Chemistry of dairy products DC 2205

Physico-chemical changes in milk constitutes

during manufacturing of milk powder by
roller(drum) and spray dried

By kumkum patel
Roll number -11
 The grading and quality of milk
for dried milks is based on the
bacterial quality of original
INTRODUCTI milk, acidity of the milk and
ON properties of milk concentrate
used for drying which affect the
final dried product.

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OBJECTIVE OF
DRYING
• To remove the moisture
• To reduce the cost of transportation
• To improve storage of the product, and
• To provide a product fit for many food
manufacturing operations.

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 MILK POWDER
Milk Powder - means the product obtained by
partial removal of water from milk of Cow and /
or Buffalo.
The fat and / or protein content of the milk may
be adjusted by addition and/ or withdrawal of
milk constituents in such a way as not to alter
the whey protein to casein ratio of the milk
being adjusted.
It shall be of uniform colour and shall have
pleasant taste and flavor free from off flavor
and rancidity.
It shall also be free from vegetable oil/ fat,
mineral oil, thickening agents, added flavor and
sweetening agent.
Chemical composition of milk
powder

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Legal standards (FSSR, 2011)

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 Methods
There are many method for preparing milk powder.
• Drum or roller drying
• Spray drying
• Vacuum drying
• Foam drying

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 Manufacturing diagram.

Preheating (82°C-
Standardization (fat 93°C for 3-5 min or Evaporation (42-
Receiving milk
: snf ratio = 0.366) 120-130°C to 51% TS)
several seconds.)

Spray drying (inlet

air -148 to 232°C.
Packaging & and outlet air - 74 Homogenization (5-
Storage to 93°C) 15 MPa)
Or
Drum drying

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 Preheating objectives

1 2 3 4 5 6 7
Intense pasteurization Destroys lipase enzymes. If Low-heat treatment Must accomplish Prolonging the shelf Beneficial influence Heating of the milk
is needed to obtain not destroyed, hydrolytic minimizes the cooked pasteurization, thus life. on heat stability of the also is necessary
resistance to rancidity will occur in whole flavour in the product reducing the viable product may occur before it enters the
autoxidation. milk. microorganisms. evaporator

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 Typical time temperature combination for different type of milk
powder.

Type Temperature Time

Low heat 74ºC 15 sec

Medium heat 79ºC 3 min

High heat 82ºC 30 min

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The milk powder manufactured undergo several changes
while conversion from liquid milk to dry product. They are:

• The manufacturing process employed on milk (~87% water, aw=0.99) eliminates majority of
water till it reaches the final stage of drying, the powder (~4% moisture, aw<0.6) .
• The process not only eliminates the water from milk but also changes the physical structure i.e.
the arrangement of the components of milk in space.
• In the process, the sol changes to a dust.
• The dried milk exhibits a well pronounced dual physical structure – the primary structure, which
is the internal build-up of the powder particles from the milk solids and small amounts of
moisture and air and – the secondary structure which represents a typical powder, a system of
closely packed solid particles in a gas.

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 Conti…

• The structural elements of dried milk particles are – lactose, either amorphous or
partly crystalline, casein micelles and whey protein particles, fat in globular or non-
globular (free fat) forms and air as spherical cells.
• The fat, protein and air are presumably dispersed in continuous phase of amorphous
lactose.
• The whole milk and infant milk powders are rich in fat (20-37%) and hence need
protection against oxygen and moisture, therefore, generally tinplate cans are used and
the packaging is done under nitrogen cover to replace air with nitrogen in the tins.
• Skim milk powders have very low fat (1.5%) and as such a good moisture barrier
material like multi wall paper sacks with one polythene liner is used.
• Recently, some skim milk powder has also been sold on polythene bags and even high
density polythene bottles are being tried for retail packages.
• The milk powders are concentrated mass of milk components in the form of particles
with small amount of moisture and air.
• If sufficient care is not taken to protect them from high humidity, high temperature of
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CHANGES OF STATE OF THE DRYING
DROPLETS

• Atomizing pure water in a drying chamber in the usual way causes the
water droplets to reach the wet-bulb temperature and to vaporize within
0.1s at this temperature.
• The presence of dry matter in the droplets, however, makes an enormous
difference. The diffusion coefficient of water decrease substantially with
increasing dry-matter content . Accordingly, the vaporization is
significantly slowed down.
• In the drying droplet, temperature equalization occurs in less than about
10 ms. i.e. the temperature is virtually constant throughout a droplet
during drying.
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DRYING STAGES
• Initially, the droplet has a very high velocity relative to the drying air.
• Therefore, there is a first stage during which circulation of liquid in the droplet occurs; this circulation
greatly enhances transfer of heat and mass.
• For a droplet of 50 µ m diameter, this stage lasts for ~2 ms. In this time, the droplet covers a distance of
about 10 cm and loses a small percentage of its water.
• Its velocity compared to the air decreases to the extent that the formed surface tension gradient of the drop
surface arrests internal circulation of liquid.
• But in the second drying stage, the difference in velocity between drop and air is still great enough to
accelerate water transport.
• The transport in the droplet occurs by diffusion but in the air by convection.
• After about 25 ms the relative velocity of the droplet has decreased so far that the water transport has
become essentially equal to that from a stationary droplet.
• Relative to the air, the droplet then has covered a distance of a few decimeters and has lost about 30% of its
original water.
• In the third stage, lasting at least a few seconds, the droplet loses the rest of the water by diffusion.
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 DRYING PROCESS
• During drying the air temperature decreases and the humidity of the drying air increases.
• Moreover, the droplets vary in size and the smallest ones will dry fastest.
• In practice, the mixing is always between the two extremes.
• For driers with a spinning disk, the situation tends to be fairly close to perfect mixing.
• In most driers with nozzles, it tends to be closer to cocurrent flows.
• In all situations, the drying time may very by a factor of, say, 100 between the smallest
and the largest drops.
• This is of great importance for fouling of the drying chamber; the largest drops have the
greatest chance of hitting the wall and of being insufficiently dry to prevent sticking to
the wall.
• Another factor that affects drying rate is the presence of vacuoles in the drying drops. It
leads to significantly faster drying.

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CONCENTRATION GRADIENTS
• A rapid decrease in drying rate of the droplets occurs after the water content is reduced to, say, 15%.
• A strong concentration gradient forms rapidly during drying.
• The higher the drying temperature, the stronger the effect.
• Therefore, stronger gradients occur for co-current drying.
• A dry outer layer, i.e., a kind of rind, is formed and because of this, the water transport is slowed down
considerably.
• The temperature can rise significantly in the dry outer layer because a dried material assumes the air
temperature, not the wet-bulb temperature.
• In other words, the decrease in temperature near the surface of the droplet caused by consumption of the heat of
vaporization becomes far smaller because the vaporization of water is slower.
• Because temperature equalization happens very quickly, the whole drying droplet increases in temperature.
• The concentration gradients are not of a lasting nature.
• The relatively dry outer layer of the droplet soon becomes firm and eventually glassy.
• This causes the droplet to resist further shrinkage.
• The droplet can react by forming vacuoles or by becoming dimpled.
• Especially at a low water content of the particles, so-called hair cracks may be formed.
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 AROMA RETENTION
• Besides water, the drying droplets lose other volatile components, including flavor compounds (aroma).
• In many cases, however, the loss of flavor compounds is far less than expected, in spite of their volatility
because of the following conditions:
• The effective diffusion coefficient of most flavor components in the relatively dry outer layer of the droplet
decreases far stronger with decreasing water content than the diffusion coefficient of water does due to the
greater molar mass.
• Thus, the aroma retention - retaining flavor compounds during drying - increases with o droplet size
because in larger droplets, the outer layer from which the flavor components get lost has a relatively
smaller volume and o Drying temperature because, at a higher temperature a solid rind forms more rapidly.
• Formation of vacuoles diminishes aroma retention, especially if hair cracks develop in the particles and the
vacuoles come into contact with the surrounding air.
• Dissolved milk powder often has a cooked flavor, which results from the flavor compounds formed during
preheating and possibly during evaporation.
• During drying, conditions are mostly not such that off-flavors are induced.
• On the contrary, a considerable part of the volatile sulfhydryl compounds is removed.
• A cooked flavor mainly results from methyl ketones and lactones formed by heating of the fat and from
Maillard products which are almost absent in skim milk powder.
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 WATER ACTIVITY
• If the water content of a product decreases, its water activity ( a w ) also decreases.
Water activity is expressed as a fraction.
• In pure water a w = 1; in a system without water, a w = 0.
• Due to the very low water activity in milk powders, it exhibits following changes:
1. The hygroscopicity increases: Usually, a (dry) product is called hygroscopic if a
small increase of a causes a considerable increase in water content. Obviously, this
mainly concerns milk powder with very low water content.
2. Diffusion coefficients decrease: At low water content the effect is very strong. The
diffusion coefficient of water decreases from approximately 10 − 9 m 2 . s − 1 in
milk to 10 − 16 m 2 . s − 1 in skim milk powder with a small percentage of water.

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Water activity value of different dairy product

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Comparison of Physico-chemical properties of drum and spray dried milk
No Properties Drum-dried Spray-dried

1. Particle size 8-20 10-250

2. Surface Wrinkled Normally smooth
3. Shape Irregular; angular with rough edges Regular; usually spherical

4. Air cell Normally absent Normally one or more present

5. Bulk density (g./ml) 0.3-0.5 0.5-0.6
6. Flowability Slightly lower (than spray-dried) Slightly higher (than drum-dried)

7. Dustiness -do- -do-

8. Reconstitutability Lower (than spray-dried) Higher (than roller-dried)
9. Flavor Definitely cooked Low heat: same as pasteurized milk
High heat: definitely cooked
10. Colour and appearance Usually of slightly darker Shade (than spray-dried) WMP
Normally light yellow for cow and creamy white for buffalo milk.
SMP
Normally yellowish-white for cow and chalky-white for buffalo milk.

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structure
• Dry milks have a dual structure, viz., primary and secondary.
• The primary structure comprises the milk solids in which are dispersed the
moisture and air cells.
• The physical mass of the particle, both in skim milk powder and whole milk
powder, is dominated by the lactose in which presumably the protein, fat and
minerals are more or less dispersed.
• The bulk of the particles sur rounded by air (whole particles are not in contact)
constitute the secondary structure.
• The size and shape of the particles and the degree of uniformity of these
characteristics affect the secondary structure.

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 State of lactose State of protein
• Lactose in dry milk and milk products • The heat-treatment given to milk
generally exists in an amorphous or during the drying process destabilizes
glass (non-crystalline) state. the milk proteins (casein and serum
• It is very hygroscopic and readily proteins) by first inducing reversible
absorbs moisture when the relative denaturation and then irreversible
humidity of the surrounding air is 50 coagulation
per cent or above.
• As sorption occurs, the lactose
becomes sticky and this initiates the
adherence of the milk particles to each
other.
• Then solidification, commonly known
as caking, occurs.

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State of fat
• The fat may exist in dry milks as globules sur rounded by a membrane covering of
proteinous nature or as 'free' fat.
• It is considered de-emulsified in the free state.
• Free fat makes the dry product greasy and produces an oily film on reconstituted
milk.
• In drum-dried whole milk powder, most of the fat (85 to 95 per cent to total) exists
in the free state and much of it is on the surface of the particles.
• This high percentage may be caused by the rupturing of the globule-membrane by
the hot drum and the scraping action of the knife when removing the film.
• In spray-dried whole milk powder, deviations from the standard drying operation
or improper storage increase the free fat.
• Free fat promotes oxidation especially free fat on the particle surface
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 Moisture content density

• The normal satisfactory range of • The density of dry milks and milk
moisture content is 3-4 per cent for products has several practical
skim milk powder and 2-3 per cent for implications.
whole milk powder. • The chief one is its pronounced
• The rate of several deteriorative influence on packaging costs.
changes is influenced by the moisture • Recovery of milk particles in cyclone
content of dry milks. is also affected, and density directly
contributes to the separators
proportion of the milk-dust nuisance.

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 flowability Milk dustiness

• This is affected by size, shape, density and • Small, light dry milk particles,
the electrostatic charge of the dried milk
particles.
• The following properties improve
flowability: (i) agglomeration; (ii)
spherical shape; (iii) high particle density;
(iv) smooth surface: (v) dryness.
• Note: Addition of free-flowing agents,
such as calcium silicate @ 1.5 per cent,
sodium-aluminium silicate @ 0.5-1.0 per
cent, etc., improves flowability.
otherwise called milk dust, easily
become air-borne.
• They cause higher entrainment losses,
are a health hazard to people allergic
to protein and create sanitation
problems in the factory.
• Milk dustiness is increased by low
solids in precondensed milk, low
moisture content.

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 Reconstitutability
• This refers to the sum total effect of solubility, dispersibility, sink ability and wettability.
• Lactose, undenatured serum protein and a portion of the salts are the most soluble.
• The casein is dispersible.
• Sink ability refers to the ability of the dried to penetrate the surface tension of water.
• Wettability is the of water into the particles.
• Reconstitutability in particles includes all those functions which take place in the process of
recombining dried milk with water.
• The ideal dry milk is one which rapidly recombines with water without agitation to give the
characteristics of regular milk.
• The factors affecting Reconstitutability include:
(i) Physical properties, viz., size, shape, density, uniformity, air content, composition (especially
ratio of solids-not-fat: fat of the particles) and presence of additives;
(ii) chemical properties, viz., extent of protein denaturation (by heat or storage), and
(iii) conditions of recombination, viz., the temperature of water and dried milk, the nature and extent
of hardness in water, and the time and nature of agitation.
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 Dispersibility
• This is affected by the total heat-treatment on the
casein during processing.
• Higher heat-treatment with a higher percentage of
total solids causes a greater degree of irreversible
denaturation; and the denatured casein under
normal reconstitution procedures does not form a
stable dispersion.
• Drum drying causes a higher degree of
denaturation than spray drying: however, heating
the milk concentrate too much or for too long, or
subjecting milk particles to above-normal
temperatures in the drier in spray drying (when
attempting to obtain production above the normal
capacity of the drier) will increase percentage
denaturation.
• Large particles of dry milks are generally
recognized as being good for dispersibility
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wettability
• The tendency of dry milks to form lumps upon
addition of water indicates lack of wettability.
• The factors which favor wettability are large-
sized and irregularly shaped particles (which
provide more space in the interstices for water
penetration for wetting); agglomeration favors
wetting by providing both the above conditions.
• The amount and dispersion of fat influences
wettability.
• The milk dried with low melting point fats has
better wettability.
• The addition of up to 25 per cent sugar (sucrose)
to milk before it is dried, or dry blending the
sugar in granulated form (powdered sugar is less
effective), improves wettability and dispersion.
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 sink ability
• This is closely related to wettability. The
amount of occluded air within the particle
has a pronounced influence on sink
ability.
• Foam spray-dried milk has very poor sink
ability.
• Agglomeration of regular spray-dried milk
improves sink ability by increasing the
aggregate weight.
• The effect of agglomeration on sink
ability is greater in skim milk powder than
whole milk powder.
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flavour
• When made from high-grade milk the flavor of dried whole
milk should be clean, rich, sweet and very pleasant; and
that of dried skim milk similar, when reconstituted, to that of
fresh skim milk.
• However, in practice, there is some degree of burnt flavor,
which is greater in drum-dried milks than in spray-dried
ones.
• Normally, drum-dried milks always possess a distinct
cooked flavor.
• The intensity with which milk is heated (mainly the pre-
heating temperature-time combination) considerably
influences the development of a cooked and caramelized
flavor in spray-dried milks.
• "Low-heat' and 'medium-heat powders give the
reconstituted milk a flavor close to that of pasteurized milk;
however, 'high-heat' powder, when reconstituted, gives a
definite cooked flavor. 29
Colour and appearance
• The colour of whole milk powder should be uniformly light-yellow for cow and creamy-
white for buffalo milk; while that of skim milk powder should be uniformly yellowish-white
for cow and chalky-white for buffalo milk.
• The yellow colour varies in intensity with the season of the year.
• Small errors in operation during drum drying can readily produce a darker shade of colour.
• Discoloration, often associated with a cooked or caramelized flavor, results from high heat-
treatment.
• A more common defect in appearance is the presence of burnt particles, commonly in drum
drying and seldom in spray drying.
• A general brown discoloration may develop as a storage defect of both roller and spray
powders (mainly when a powder with a high moisture content is exposed to high
temperatures).

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