Showcasing next-generation dairy ingredient technologies

Dairy ingredients serve as the foundation for various food sectors, such as infant formulas, baking and confections, and sports nutrition. Dairy manufacturers have embraced numerous innovative processing technologies to produce these ingredients. However, amid growing environmental concerns associated with food processing and increased consumer awareness of healthy food products, there is a noticeable shift toward greener processing methods, emphasizing the importance of preserving the natural characteristics of food to the maximum extent possible.

Due to the heat-sensitive nature of milk components, non-thermal processing technologies are gaining popularity in the dairy industry. These technologies are viewed as potential alternatives to traditional milk pasteurization methods. This transition addresses environmental considerations and aligns with the broader trend of prioritizing a health-conscious approach in the production of dairy products.

The implementation of ultra-shear technology has proven to be a pivotal approach in the production of clean-label beverages. By reducing the particle size of the product through intense shear forces (400 MPa), this technology plays a crucial role in eliminating the necessity for stabilizers and enhancing suspension stability. Furthermore, it effectively deactivates pathogenic and spoilage-causing microorganisms without requiring thermal exposure, thereby preserving the natural components more effectively.

Another breakthrough and an emerging technique known as Millisecond technology (MST) can be integrated with High-Temperature Short Time pasteurization to address post-pasteurization contamination concerns in milk. This technologically advanced solution significantly enhances the overall quality and shelf life of dairy products. The method involves subjecting the milk to rapid pressurization followed by immediate depressurization, coupled with instant heating (72℃, 0.02-0.05 sec) and rapid cooling. This process alters the structure of microbial cells, leading to their deactivation.

The dairy industry has also experienced advancements in Cold Plasma (CP) and Ultrasound (US) technology. CP, acknowledged as the fourth state of matter, exists in a gaseous state involving radiation, free radicals, and charged particles. In this processing technology, microbial inactivation occurs due to oxidative stress generated by reactive oxygen species. Electric discharge-generated CP is undergoing thorough testing for its potential to preserve perishable dairy products. This method retains nutritional content while deactivating microorganisms and enzymes responsible for color changes and off-flavors. On the other hand, the US process employs sound waves at frequencies higher than 16 kHz to create tiny bubbles through cavitation. These bubbles rapidly expand and contract, generating shocking waves and heat energy. Beyond microbial inactivation, this technology holds promise in whey ultrafiltration, functional food extraction, viscosity reduction, milk fat globule homogenization, and cheese block cutting.

Sonali Sharma is a Business Partner in Process Transformation at Agropur US Inc. where she manages and executes project activities for organizational transformation. She completed her M.S. in Food Science from Washington State University and a B.S. in Dairy Technology. Actively involved in the scientific community, she is a member of the IFT’s Scientific Discovery Workgroup and oversees social media for Minnesota IFT. Sonali’s industrial and research projects have focused on manufacturing dairy products, dairy microbiology, and food safety.

Pranav Vashisht serves as a Continuous Improvement Specialist at Idaho Milk Products, where he leads and manages process development and improvement projects. He is also a team leader of the Special Initiative Team of the Dairy Foods Division of IFT and a board member of Intermountain IFT. Pranav has a M.S. in Food Science and a B.S. in Dairy Technology. Pranav has a strong background in dairy products manufacturing and industrial/research experience involving multiple projects with three dairy industries and three research groups.

Artificial intelligence (AI) is another domain making significant strides in the dairy sector, playing a crucial role in transforming the dairy business, especially in quality assurance and dairy product production. It is actively utilized in milk quality control, leveraging advanced algorithms to detect abnormalities and swiftly ensure strict adherence to quality standards. Integrating AI in the dairy industry brings advantages such as increased productivity, enhanced product quality, and the potential for groundbreaking advancements in dairy processing. As AI continues to be integrated, the dairy sector is poised to experience novel developments contributing to its overall growth and efficiency.

Beyond processing techniques, alterations in product formulations have been noted, specifically in ingredient modifications. Incorporating biosurfactants, such as glycolipids, lipoproteins, and lipopeptides, has captured the attention as emulsifiers in ice cream manufacturing or as antimicrobial agents. When used for emulsification, this enhances the creaminess and texture of ice cream products. Simultaneously, their antimicrobial properties play a crucial role in preventing the formation and adhesion of biofilms on surfaces.

In addition to environmental concerns within the dairy processing industry, consumers have also taken notice of environmental issues associated with dairy farms. This heightened awareness is likely to result in a reduction in milk production. As a response to this challenge, there is a notable interest in synthetic biology, an innovative approach that empowers researchers to modify the genetics of microorganisms to replicate the intricate processes occurring inside a bovine's body, ultimately leading to the generation of milk constituents. The precision fermentation process, a facet of synthetic biology, is revolutionizing the traditional dairy production process. It addresses environmental concerns linked to conventional farming, aiming for a pure and uniform final product.

Precision fermentation is seen as a tool to produce highly efficient microbial strains capable of generating nature-identical casein and whey proteins, allowing the production of imitation dairy products with functionality comparable to traditional ones. Notably, a France-based startup has recently developed a yeast capable of fermenting a vegetable-based medium, generating milk proteins with an identical texture and taste. Another innovative HYDRO project, initiated by the European Council, is dedicated to developing microbes capable of transforming carbon dioxide and hydrogen into β-lactoglobulin using electricity and water.

Overall, regardless of the transformations witnessed among consumers, the dairy industry is well-prepared and positioned on the brink of a bright and promising future. This optimistic trajectory is fueled by a plethora of recent breakthroughs and advancements, encompassing cutting-edge technologies and a heightened emphasis on sustainability. These progressive developments serve as guiding forces, steering the dairy sector toward a prosperous tomorrow. DF