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The fresh casein curd passed from a de-watering device (about 45% solids) is minced
and the finely-divided curd mixed with water at 40°C to give a solid content of 25-
30% solids. If dried casein is used, it is ground and held in water for sometime so that
it absorbs water and becomes softened. Casein suspension is then passed through the
colloid mill. The temperature of the emerging slurry, which may have the consistency
of 'toothpaste', should be below 45°C, since it has been observed that milled curd can
re-agglomerate at higher temperatures.
Sodium hydroxide solution with strength of 2.5 M is pumped into the casein slurry,
emerging with the consistency of ‘toothpaste’ from the colloid mill at >45oC. The
quantity of sodium hydroxide required is generally 1.7-2.2% by weight of the casein
solids. Other alkalis such as sodium bicarbonate or sodium phosphates may be used,
but the amounts required and their cost is both greater than those of sodium
hydroxide. Hence, they would generally be used only for specific purposes such as in
the manufacture of citrated caseinates. The addition of the dilute alkali must be
carefully controlled with the aim of reaching a final caseinate pH of 6.6-7.0
(generally about 6.7). The recommended technique for achieving the correct caseinate
pH is to add sufficient alkali to bring the pH close to, but below, the specified value
and then add the additional alkali needed towards the end of the dissolving operation.
This technique is used for following main reasons
● Firstly, because reduction of the pH of a sodium caseinate solution by addition
of acid is likely to cause localised precipitation of casein, and
● Secondly, the development of any off-flavours associated with localised
conditions of high alkalinity is minimized.
● A third reason is the potential for formation of lysinolamine when the pH is
excessively high (e.g. > 10).
12.2.3 Dissolving
The casein alkali mixture is transferred to first dissolving vat, where it is recirculated
and/or pumped to a second dissolving vat where solubilisation is completed as the
solution temperature is raised to about 75°C. An in-line pH meter is used to monitor
and regulate the addition of the NaOH solution. The viscosity of sodium caseinate
solutions is a logarithmic function of the total solid concentration. Each dissolving
vat, therefore, must be equipped with a powerful agitator and a high speed
recirculating pump (Fig. 12.2: F1, F2). In addition to concentration, other factors
which affect viscosity of sodium caseinate solutions are temperature (semi-
logarithmic), pH, calcium content of the curd, type of alkali used and seasonal and
genetic factors. Once the solution is prepared, it is important to raise the temperature
as quickly as possible to 60-75°C to reduce the viscosity. However, care should be
taken to avoid holding the hot (>70°C) concentrated sodium caseinate solution for
extended periods prior to drying, since it is possible for brown colour to develop in
the solution due to reaction between the protein and residual lactose. During the
dissolving operation, the incorporation of air should be kept to a minimum since
caseinate solutions form very stable foams. For this, all joints on pipes, especially on
suction side of pumps, must be airtight and recirculation line must discharge below
surface of liquid in dissolving vat. In view of the many variables which can affect the
viscosity of sodium caseinate solutions, it is considered desirable to standardize them
to a constant viscosity, rather than to a constant concentration, prior to drying.
The homogeneous sodium caseinate solution is usually spray dried in a stream of hot
air. In order to ensure efficient atomization of the sodium caseinate solution, it must
have a constant viscosity as it is fed to the drier. It is common practice to minimise
the viscosity by preheating the solution to a temperature of 90-95°C just prior to
spray drying. However, care should be taken to minimise the time for which the
caseinate solution is at high temperature.
The total solid content of the solution destined for spray drying ranges between 20
and 22% and only occasionally may be as high as 25%. The highest possible
caseinate concentration is determined experimentally for every spray drier. At about
20% solid concentration of the sodium caseinate solution, approximately 4 kg of
water need to be evaporated to produce 1 kg of powder. Hence, the solids output from
a drier used for caseinate is about one quarter of that when used for drying of skim
milk (feed concentration usually 45-50% solids). However, it is possible to increase
the inlet air temperature in order to increase the water evaporation rate. Thus, while
steam radiators may produce inlet air temperatures of up to 170°C, it is possible (with
indirect oil heating or direct gas firing) to produce inlet air temperatures of up to
260°C. The warm spray dried sodium caseinate powder is cooled in a fluid bed drier.
The low solids content of the feed solution produces a spray-dried powder with a low
bulk density. It may vary from 0.25 g/ml to 0.40 g/ml. Generally, pressure nozzle
dryers, operating at 100-250 bar, produce caseinate with a higher bulk density than
that from disc atomizing dryers. The powder particles produced on disc dryers tend to
be in the shape of hollow spheres. Since the powder is so light, the losses from the
product recovery cyclones may be rather high, and it is, therefore, considered prudent
to install bag filters for improved recovery. The moisture content of spray-dried
sodium caseinate should be less than 5% for satisfactory storage and this appears to
be consistent with many product specifications.
12.2.3 Melarutkan
Campuran alkali kasein dipindahkan ke wadah pelarut
pertama, di mana ia disirkulasikan kembali dan/atau
dipompa ke wadah pelarut kedua di mana pelarutan
selesai saat suhu larutan dinaikkan menjadi sekitar 75
°C. Sebuah pH meter in-line digunakan untuk memantau
dan mengatur penambahan larutan NaOH. Viskositas
larutan natrium kaseinat adalah fungsi logaritmik dari
konsentrasi total padatan. Oleh karena itu, setiap tong
pelarut harus dilengkapi dengan pengaduk yang kuat dan
pompa resirkulasi berkecepatan tinggi (Gbr. 12.2: F1,
F2). Selain konsentrasi, faktor lain yang mempengaruhi
viskositas larutan natrium kaseinat adalah suhu (semi-
logaritmik), pH, kandungan kalsium dadih, jenis alkali
yang digunakan dan faktor musiman dan genetik. Setelah
larutan disiapkan, penting untuk menaikkan suhu secepat
mungkin hingga 60-75 °C untuk mengurangi viskositas.
Namun, harus berhati-hati untuk menghindari memegang
larutan natrium kaseinat pekat yang panas (>70 ° C)
untuk waktu yang lama sebelum pengeringan, karena
mungkin warna coklat berkembang dalam larutan karena
reaksi antara protein dan sisa laktosa. Selama operasi
pelarutan, masuknya udara harus dijaga seminimal
mungkin karena larutan kaseinat membentuk busa yang
sangat stabil. Untuk ini, semua sambungan pada pipa,
terutama pada sisi hisap pompa, harus kedap udara dan
saluran resirkulasi harus mengalir di bawah permukaan
cairan dalam tong pelarut. Mengingat banyak variabel
yang dapat mempengaruhi kekentalan larutan natrium
kaseinat, dianggap diinginkan untuk
menstandarisasikannya ke viskositas konstan, daripada
konsentrasi konstan, sebelum pengeringan.