Patent Application
20190008176
The present invention relates to an improved method for manufacturing a strained fermented dairy product.
Fermented dairy products are recognized by consumers as healthy food having nutritional benefits. Among these fermented dairy products, strained fermented dairy products present the interest to contain higher levels of proteins than in conventional fermented dairy products, which represent an additional nutritional benefit.
Such strained fermented dairy products are generally prepared by the same method as for conventional fermented dairy products, with an additional step consisting in the separation of a liquid phase also called whey (containing generally water, lactose, minerals, etc.) from the conventional fermented dairy products. The remaining solid phase constitutes the desired strained fermented dairy products having an increased protein content. Such processes are disclosed notably in WO 2014/114970 or WO 2014/169171.
The separation step can be performed notably by centrifugation. However, due to the formation of a thicker dairy product (solid phase) during this step, clogging issues of the separating device can occur after only few hours of operation of the production line.
There is thus a need for an improved method for manufacturing strained fermented dairy products, preventing the clogging of the separating device. The inventors of the present invention have surprisingly discovered that such a clogging issue could be solved by adding a lactase at the time of the fermentation step.
The present invention relates thus to a method for manufacturing a strained fermented dairy product comprising the following successive steps:
Dairy Product:
In the context of the present invention, “dairy product” designates more particularly a dairy product ready for human consumption made from milk of animal or vegetal origin.
The dairy product based on milk of animal origin can be made from milk and milk components having a cow, goat, sheep, buffalo, donkey or camel origin, preferably a cow origin.
The dairy product based on milk of vegetal origin can be made from grain milk such as barley milk, oat milk, rice milk or spelt milk; legumes-based milk such as lupin milk, pea milk, peanut milk or soy milk; nut milk such as almond milk, cashew milk, hazelnut milk or walnut milk; or seed milk such as hemps milk, quinoa milk, sesame seed milk, sunflower seed milk or coconut milk. It contains thus vegetal proteins. Preferably, the dairy product based on milk of vegetal origin will be made from soy milk, oat milk, rice milk or almond milk.
According to a preferred embodiment, the dairy product is made from milk and milk components of animal origin, and in particular of cow origin.
Food additives can also be present in the dairy product, notably chosen among:
If need be, the skilled person will be able to choose appropriate food additives among all the well-known food additives available on the market. These food additives can be added at different stages of the method of manufacturing of the strained fermented dairy product.
Strained Fermented Dairy Product:
The dairy product produced by the method according to the present invention is a strained fermented dairy product.
In the context of the present invention, “strained fermented dairy product” designates more particularly a strained fermented dairy product ready for human consumption, such as a strained fermented milk such as, skyr, greek or a strained yoghurt “also called concentrated yoghurt, Greek-style yoghurt or labneh.
The terms “fermented milk” and “yoghurt” are given their usual meanings in the field of the dairy industry, that is, products intended for human consumption and originating from acidifying lactic fermentation of a milk substrate, having an animal or vegetal origin, preferably an animal origin.
The expression “fermented milk” is thus reserved in the present application for a dairy product prepared with a milk substrate which has undergone treatment at least equivalent to pasteurisation, seeded with microorganisms belonging to the characteristic species or species of each product.
The term “yoghurt” is reserved for fermented milk obtained, according to local and constant usage, by the development of specific thermophilic lactic bacteria known as Lactobacillus delbrueckii subsp. bulgaricus and Streptococcus thermophilus, which must be in the living state in the finished product, at a minimum rate. In certain countries, regulations require the addition of other lactic acid bacteria to the production of yoghurt, and especially the additional use of strains of Bifidobacterium and/or Lactobacillus acidophilus and/or Lactobacillus casei. These additional lactic acid bacteria strains are intended to impart various properties to the finished product, such as that of favouring equilibrium of intestinal flora or modulating the immune system.
In practice, the expression “fermented milk” is therefore generally used to designate fermented milks other than yoghurts.
The term “strained” dairy product refers to a dairy product obtained by a separation step in which a liquid whey is separated from a solid phase (the strained dairy product), such as in step (c) of the method according to the invention.
According to a preferred embodiment, the strained fermented dairy product will not be a cheese.
The strained fermented dairy product obtained by the method according to the invention can have a total protein content comprised between 6 and 16%, notably between 7 and 12%, such as between 8 and 10%.
The “total protein content” of a dairy product corresponds to the weight of the proteins present in the dairy product relatively to the total weight of the dairy product. The total protein content is expressed as a weight percentage.
The total protein content can be measured by Kjeldahl analysis (NF EN ISO 8968-1) as the reference method for the determination of the total protein content of dairy products based on measurement of total nitrogen content. The method is described in both AOAC Method 991.20 (1) and international Dairy Federation Standard (IDF) 2013:1993.
The strained fermented dairy product obtained by the method according to the invention can have a fat content comprised between 0 and 6%, notably between 1 and 5%, such as between 2 and 3%.
The “fat content” of the dairy product corresponds to the weight of the fat components present in the dairy product relatively to the total weight of the dairy product. The fat content is expressed as a weight percentage.
The fat content can be measured by the Weibull-Berntrop gravimetric method described in the standard NF ISO 8262-3.
The strained fermented dairy product used in the method according to the present invention is a high textured dairy product, i.e. a thick dairy product having a viscosity comprised between 1500 and 5000 mPa·s, notably between 3000 and 4000 mPa·s, advantageously between 3300 and 3700 mPa·s.
The viscosity is measured at 24 h (i.e 24 h after the production of the product) by a viscometer, more particularly of Rheomat type, equipped with a measuring bob/measuring tube system of type 2/2 with a shear rate of 64 s−1 during 90 s at 10° C. The viscometer can be for example a Rheomat RM200. The measuring bob/measuring tube system of 2-2 type is a system in which the measuring bob is of type 2 and has a diameter of 24 mm and the measuring tube is of type 2 and has a diameter of 26.03 mm.
The viscosity of the dairy product is the viscosity as measured after 24 h cold storage at 2 to 6° C. after the end of step (c). Indeed, this viscosity can change during the shelf life of the product. In particular, the viscosity of a fermented dairy product increases during its shelf life.
Step (a)—Providing a Dairy Product
The dairy product used as a starting material to prepare the strained fermented dairy product according to the invention is a non-fermented dairy product, also called dairy mix or dairy starting material, containing milk and milk components of animal or vegetal origin, and optionally other food additives such as those indicated previously. The dairy product is thus obtained by the mixing of its various ingredients.
The milk and milk components of animal original can be whole milk and/or wholly or partly skimmed milk, which can be used in a powder, concentrated or retentate form which can be reconstituted by addition of water. Other milk components can be added such as cream, casein, caseinate (for ex. calcium or sodium caseinate), whey proteins notably in the form of a concentrate (WPC), milk proteins notably in the form of a concentrate (MPC), milk protein hydrolysates and mixtures thereof.
The milk and milk components of animal origin can have a cow, goat, sheep, buffalo, donkey or camel origin, preferably a cow origin.
The milk and milk components of vegetal origin can be obtained from grain milk such as barley milk, oat milk, rice milk or spelt milk; legumes-based milk such as lupin milk, pea milk, peanut milk or soy milk; nut milk such as almond milk, cashew milk, hazelnut milk or walnut milk; or seed milk such as hemps milk, quinoa milk, sesame seed milk, sunflower seed milk or coconut milk. It contains thus vegetal proteins. Preferably, the dairy product based on milk of vegetal origin will be made from soy milk, oat milk, rice milk or almond milk.
According to a preferred embodiment, the dairy product is made from milk and milk components of animal origin, and in particular of cow origin.
The dairy product provided in step(a) can have a total protein content comprised between 2.8 and 4.6%, notably between 3.1 and 4.0%, such as between 3.2 and 3.6%.
The dairy product provided in step(a) can have a fat content between 0 and 2.0%, notably between 0.05 and 1.0%, such as between 0.1 and 0.3%.
According to an embodiment, the dairy product provided in step a) is a heat-treated dairy product.
The heat-treatment of the dairy product is also called pasteurisation. It aims to kill microorganisms, including pathogenic microorganisms, in the dairy product in order to preserve the quality and the organoleptic properties of the final product and to prevent the consumer to be infected by pathogenic microorganisms present in the dairy product and develop diseases.
The heat-treatment is commonly performed at a temperature (heat-treatment temperature) comprised between 72° C. and 140° C., preferably during 2 seconds to 30 minutes.
The heat-treatment can also be performed in several steps, notably two steps, where the dairy product is heated at distinct temperatures in each step. For example, the heat-treatment can be performed according to the two following successive steps:
Advantageously, a homogenisation step is performed between the 2 heating steps, notably at a pressure comprised between 20 and 300 bars (20-300·105 Pa), notably between 50 and 250 bars (50-250·105 Pa). This homogenisation step will be performed more particularly at a temperature of between 55 and 95° C.
Step (b)—Adding Lactase and a Culture of Bacteria and Fermentation
Lactase and a culture of bacteria are added to the dairy product, in particular to a dairy product which has been heat-treated. The dairy product is fermented in particular at a temperature (fermentation temperature) between 25° C. and 44° C., notably between 30 and 40° C. The fermentation is performed in particular for 3 to 25 hours, preferably for 5 to 15 hours.
The lactase and the culture of bacteria cannot be added to the dairy product at a too high temperature and are generally added at the fermentation temperature.
Consequently, when the dairy product has been heat-treated, it is necessary to cool the heat-treated dairy product obtained at the end of the heat-treatment step to the fermentation temperature before inoculating the lactase and the culture of bacteria and performing the fermentation step.
The fermentation step is commonly a lactic fermentation which involves techniques well-known to the skilled person.
When reference is made to a “lactic fermentation”, this means an acidifying lactic fermentation which results in milk coagulation and acidification following the production of lactic acid which may be accompanied by the production of other acids, carbon dioxide and various substances such as exopolysaccharides (EPS) or aromatic substances, for example diacetyl and acetaldehyde.
Various bacteria can be used for performing the fermentation of the dairy product and in particular lactic acid bacteria such as:
Preferred lactic acid bacteria to be used in the present invention are selected from Lactobacillus bulgaricus, Streptococcus thermophilus, Lactococcus lactis, Bifidobacterium animalis subsp. lactis, and combinations thereof.
More preferred lactic acid bacteria to be used in the present invention are selected from:
In the framework of the present invention, the culture of bacteria comprises:
By “mesophilic lactic acid bacteria” is meant, in the present invention, lactic acid bacteria that grow best in moderate temperature, typically between 20 and 30° C. The mesophilic lactic acid bacteria can be in particular Lactococcus sp. such as defined previously, and even more particularly Lactococcus lactis subsp. lactis.
By “thermophilic lactic acid bacteria” is meant, in the present invention, lactic acid bacteria that grow best in relatively high temperature, typically above 35° C., notably between 38 and 44° C. The thermophilic lactic acid bacteria can be selected in the group consisting of Streptococcus sp., Lactobacillus sp., Bifidobacterium sp. and combinations thereof, such as defined previously, and notably Streptococcus thermophilus, Lactobacillus delbrueckii subsp. bulgaricus, Bifidobacterium animalis subsp. lactis, or a combination thereof.
According to a particular embodiment, the culture of bacteria used in the present invention comprises:
According to a preferred embodiment, the culture of bacteria used in the present invention comprises:
According to another embodiment, the culture of bacteria comprises at least one strain of Bifidobacterium sp. The Bifidobacterium sp. can be Bifidobacterium bifidum, Bifidobacterium infantis, Bifidobacterium animalis and especially Bifidobacterium animalis subsp. lactis, Bifidobacterium breve, Bifidobacterium longum or a combination thereof.
According to a particular embodiment, e culture of bacteria comprises, notably consists in, a combination of Lactobacillus delbrueckii subsp. bulgaricus, Streptococcus thermophilus and Lactococcus lactis subsp. lactis.
According to another particular embodiment, the culture of bacteria comprises, notably consists in, a combination of Lactobacillus delbrueckii subsp. bulgaricus, Streptococcus thermophilus, Lactococcus lactis subsp. lactis and Bifidobacterium animalis subsp. lactis.
The fermentation step will be stopped, notably by cooling, advantageously when the breaking pH is reached, i.e. a pH comprised between 4.80 and 4.20, notably between 4.65 and 4.35.
The lactase used in the present invention can be any kind of lactase such as:
The lactase is advantageously added in an amount of 0.005 wt % to 0.20 wt %, in particular 0.01 wt % to 0.15 wt %, preferably 0.02 wt % to 0.06 wt %, based on the total weight of the dairy product.
The lactase and the culture of bacteria are added to the dairy product simultaneously or separately. Advantageously, the lactase is added before or along with the culture of bacteria. Preferably, the lactase is added before the culture of bacteria, notably at least 10 min and in particular at least 20 min before the culture of bacteria, such as 10 to 40 min before the culture of bacteria, in particular 20 to 30 min before the culture of bacteria.
Indeed, it has been surprisingly demonstrated that the addition of lactase to the dairy product slightly before the culture of bacteria allows further improving the separation step (see example 4).
According to a preferred embodiment, no other enzyme will be added in this step or another step of the method according to the invention. In particular, no chymosin (present in rennet) will be added in this step or another step of the method according to the invention.
Step (c)—Separating a Liquid Phase (Called Whey) from the Fermented Dairy Product
After fermentation, the fermented dairy product is subjected to a separating step in order to form a strained fermented dairy product having a higher total protein amount than the one of the starting fermented dairy product.
In this step, a liquid phase (the whey) containing mainly water, lactose and minerals is separated from the fermented dairy product so that the strained fermented dairy product remains.
This step is preferably performed by centrifugation, using thus a centrifugal separator as separating device.
This step is advantageously performed at a temperature (separation temperature) comprised between 30 and 45° C., notably between 35 and 43° C. Consequently, it could be necessary to heat or cool (notably heat) the fermented dairy product obtained at the end of the fermentation step (b) to the separation temperature before performing the separation step (c).
Advantageously, most of the proteins contained in the fermented dairy product remains in the final strained fermented dairy product. The protein recovery rate (PRR) is thus advantageously above 93 wt %, preferably above 95 wt %.
By “protein recovery rate” is meant, in the present invention, the percent ratio between the total protein content (in wt) in the fermented dairy product and the total protein content (in wt) in the strained fermented dairy product (i.e. the ratio of the total protein content (in wt) in the dairy product before and after the separation step (c)).
The strained fermented dairy product obtained at the end of this step will have thus advantageously a total protein content comprised between 6 and 16%, notably between 7 and 12%, such as between 8 and 10%. Indeed, the aim of the separation step (c) is to obtain a target total protein content.
In the absence of lactase, a clogging of the separating device is observed after only few hours of operation of the production line requiring to stop the production line and to clean the separating device (see example 1 and
Actually, the clogging issue referred here is not related to standard nozzles clogging, commonly observed in standard centrifugal separation processes, when small particles collapses one or two nozzles and the outlet flow rates of the device are affected as immediate consequences.
The clogging phenomenon described here is observed between the separation disks of the centrifugal device (see
It can be hypothesized that a small part of proteins not solubilized could “initiate” the clogging by sticking onto the walls of the separating device due to a specific biofilm produced by the specificity of the bacteria strains used in the fermentation step. Then, the more the process is going ahead, the more the proteins accumulate on the disks.
When this clogging issue occurs, the total protein content in the liquid phase or whey increases, whereas the total protein content in the strained fermented dairy product decreases (see example 1/
Without wishing to be bound by any theory, the inventors are of the opinion that this disks clogging issue could be due to the production of exopolysaccharides (EPS) by the bacteria which could lead to the obtaining of a gel structure having a lower permeability, an increased water binding, and the formation of a biofilm which can stick to the inner walls of the separating device.
The inventors are of the opinion that the lactase addition, at the time of the fermentation step, allows overcoming this clogging issue probably by modifying the metabolism of the bacteria used for the fermentation step impacting then the EPS production (notably in amount and/or in nature).
Optional Step (d)—Smoothing
A smoothing step (e) can also be performed after the separation step (c).
This smoothing step can be carried out by means of a rotor stator mixer such as defined in WO 2007/095969.
This step can be carried out at a temperature (smoothing temperature) of between 30 and 45° C.
Optional Step (e)—Cooling
Advantageously, the strained fermented dairy product is a refrigerated product, i.e. a product having a storage temperature of between 1 and 10° C., notably between 4 and 8° C.
The method according to the invention can thus comprise after step (c), and notably after step (d) when a smoothing step is performed, an additional step (e) of cooling the strained fermented dairy product to its storage temperature.
Optional Step (f)—Adding Food Additives after the Separation Step
It could be envisaged to add to the strained fermented dairy product, after the separation step (c), and notably after step (d) when a smoothing step is performed, and notably after step (e) when a cooling step is performed, additional food additives, such as a cream material and/or a fruit preparation, if necessary.
The cream material can be cream or a mixture of cream and milk. It can have a fat content of from 20 to 50 wt %, in particular from 23 to 40 wt %.
The fruit preparation can be selected from fruits, fruit pieces, fruit puree, fruit compote, fruit sauce, fruit coulis, fruit jam, fruit jelly, fruit juice and mixtures thereof, optionally in a concentrated or dried form, optionally present in a matrix.
For example, the fruit(s) of the fruit-based preparation can be selected from strawberry, raspberry, blackberry, blueberry, cherry, apricot, peach, pear, apple, plum, pineapple, mango, banana, papaya, passion fruit, pomelo, orange, lemon, kiwi, coconut, vanilla and mixtures thereof.
The present invention relates also to the use of a lactase for preventing the clogging of the separating device used in the preparation of a strained fermented dairy product.
The strained fermented dairy product can be as defined previously. In particular, the strained fermented dairy product will have a total protein content comprised between 6 and 16%, notably between 7 and 12%, such as between 8 and 10%. The strained fermented dairy product can be more particularly a refrigerated product, i.e. a product having a storage temperature of between 1 and 10° C., notably between 4 and 8° C.
This strained fermented dairy product is prepared from a fermented dairy product by a separation step, using a separating device. The separating device is advantageously a centrifugal separator. The separation step can be performed notably as defined above for step (c). The separation step can be followed by a cooling step of the strained fermented dairy product to its storage temperature.
The fermented dairy product used to prepare the strained fermented dairy product will have advantageously a total protein content comprised between 2.8 and 4.6%, notably between 3.1 and 4.0%, such as between 3.2 and 3.6%. The fermented dairy product can be prepared from a dairy product, notably as defined in step (a) above. The preparation of the fermented dairy product from the dairy product comprises at least a fermentation step using notably the culture of bacteria defined previously. This fermentation step is advantageously preceded by a heat-treatment step. The fermentation step and the heat-treatment step can be performed as defined previously (see steps (a) and (b)).
The lactase can be any kind of lactase such as:
The lactase and the culture of bacteria can be added simultaneously or separately. Advantageously, the lactase is added before or along with the culture of bacteria. Preferably, the lactase is added before the culture of bacteria, notably 10 to 40 min before the culture of bacteria, in particular 20 to 30 min before the culture of bacteria.
Further details or advantages of the invention might appear in the following non-limitative examples illustrated by the following figures.
1. Evolution of Total Protein Content at the Outlet of the Separator Device During Separation Before and after Disk Clogging Appears
A strained fermented dairy product was prepared by fermenting a heat-treated skimmed dairy mix (prepared from skimmed milk and skimmed milk powder in proportions so as to obtain a total protein content of about 3.5%) with a culture of lactic acid bacteria consisting of a mix of Lactobacillus delbrueckii subsp. bulgaricus, Streptococcus thermophilus, Lactococcus lactis subsp. lactis and Bifidobacterium animalis subsp. lactis.
The heat-treatment was performed according to the following steps:
The heat-treated dairy mix was fermented at 37° C. and went into lactic acidification until reaching a targeted pH of 4.60.
The fermented dairy product was then re-heated to an appropriate separation temperature, around 41° C., and then separated by a 12 nozzles centrifugal separation device to produce around ⅓ of a strained fermented dairy product reaching a total protein content of about 10% and ⅔ of whey.
After some hours of production, the total protein content in the strained fermented product at the outlet of the device suddenly decreases (below 9.3% total protein content) whereas the total protein content recovered in the whey increases the other way around (above 0.50%), without observing any fluctuation on the flows neither of the whey nor on the strained fermented mass outlet (see
When this effect appears, we observe a degradation of the main separation performance parameters: protein recovery rate decreases significantly (2% versus the starting phase of the production and getting worse when going ahead with the production) and the yield was increasing in the same way.
A heat-treated dairy mix was prepared as in example 1. The heat-treated dairy mix was then divided in 3 batches, to be inoculated with 3 different cultures of bacteria:
The three heat-treated dairy mixes were then fermented as indicated in example 1. The fermented dairy products were then re-heated to the appropriate separation temperature, around 41° C., and then separated at laboratory spin centrifuge: 4 samples of 40 g of each fermented dairy product, at 4000 rpm during 4 min. Then, the whey separated was weighted with a precision weighting device. The results obtained are presented on
These results demonstrate that the quantity of whey released by each fermented dairy product is fully dependent on the type of bacteria used for the fermentation step: in all the products where a combination of thermophilic and mesophilic lactic acid bacteria strains (products b) and c)) were used for the fermentation step, a decrease of whey releasing capacity was observed.
Without wishing to be bound by any theory, the inventors are of the opinion that depending upon the type of bacteria used to performed the fermentation step, the secondary compounds resulting from the standard lactic acid fermentation may vary, producing differences in the permeability of the coagulum, therefore, producing differences in the way the curd is able to separate the liquid phase (whey) from the solid phase.
The fermented dairy products a) and b) were also observed in microscopy confocal (Confocal microscope Leica TC SP2—fluorescent markers for proteins DyLight 488, λabs=493 nm; λemi=518 nm, 10 μL in 500 μL of fermented product—×40 water immersion at 20° C.). The corresponding photos are presented on
Without wishing to be bound by any theory, the inventors are of the opinion that the “dark” spaces in the proteins networks could contain different types and amounts of secondary metabolites of the fermentation (as for ex. exopolysaccharides), able to bind water, therefore, making the coagulum more impermeable and thus, more difficult to be separated.
3. Impact of the Addition of a Lactase on the Whey Releasing Capacity of a Dairy Product Fermented with a Culture of Thermophilic and Mesophilic Lactic Acid Bacteria Strains
A heat-treated dairy mix was prepared as in example 1. The heat-treated dairy mix was then divided in 3 batches, to be inoculated as follows:
The three dairy mixes were fermented as detailed in example 1. The fermented dairy products were then re-heated to the appropriate separation temperature, around 41° C., and then separated at laboratory spin centrifuge: 4 samples of 40 g of each fermented dairy product, at 4000 rpm during 4 min. Then, the whey separated was weighted with a precision weighting device. The results obtained are presented on
It was observed that the quantity of whey released by each fermented dairy product is fully dependent on the type of bacteria culture as mentioned in example 2 (product a) v. product c)). It was also observed that the addition of the lactase leads to a significant increase of the permeability of the curd (product a) v. product b)), close to the permeability of the curd of the dairy product fermented with only thermophilic strains (product c)).
4. Impact of the Dosage and Time of Addition of the Lactase on the Whey Releasing Capacity of a Dairy Product Fermented with a Culture of Thermophilic and Mesophilic Lactic Acid Bacteria Strains
A heat-treated dairy mix was prepared as in example 1. The heat-treated dairy mix was then divided in 5 batches, to be inoculated as follows:
The five dairy products were then fermented as in example 1. The fermented dairy products were then re-heated to the appropriate separation temperature, around 41° C., and then separated at laboratory spin centrifuge: 4 samples of 40 g of each fermented dairy product, at 4000 rpm during 4 min. Then, the whey separated was weighted with a precision weighting device. The results obtained are presented on
It was observed that the quantity of whey released by each coagulum is fully dependent on the type of bacteria culture (product a) v. product e)) as mentioned in examples 2 and 3. It was also observed that the addition of a lactase leads to a significant increase of the permeability of the curd (products b), c) and d) v. product a)). Moreover, it was observed that the time of addition of the lactase has an additional impact on the separation step (product c) v. product d)). When the lactase was added 20 minutes before the culture of bacteria, the impact on the whey releasing capacity was greater, allowing a slight decrease on the dosage of the lactase itself.
The total protein content of the strained fermented dairy products obtained in each case is presented on
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2015/002576 | 12/24/2015 | WO | 00 |
