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Milk Powder: Types and Manufacture
Milk Powder: Physical and Functional Properties of Milk Powders
Dairy Ingredients in Non-Dairy Foods
Infant Formulae
fractionation by membrane processes (e.g., microfiltra- • are a valuable food reserve for emergencies;
tion, ultrafiltration, nanofiltration, and reverse osmosis),
electrodialysis or ion exchange, provided opportunities
• suitable for various tailor-made food products.
are
The most frequently used technique for the dehydration of
and versatility to drying of milk, milk components, and dairy products is spray drying. It became popular in the dairy
products. Dry milk products currently include milk pow- industry in the 1970s, but at that time there were few scien-
der, skim milk powder, whey powder, various whey tific or technical studies on spray drying and, in particular,
protein powders, dry dairy-based beverages, casein, case- none on the effects of spray drying parameters or on the
inates, coprecipitates, infant formula and cheese products, effects of the physicochemical composition and microbiol-
lactose, coffee whiteners, and dry ice cream mixes. The ogy of the concentrates on powder quality. Manufacturers
dairy industry has developed new technologies for isolat- acquired expertise in milk drying, and eventually in whey
ing and purifying proteins (e.g., casein, caseinates, and drying processes, through trial and error. Because of the
whey proteins) such as milk protein concentrates variety and complexity of the mixes to be dried, a more
(MPCs), milk protein isolates (MPIs), whey protein con- rigorous method based on physicochemical and thermo-
centrates (WPCs), whey protein isolates (WPIs), micellar dynamic properties has become necessary. Greater
casein concentrates (MCCs), micellar casein isolates understanding of the biochemical properties of milk products
(MCIs), whey concentrates, and selectively deminera- before drying, water transfer during spray drying, and the
lized whey concentrates. Availability of new membrane properties of powders and influencing factors is now essential
separation techniques and improvements in chromato- for the production of milk powder. The lack of technical and
graphic resins now provide the dairy technologist with economic information and the lack of understanding of
several options for the extraction and purification of scientific methods prevent the manufacturer from optimiz-
almost all of the major milk proteins. ing his plant in terms of energy costs and powder quality.
World production of dry dairy products has increased The aim of this article is to provide information on two
steadily in recent years, due to the main advantages of the areas, that is, the principles of spray drying and the
powders, which manufacture of milk powders.
108
Dehydrated Dairy Products | Milk Powder: Types and Manufacture 109
Principles of Spray Drying water vapor are spontaneously established between the
droplet and the air:
Drying is defined as the removal of a liquid (usually
water) from a product by evaporation, leaving the solids • heat transfer from the air to the droplet occurs under
the influence of the temperature gradient;
in an essentially dry state. A number of different drying
processes are in use in the dairy, food, chemical, and • water transfer occurs in the opposite direction,
explained by variation in the partial pressure of water
pharmaceutical industries, such as spray drying, fluid
vapor between the air and the droplet surface.
bed drying, roller drying, freeze drying, microwave
drying, and superheated steam drying. The drying kinetics are related to three factors:
In special circumstances, roller drying (Figure 1) is
used for the production of milk powder for particular • the evaporation surface,
applications, for example, confectionery and animal • between
the difference in the partial pressure of water vapor
the particle and the drying air,
feeds. Direct contact of concentrated milk with rotating
steam-heated rollers adversely affects the components of • particle toward
the rate of water migration from the center of the
its surface.
milk, especially proteins and lactose. Some reactions such
as protein denaturation, Maillard reactions, and lactose The main components of a spray drying installation are as
caramelization are irreversible. follows (Figure 2):
Due to considerations related to drying economics and
final product quality, the processes of greatest significance • Drying chamber (Figure 2, position 7).
for milk and dairy powder manufacture are spray drying and • Air heating system.
Air filtration (Figure 2, position 17).
drying), as drying is accomplished in a very short time Three-stage systems combine all the advantages of
and at a low temperature; extended two-stage drying, using spray drying as the
• the process is fully automatic with complete control of
drying parameters and minimal labor of any type;
primary stage, fluid bed drying of a static fluid as the
second drying stage, and drying on an external vibrating
• the product comes into contact with the drying cham-
ber wall only in the powder form, so there is neither a
fluid bed as the third drying stage. Although two- and
three-stage drying may produce both nonagglomerated
problem of equipment maintenance nor a problem with and agglomerated powders, their principal products are
the microbiological quality of the final product. instant milk powders, which are discussed later in this
article.
However, the investment cost for a spray drying plant is
Table 1 shows that energy consumption varies
high, and is economically justified only for large quanti-
according to the drying processes. Energy consumption
ties or for products with high added value. is 6677, 5362, 4602, and 4020 kJ for a one-stage spray
Single-stage spray dryers are now considered obsolete dryer, two-stage spray dryer, and two-stage spray dryer
although many are still in operation. The residence time with a vibro-fluidizer, with CD-type static fluid bed or
is not long enough to obtain a real equilibrium between MSD type with static fluid bed, respectively, to pro-
the relative humidity (RH) of the outlet air and water duce 1 kg of powder from skim milk concentrate
activity of the powder. The outlet temperature of the air containing 48% total solids. The reduction in energy
must therefore be high, reducing the thermal efficiency of consumption with increased number of drying stages is
the single-stage spray dryer. The two-stage drying system due to increased product residence time, allowing an
consists of limiting the spray drying to a process with a increase in the inlet air temperature and increased con-
longer residence time (several minutes) to provide a bet- centrate flow rate.
ter thermodynamic balance. A second final drying stage is
necessary to optimize the moisture content by using an
integrated fluid bed (static) or an external fluid bed
(vibrating) (Figure 2, positions 11 and 14). The integrated Milk Powder
fluid bed can be either circular (e.g., Multi-Stage Dryer
(MSD) chamber) or annular (e.g., compact dryer (CD) The flow chart of milk powder production, consisting of
chamber). The three-stage drying systems, with an inter- reception, clarification, cooling, standardization, heat
nal fluid bed as a second stage in combination with an treatment, evaporation, homogenization, drying, and
external vibrating fluid bed as a third-stage dryer, first packaging, is shown in Figure 3.
appeared at the beginning of the 1980s and were called Raw full-fat milk used for powder production must be
compact dryer instantization (CDI) or MSD. Today, of high chemical, sensory, and bacteriological quality,
they dominate the dairy powder industry (Figure 2). which is regulated by government standards. After
Dehydrated Dairy Products | Milk Powder: Types and Manufacture 111
SD
SD
Inlet air temperature C 200 230 230 260
1
Drying air kg h 31 500 31 500 31 500 31 500
1
Skim milk with 8.5% solids kg h 12 950 19 800 24 000 31 300
1
Concentrate with 48% solids kg h 2290 3510 4250 5540
1
Evaporation in chamber kg h 1150 1720 2010 2620
Powder from chamber:
1
3.5% moisture kg h 1140
1
6.0% moisture kg h 1790
1
9.0% moisture kg h 2240 2920
1
Fuel oil consumption kg h 175 205 205 230
Power consumption kW 120 130 140 150
Energy consumption:
Total spray drying MJ 7612 8876 8918 9965
Energy per kg powder in chamber kJ 6677 4959 3981 3413
FB VF SFB SFB
Inlet air temperature C 100 115 120
1
Drying air kg h 4290 6750 11 500
1
Evaporation in VF/SFB kg h 45 125 165
1
Powder from FB, 3.5% moisture kg h 1745 2115 2755
1
Steam consumption kg h 167 290 400
Power consumption kW 20 25 35
Total energy consumption in FB MJ 481 816 1110
Total drying
Total energy consumption MJ 7612 9357 9734 11 075
Total energy per kg powder kJ 6677 5362 4602 4020
Energy ratio % 100 80 69 60
Dryer efficiency 0.54 0.66 0.69 0.79
FB, fluid bed; MSD, Multi-Stage-Dryer; SD, spray dryer; SFB, static fluid bed; VF, vibro-fluidizer.
reception, milk is clarified, usually by centrifugal separa- solids for spray drying. Concentrating milk prior to
tors, and cooled to 4 C in plate heat exchangers, followed drying has a positive effect on milk powder quality: milk
by storage at the same temperature. The next operation is powder produced from concentrated milk consists of
standardization, which is used to adjust the ratio of milk larger powder particles containing less occluded air,
fat to total solids as required in the final product. Heat and therefore results in better storage stability.
treatment is commonly performed using the indirect Homogenization is not an obligatory operation, but is
method in a tubular or plate heat exchanger at 88–95 C usually applied with the aim of reducing the free-fat
for 15–30 s, the aims being to destroy pathogenic bacteria content in full-fat milk powder, which has a negative
and most of the saprophytic microorganisms, to inactivate effect on powder solubility and its susceptibility to
enzymes, especially lipase, and to activate SH groups in oxidation.
-lactoglobulin, which results in an antioxidative effect.
Evaporation is used to concentrate milk prior to drying,
and can be combined with reverse osmosis. Evaporation is
performed in multiple effect vacuum evaporators with Skim Milk Powder
mechanical or thermal steam recompression, where
energy consumption is about 10–30 times lower than in The procedure for the manufacture of skim milk powder
spray drying. The differences in the concentration of total (nonfat dry milk) differs in several features from the
solids are determined by the drying technique used: process for full-fat milk powder: fat standardization
30–35% total solids for roller drying and 45–50% total leads to very low fat content in skim milk, that is,
112 Dehydrated Dairy Products | Milk Powder: Types and Manufacture
WPNI
1
Class (mg N g powder)
Figure 5 Flow chart for ultralow-heat skim milk powder Figure 6 Flow chart for instantized milk powder production by
production. ‘rewetting’ procedure.
114 Dehydrated Dairy Products | Milk Powder: Types and Manufacture
(SD2P) registered under the following identification: ready-made dishes, breakfast blends, food blends for special
IDDN.FR.001.480002.002.R.P.2005.000.30100. categories (nutrition blends for geriatric subjects, sports
people, or convalescents), blends for meal replacements,
modified milk products, and imitation milk products.
Packaging and Storage
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