distributions (that is, JM-Coarse and JM-Fine) or freeze-dried (FD), in order to improve the functional properties of MPC85 for use in high-protein nutrition (HPN) bars. Volume-weighted mean diameter decreased from 86 μm to 49, 22, and 8 μm in FD, JM-Coarse, and JM-Fine, respectively (P < 0.05). The MPC85 powders modified by jet-milling and freeze-drying were significantly denser than the control MPC85 (P < 0.05). Volume of occluded air in the modified powders decreased (P < 0.05) by an order of magnitude, yet only FD possessed a lower volume of interstitial air (P < 0.05). Particle size reduction and freeze-drying MPC85 decreased its water holding capacity and improved its dispersibility by at least 20%. Contact angle measurements showed that these modifications increased initial hydrophobicity and did not improve wettability. HPN bars made from JM-Fine or FD were firmer by 40 or 17 N, respectively, than the control on day 0 (P < 0.05). HPN bar maximum compressive force increased by 38%, 33%, and 242% after 42 d at 32 °C when formulated with JM-Fine, FD, or control MPC85, respectively. HPN bars prepared with JM-Fine were less crumbly than those formulated with control or FD MPC85. Physically altering the particle structure of MPC85 improved its ability to plasticize within HPN bars and this improved their cohesiveness and textural stability.