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Lanza Pacheco Antonio Carlos QUESO
Lanza Pacheco Antonio Carlos QUESO
O RI GI NA L
RESEA RCH Optimization of process parameters for the development of
a cheese analogue from pigeon pea (Cajanus cajan) and
soy milk using response surface methodology
P VER MA 1 , U S AGRAWAL 1 , A K S HAR M A 2 * , B C S AR KAR 2 and H K
S HAR MA 2
1
Department of Post Harvest Process and Food Engineering, G.B. Pant University of Agriculture and Technology,
Pantnagar, U.A. 263 145, India and 2Department of Food Technology, Sant Longowal Institute of Engineering and
Technology, Longowal, Sangrur, Punjab 148 106, India
Response surface methodology was used to optimize starter culture concentration (3–7%), pigeon pea–
soy solids ratio (1 : 0.3 –1 : 1.1), pigeon pea–water ratio (1 : 12–1 : 9), incubation temperature (37–45°C)
and coagulation temperature (75 –95°C) in the development of a cheese analogue from pigeon pea and
soy milk. Pigeon pea milk and soy milk were prepared by a hot water grinding method, followed by
filtration and inoculation. Cheese analogue was obtained through coagulation of the fermented milk by
boiling for 15 min, followed by filtration using double-layered muslin cloth and pressing at 1 kg/cm2
pressure for 1 h. The results showed that the total solids recovery ( TSR), protein content, fat content and
pH varied from 51.09–62.61%, 40.04–55.93%, 9.35–15.36% and 4.48–4.9, respectively, depending on
the experimental conditions. The optimum conditions of process parameters for maximum total solids
recovery were 6.0% starter culture concentration, 1 : 0.4 pigeon pea–soy solids ratio, 1 : 11 pigeon pea–
water ratio, 40.5°C incubation temperature and 88.5°C coagulation temperature.
Keywords Cheese analogue, Pigeon pea milk, Response surface methodology (RSM), Soy milk.
I N T RO D U C T I O N
incubation temperature, coagulation temperature,
Legumes are an important source of vegetable pigeon pea–soy solids ratio and pigeon pea–water
protein and many essential amino acids of the ratio on the development of cheese analogues from
vegetarian diet in the Indian subcontinent, but their pigeon pea milling by-products and soybeans.
per capita availability is very low (37.8 g /day). A
potential solution is the development of imitation
M AT E R I A L S A N D M E T H O D S
milk and milk products by utilizing protein from
legumes and their milling by-products. Imitation Materials
milk and milk products replace or extend animal Pigeon pea (Cajanus cajan) grains of the UPAS-20
milk which is too expensive (Padda et al. 1985). variety were procured from U.P. Seed and Tarai
They can also be used to produce cheese analogues Development Corporation, Haldi, India and soybean
which are balanced in minerals and vitamins as (Glycine max) grains were obtained from a local
well as protein and energy (Hallens and Milner market. Streptococcus thermopilus and Lactobacillus
1969). Cheese analogues may have better keeping delbrueckii subspp. bulgaricus obtained from the
quality than natural cheese because vegetable fat is National Dairy Research Institute, Karnal, India,
less likely to develop rancidity than butterfat. The were used to prepare bulk starter culture.
absence of microbial cultures and the enzyme
systems of cheese analogues creates a more stable Methods
flavour and texture. Lactic acid fermentation has Bulk starter culture was prepared following the
also been used to prolong the shelf life of legume- steps shown in Figure 1. Pigeon pea grains were
*Author for based milk and also to improve its nutritional value dehulled, cleaned, dried overnight at 60°C and
correspondence. (Gebre-Egziabher 1983; Rao and Pulusani 1988; were used to prepare pigeon pea powder (average
E-mail: eraksharma@
Ofuya and Njku 1991). This research was there- particle = 1.0 mm) in a Willey mill. The powder
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fore undertaken with the overall objectives of was then converted to pigeon pea milk at the
© 2005 Society of optimizing process parameters with respect to pH, desired pigeon pea solid and water ratio by hot
Dairy Technology total solid recovery, protein content and fat con- water grinding. Preparation steps are shown in
Figure 2. Soy milk was prepared using cleaned, dry X1 (starter culture, %) = (x1 − 5)/1, X2(pigeon pea
whole soybean grains by following the steps in solid : water ratio) = (x2 − 0.7)/0.2, X3(pigeon pea
Figure. 3. solid : soybean solid ratio) = (x3 − 10)/1, X4(incubation
temperature, °C) = (x4 − 41)/2, and X5(coagulation
Experimental design temperature, °C) = (x5 − 85)/5
Response surface methodology (RSM) (Conlon
and Khuri 1988) was used to design the experi- where, X1, X2, X3, X4, X5 and x1, x2, x3, x4, x5 are
mental combinations. A second order central com- coded and uncoded variables, respectively.
Coded variables
Number of
X1 X2 X3 X4 X5 Combinations Replications experiments
0 0 0 0 0 1 6 6
±1 ±1 ±1 ±1 ±1 16b 1 16
±2 0 0 0 0 2 1 2
0 ±2 0 0 0 2 1 2
0 0 ±2 0 0 2 1 2
0 0 0 ±2 0 2 1 2
0 0 0 0 ±2 2 1 2
a
Code ‘0’ is for centre point of the parameter range investigated, ‘±1’ for factorial
points, and ‘±2’ for augmented points; X1, Starter culture concentration; X2, pigeon pea
solids–soy solids ratio; X3, pigeon pea solids–water ratio; X4 incubation temperature;
X5 coagulation temperature
b
Factorial points were in half replication
−2 −1 0 1 2
(augmented ( factorial (centre ( factorial (augmented
Experimental parameters form) point) point) point) form)
these steps (Conlon and Khuri 1988) was used for 0.054, 0.033, 0.022 and 0.02 corresponding to
this purpose. Contours were plotted using a surfer equations 1, 2, 3 and 4, respectively.
version 6.04.
Y (% TSR ) = 55.2752 − 0.4250 X1 − 0.5867 X 2 −
R E S U LT S A N D D I S C U S S I O N 0.4892 X 3 − 0.3150 X 4 + 0.8125 X 5* +
Total solid recovery (TSR), protein content, fat con- 1.4888 X1 X 2*** − 1.3575 X1 X 3** − 0.4850 X1 X 4 +
tent and pH of the cheese analogue, under different 0.1063 X1 X 5 + 1.7550 X 2 X 3*** + 0.3150 X 2 X 4 −
experimental conditions, as given in Table 3, varied 0.8212 X 2 X 5* + 0.2837 X 3 X 4 − 0.2450 X 3 X 5 +
from 51.09–62.61%, 40.04–55.93%, 9.35–15.36% 0.0500 X 4 X 5 − 0.1102 X12 + 0.1823 X 22 −
and 4.48–4.9, respectively. To optimize the process
0.2727 X 32 + 0.5535 X 42 + 0.0510 X 52 . . . . . . . . . (1)
parameters, response surface models for the
maximum TSR, protein, fat and minimum pH of
the finished product were developed employing Y (% Protein content) = 45.3783 + 0.0079 X1 +
multiple regression techniques and represented 0.7579 X 2 + 0.4096 X 3 + 0.3104 X 4 − 0.0929 X 5 −
by equations 1– 4. Analysis of variance (anova) of 0.6319 X1 X 2 + 0.9831X1 X 3 + 0.1506 X1 X 4 −
equations 1– 4 resulted in coefficients of determi- 0.1531X1 X 5 + 0.5169 X 2 X 3 + 1.0794 X 2 X 4* −
nation for TSR, protein content, fat content and pH
1.1644 X 2 X 5* + 1.2469 X 3 X 4** − 0.1044 X 3 X 5 −
of 82.4%, 84.5%, 85.9% and 86.2%, respectively
(Table 4), indicating the adequacy of fit of the 1.5344 X 4 X 5** + 0.1730 X12 − 1.8142 X 22*** +
complete second order models with P-values 0.3992 X 32 − 1.1745 X 42** + 0.2242 X 52 . . . . . . . . (2)
Table 4 Analysis of variance (anova) of full second-order response surface models 1, 2, 3 and 4
Sources of variation Degree of freedom Sum of squares Mean sum of squares F-value (calculated) P
Y (% Fat content) = 10.8664 + 0.1800 X1 + ables, and the combined effect of variables at
0.7442 X 2*** − 0.6725 X 3*** − 0.1492 X 4 + linear, interactive and square level on the responses,
is also given in Table 5. The total effect of starter
0.3267 X 5* − 0.2325 X1 X 2 + 0.2075 X1 X 3 − culture on TSR was found significant (P < 0.05).
0.0937 X1 X 4 + 0.0450 X1 X 5 + 0.3112 X 2 X 3 + This may be attributed to the pigeon pea-rich
0.1825 X 2 X 4 − 0.5263 X 2 X 5** − 0.0800 X 3 X 4 − substrate favouring the culture which developed
0.3788 X 3 X 5 + 0.3950 X 4 X 5 + 0.5149 X1 ** + 2 higher acidity and facilitated coagulation of
substrate, leading to higher TSR. Pigeon pea–
0.2699 X 22 + 0.1849 X 32 + 0.5536 X 42** + soy solids ratio significantly affected total solid
0.5161X 52**. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) recovery, protein and fat content at levels of P <
0.05, P < 0.01 and P < 0.05, respectively (Table 5).
Y (pH) = 4.5423 − 0.0025 X1 + 0.0008 X 2 + Pigeon pea–water ratio significantly affected TSR
0.0367 X 3** − 0.0875 X 4*** − 0.0142 X 5 − (P < 0.05) and fat content (P < 0.10), which may
0.0038 X1 X 2 − 0.0288 X1 X 3 − 0.0200 X1 X 4 − be due to more concentration of solids at lower
levels of water. Incubation temperature signific-
0.0050 X1 X 5 − 0.0238 X 2 X 3 − 0.0175 X 2 X 4 −
antly affected pH (P < 0.01) and protein content
0.0200 X 2 X 5 + 0.0075 X 3 X 4 − 0.0075 X 3 X 5 + (P < 0.05) of the product, which is attributed to
0.0113 X 4 X 5 + 0.0427 X12** + 0.0327 X 22** + increased activity of the culture at higher temper-
2 2 2
0.0465 X 3 *** + 0.0390 X 4** + 0.0265 X 5*. . . . . (4) atures within the given range. Coagulation temper-
ature also affected pH and fat content, which may
Further anova (Table 5) indicated that coagula- be due to an increased coagulation rate at higher
tion temperature significantly (P < 0.100) affected temperatures in the selected range. The combined
TSR and fat content positively at linear level. A effect of all parameters on TSR and protein content
similar effect was observed for pigeon pea–water at interactive levels was significant at 5% and 10%
ratio on pH and fat content. Starter culture affected levels of significance, respectively. At linear level,
TSR interactively with pigeon pea–soy solid ratio the combined effect of all parameters was signifi-
(P < 0.01) and pigeon pea–water ratio (P < 0.05). cant (1% level of significance) on pH and fat
Pigeon pea–soy solid ratio and pigeon pea–water content. The combined effect at quadratic level was
ratio interactively affected TSR (P < 0.01). It was observed to be significant on all responses except
observed that all variables except starter culture TSR.
affected protein content significantly at interactive The contour plots in Figures 5–9 were obtained
and square level. The total effect of individual vari- from the predictive models in equations 1–2 of
Table 5 Analysis of variance for total effect of individual parameter and combined
effect at linear, interactive and square level
Significant at: ***P < 0.01, **P < 0.05, *P < 0.1
Responses Value x1 x2 x3 x4 x5
Total solid recovery, % d.b. (TSR) 60.78 6 1 : 0.4 1 : 11 40 88
Protein content, % d.b. (PC) 58.67 5 1 : 1.1 1 : 9.5 42 81
Fat content, % d.b. (FC) 15.98 5 1 : 0.6 1 : 10.9 39 93
pH 4.48 5.2 1 : 0.7 1 : 9.6 43 85
Table 7 Responses at combined optimum conditions The optimum conditions of process parameters for
maximum total solids recovery were 6.0% starter
At optimum condition for culture concentration, 1 : 0.4 pigeon pea–soy
Response TSR pH PC FC
solids ratio, 1 : 11 pigeon pea–water ratio, 40.5°C
incubation temperature and 88.5°C coagulation
b
Total solid recovery, % d.b. (TSR) 60.78 55.58 57.39 60.45a temperature.
Protein content,% d.b. (PC) 51.21a 43.58 58.67b 50.20
Fat content, % d.b. (FC) 13.94 11.97 14.89a 15.98b
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