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REFERENCE MANUAL FOR U.S. WHEY AND LACTOSE PRODUCTS

REFERENCE MANUAL FOR U.S. WHEY AND LACTOSE PRODUCTS

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<strong>REFERENCE</strong> <strong>MANUAL</strong><strong>FOR</strong> U.S. <strong>WHEY</strong><strong>AND</strong> <strong>LACTOSE</strong> <strong>PRODUCTS</strong>


Since 1995, the U.S. Dairy Export Council has been committed todeveloping educational materials on U.S. dairy ingredients based oncurrent scientific research. This manual is an update of the first two editionsof “Reference Manual for U.S. Whey Products.” We have again attemptedto review the most current technical and scientific information availableon the characteristics, functions and benefits of whey-based ingredients.Many USDEC members, U.S. suppliers, processors, industry experts,consultants, researchers, Dairy Management Inc. and USDEC staff haveshared their knowledge and contributed their own resources to this newvolume, part of our effort to provide up-to-date information to potentialcustomers, educators, health professionals, food scientists and other interestedgroups. We hope this new edition will continue to be a useful resource onU.S. whey and lactose ingredients.Véronique LagrangeEditorU.S. Dairy Export Council2 Reference Manual for U.S. Whey and Lactose Products


TABLE OF CONTENTS1234SectionPageAcknowledgements 5Glossary 5The U.S. Dairy Industry 6Overview 6The U.S. Dairy Export Council 8Dairy Management Inc. 9American Dairy 10Products InstituteWhey and Lactose: 11Natural Milk Products1.1 U.S. Whey and Lactose 12Production: General OverviewQuality Standards, Quality 15Assurance and CertificationsBy F.T. SchonrockSchonrock Consulting2.1 USDA Standards, 16Grading Services2.2 Plant Surveys 172.3 Export Certification and 17Laboratory Services2.4 Kosher and Halal Certification 182.5 State Departments of Agriculture 182.6 Other Certification and Tests 18Production Technologies 19By Dr. K. SmithEdited by Dr. R. BishopWisconsin Center for Dairy Research3.1 Technologies for Whey 20Processing: An Overview3.2 Evaporation and Drying 213.3 Value-added Processes 213.4 Other Processes 23Questions and Answers 243.5 Advanced Whey Ingredient 25TechnologiesCopy courtesy of DMI3.6 Protein Polymerization 25and ModificationBy Dr. A. RaoDavisco Foods International, Inc.Whey Products Definition, 27Composition, FunctionsInformation courtesy: U.S. Suppliers,USDEC, ADPI and DMIOverview 284.1 Sweet Whey Powder 284.2 Acid Whey Powder 294.3 Reduced Lactose Whey 294.4 Demineralized Whey 304.5 Whey Protein Concentrate 3134% Protein (WPC34)Heat Stability of Whey Protein 31ConcentratesBy Dr. A. HuguninConsultant456SectionPage4.6 Whey Protein Concentrate 3250% Protein (WPC 50)4.7 Whey Protein Concentrate 3260% Protein (WPC 60)4.8 Whey Protein Concentrate 3275% Protein (WPC 75)4.9 Whey Protein Concentrate 3380% Protein (WPC 80)4.10 Whey Protein Isolate (WPI) 334.11 Lactoferrin 344.12 Lactoperoxidase 364.13 GMP (Glycomacropeptide) 364.14 Dairy Products Solids 37(Permeate)4.15 Mineral-concentrated Whey 38(Reduced Lactose Whey)4.16 Dairy Minerals, Calcium 39Lactose Products Definition, 41Composition, FunctionsInformation courtesy: U.S. Suppliers,USDEC, ADPI and DMIOverview 425.1 Industrial Grade Lactose 42Products5.2 Food Grade Lactose Products 435.3 Pharmaceutical Grade Lactose 46Defining Pharmaceutical 47Grade LactoseBy H. BrittainCenter for Pharmaceutical PhysicsCopy courtesy of Foremost Farms USANutritional Properties 49of Whey, Lactose andMilk Minerals ProductsEdited by C. SorensenWhey Protein InstituteDr J. O’DonnellCalifornia Dairy Research FoundationOverview 506.1 Nutritional Properties of 53Whey ProductsBy Dr. R. WalzemTexas A&M University,Copy contributed by USDEC6.2 Biological Properties of 58Whey ComponentsBy Dr. J. HarperOhio State University,Copy contributed by ADPI6.3 Health Enhancing Properties of 62Whey Proteins and Whey FractionsBy Dr. R. WalzemTexas A&M UniversityC.J. Dillard,Dr. J.B. GermanUniversity of California, DavisSectionPage6.4 Whey Protein and 64Sports NutritionDr. G. PasinPasin Group, University of California, DavisBy Dr. S. MillerNational Dairy Council6.5 Whey Proteins and 68Cardiovascular HealthBy S. GerdesSK Gerdes ConsultingDr. J. HarperOhio State UniversityEdited by Dr. G. MillerNational Dairy Council6.6 Whey Protein Isolate versus Soy 70Protein Isolate: Effects in HumansBy L.A. NelsonDavisco Foods International. Inc.C.M. ColkerD.S. KalmanM. Swain-O’NeillPeak Wellness, Inc.6.7 Whey Products, Milk Minerals 75and Dairy Calcium: New Findingsand BenefitsEdited by Dr. D. DiRienzoNational Dairy Council6.7.1 Balance in Dietary 78Mineral ConsumptionBy Dr. E. BastianGlanbia Nutritionals USA6.8 Nutritional and Physiological 79Properties of LactoseBy L. McBeanNutrition and Health Communications6.9 Whey Proteins in Medical and 80Feeding Applications (Including HIV)By R.W.J. CampbellAdvanced Business Concepts International (ABCI),a subsidiary of Land O’Lakes7.1 Functional Properties of 81Whey ProductsEdited by K.J. BurringtonWisconsin Center for Dairy ResearchSolubility 82Water Binding and Viscosity 83Gelling 83Emulsification 83Whipping, Foaming 83and AerationFlavor 83Dispersibility 84Edible Film Formation 84Antioxidant Activity 84Adhesion 84Browning 84Reference Manual for U.S. Whey and Lactose Products673


891011SectionPage8.1 Functional Properties 85of Lactose ProductsEdited by K.J. BurringtonWisconsin Center for Dairy ResearchFlavor, Color Absorption 86and RetentionBrowning 86Hygroscopicity 86Sweetness 86Solubility/Crystallization 87Fermentation Substrate 88Tableting Excipient 88Lactose Particle Size 88Quick Guide to Whey 89and Lactose Products9.1 Table 9.1 Whey Products 90Function, Characteristics,Functional Benefits,Marketing Benefits, Applications9.2 Table 9.2 Lactose Products 92Function, Characteristics,Functional Benefits,Marketing Benefits, Applications9.3 Table 9.3 94Whey Ingredients and TheirImportant Functional PropertiesBakery Applications for 97Whey and Lactose ProductsFormulary edited by K. NelsonWisconsin Center for Dairy Research10.1 An Overview and Latest 98DevelopmentsBy B. StroutsAmerican Institute of Baking10.2 Whey Products in 100Baked GoodsBy K.J. BurringtonWisconsin Center for Dairy Research10.3 Using Lactose and Permeate 106in Baked GoodsBy S. GerdesSK Gerdes Consulting10.4 Lactose Functionality 109By K.J. BurringtonWisconsin Center for Dairy Research10.5 Formulations 110Beverage Applications for 115Whey and Lactose ProductsFormulary edited by K. NelsonWisconsin Center for Dairy Research11.1 An Overview 116By K.J. BurringtonWisconsin Center for Dairy ResearchReprinted with permission fromWeeks Publishing Company11121314SectionPage11.2 Whey Proteins in 118Dairy-based DrinksBy V. LagrangeUSDECDr. G. PasinPasin Group, University of California, Davis11.3 Formulations 121Confectionery Applications 125for Whey and LactoseProductsFormulary edited by K. NelsonWisconsin Center for Dairy Research12.1 An Overview and 124New DevelopmentsBy Dr. R. BoutinKnechtel Laboratories12.2 Whey Products and Lactose in 127Confectionery ApplicationsBy Dr. J. BouzasHershey Foods Corp.12.3 Formulations 133Dairy Applications for 145Whey and Lactose ProductsFormulary edited by K. NelsonWisconsin Center for Dairy Research13.1 An Overview 146By Dr. P.S. TongCalifornia Polytechnic State University13.2 Whey Products in Cold Pack 147and Pasteurized ProcessedCheesesBy Dr. S. YoungSteven Young Worldwide13.3 Whey Products in Yogurt and 151Fermented Dairy ProductsBy Dr. A. HuguninConsultant13.4 Whey Products in Ice Cream 156and Frozen DessertsBy Dr. S. YoungSteven Young Worldwide13.5 Lactose and Other Whey 161Products in ProteinStandardization of MilkBy Dr. P.S. TongCalifornia Polytechnic State University13.6 Formulations 163Processed Meat and Fish 169Applications for Whey andLactose ProductsFormulary edited by K. NelsonWisconsin Center for Dairy Research14.1 An Overview 170By Dr. G. PrabhuProliant, Inc.14.2 Whey Protein and Lactose 171Products in Processed MeatsBy Dr. J. KeetonTexas A&M University14.3 Formulations 1754 Reference Manual for U.S. Whey and Lactose Products151617SectionPageProcessed Foods and 183Snack Applications forWhey and Lactose ProductsFormulary edited by K. NelsonWisconsin Center for Dairy Research15.1 Whey Products in Snack 184ApplicationsBy Dr. B. JohnsonFS&T Consulting15.2 Whey Protein Films in 188Snack ApplicationsContributed by Dairy Management Inc.15.3 Whey Products in 190Low-fat FoodsBy Dr. B. JohnsonFS&T Consulting15.4 Whey Products, Edible Films 193and CoatingsEdited by Dr. J. KrochtaUniversity of California, DavisDr. A. FoegedingNorth Carolina State University15.5 Formulations 194Nutritional Products 201Applications for WheyProductsFormulary edited by K. NelsonWisconsin Center for Dairy Research16.1 Whey Products in Infant 202Formula/Child NutritionBy Dr. B. LloydGlobal Research Solutions16.2 Whey, Lactose and Their 205Derivatives in Nutritional andSports Food ProductsBy Dr. K. LeeProliant, Inc.16.3 Whey Applications in Sports 205and Nutrition BarsBy Dr. J. BouzasHershey Foods Corp.16.4 Whey Products, Calcium 206and Weight LossBy Dr. ZemelUniversity of Tennessee, Knoxville16.5 Ingredients and Milk Minerals 210in Fortified FoodsBy Dr. E. BastianGlanbia Nutritionals USA16.6 Formulations 211References, Index, 219and Formulations IndexReferences 220Index 222Formulations Index 224


INTRODUCTIONEDITORS:Mr. James PageAmerican Dairy Products InstituteMr. Dan MeyerAmerican Dairy Products InstituteDr. Bill HainesDairy Management Inc.Véronique Lagrange,Audrey Kenneyand USDEC StaffContributor:Dr. W.S. Clark, Jr.ACKNOWLEDGEMENTSThe U.S. Dairy Export Council wishes toextend its appreciation to all the individuals,companies, and associations whocontributed to the development, reviewand production of this manual. In addition tothe many experts in the field, who cannot allbe listed here, the U.S. Dairy Export Councilwould like to recognize the contributionof its member companies (list availableat www.usdec.org) , the American DairyProducts Institute, the California DairyResearch Foundation, the Dairy ProductsTechnology Center at California PolytechnicState University, Dairy Management Inc.,Design Two Ltd., the Whey Protein Instituteand the Wisconsin Center for Dairy Research.GLOSSARYSome of the terms in this manual havesynonyms which are used in relatedindustries or other nations. The intent ofthe following list is to reconcile the termsused in this manual with other frequentlyused terms and closely related words.Term used in this manual or abbreviationAcid-type whey powder, acid whey powderDairy products solidsDemineralized wheyPermeateProcessed cheeseReduced-lactose whey,reduced-lactose whey powderSkim milk powder, SMPSweet-type whey powder,sweet whey powderWheyWhey creamWhey productsWhey powder(s)Whole milk powder, WMPWPCWPISynonym or closely related termDry acid wheyPermeate, deproteinized wheyDe-mineralized whey, reduced-mineralswhey, dry-reduced minerals wheyDairy products solids, deproteinized wheyProcess cheeseDry reduced-lactose wheyNonfat dry milk, NFDM, NDMDry sweet wheyDairy wheyMilkfat from wheyIncludes various types of whey, wheyprotein concentrates, isolates and lactoseDry whey, dried whey—sweet of acidDry whole milkWhey protein concentrateWhey protein isolateReference Manual for U.S. Whey and Lactose Products5


THE U.S. DAIRY INDUSTRYOVERVIEWThe United States is the world’s largestdairy producer, marketing over75 million metric tons of milk per year,or approximately 19.5% of the world’smilk supply. U.S. dairy farmers producetwo-and-a-half times more milk than anyEuropean country and seven times asmuch as Australia or New Zealand.More than one quarter of the world’s wheyand lactose—935,000 metric tons—is manufactured at over 200 whey plantsin the United States. With one of theworld’s largest cheese industries, anabundance of land and investments inresearch and development, the U.S. wheyindustry is capable of unrestrained growth.Each year, U.S. manufacturers process over25 million mt of fluid milk, 3.7 million mtof cheese, 935,000 mt of whey and lactose,700,000 mt of milk powders, 583,000 mt ofyogurt, 540,000 mt of butter and 565,000 mtof ice cream, making the United States thelargest dairy processing country in the world.Many of these dairy products are used asingredients in the formulation of other foods.U.S. food processors with internationalrecognition use U.S. dairy ingredients,including U.S. milk powders, to successfullydevelop bakery products, confections, meats,sauces, soups and other dairy foods for bothdomestic and export sales.The United States has been able toachieve its current milk output through acombination of scientific and managementadvancements at all levels of production,processing, regulation and marketing. On thefarm, management techniques, includingexpanded use of balanced feed rations andthe use of superior genetics, have beeninstrumental in increasing milk output percow. Between 1990 and 2000, average annualyield per cow increased from 6,720 kgto about 8,061 kg, while cow numbersdecreased from nearly 10 million to slightlyfewer than 9.1 million. This type of productionefficiency demonstrates the industry’sability to maximize its resources to meetthe growing demand for dairy productsworldwide. These same practices have led tomodifications in the composition of milk,which have resulted in an increase of solidsnonfat(SNF) to meet food manufacturers’demands for more milk protein.Advanced U.S. technologies ensure efficientdelivery of the highest quality milk products.State-of-the-art milking and milk handlingequipment, including automated milkingsystems, have improved the speed ofcleaning, sanitizing, and cooling product,as well as delivering it to processing plants.Dairy farmers and dairy processors alikeabide by strict U.S. sanitary standards. Inaddition to self-imposed sanitary guidelines,dairy farmers are visited regularly bygovernment regulatory agencies, whichconduct quality assurance and safetyinspections at the farms. These inspectorsconfirm herd health, oversee veterinarypractices, monitor sanitation of the facilitiesand milking equipment, and verify thatthe milk is being rapidly cooled andproperly stored until delivered to theprocessing facilities.6 Reference Manual for U.S. Whey and Lactose Products


At the processing facilities, milk movesthrough sanitized pipes, vats and tanks asit is transformed into more than 300 varietiesand styles of cheese, 100 flavors of ice creamand frozen yogurt, 75 flavors and set-typesof yogurt, various milk powder and wheyprotein products, and numerous blends ofbutter and cultured products. Virtually allU.S. dairy processing plants employ qualitymanagement programs, such as HACCP(Hazard Analysis Critical Control Point)or ISO (International Organization forStandardization), to ensure that thefinished products meet the highestattainable standards.The U.S. industry has made continued,large investments in new, state-of-the-artdairy manufacturing facilities. During thepast decade, such developments haveenabled a 45% reduction in the number ofmanufacturing facilities while total outputhas increased by 4% to 5% annually.Continued investment will mean still lowerprocessing costs and higher milk volumes.Employees at these facilities do morethan manufacture dairy products, throughresearch and development laboratoriesthey generate new products and devise newuses for milk and its components. Dairytechnologists and food scientists worktogether to discover how the functionalproperties of milk components can bepreserved or modified by fractionation andother processing procedures. State-of-the-artequipment for drying milk, manufacturingcheese and processing whey has enabled theindustry to create a wide variety of newproducts such as differentiated milk powders,lactose-free cheeses, aseptic milk andlactoferrin. These new products have beendeveloped to meet the expanding globaldemand for highly nutritional dairy productsand ingredients.As trade agreements continue to open globalmarkets, other countries are able to benefitfrom using U.S. dairy products. Additionalinformation on specific whey and lactoseingredients is available from the suppliers ofthe products. The U.S. Dairy Export Councilhas available the names, addresses andphone/fax information for U.S. companiesprocessing and/or marketing each of thetypes of milk powders.This handbook is designed to guide andeducate international product developerson using U.S. whey and lactose ingredients.It is designed as a resource that includes:• A description of the U.S. whey industry.• Definitions of most whey and lactoseproducts.• Descriptions of the processes used toproduce whey and lactose ingredients,and to enhance their nutritional orfunctional properties.• Discussions of the functional andnutritional properties of whey andlactose ingredients.• Applications for these functional,nutritional dairy ingredients.Photo courtesy: Hilmar Cheese CompanyThe U.S. Dairy Export Council recommendsyou always check with your U.S. supplierto obtain detailed product specifications,and that you consult local regulationsregarding ingredient usage and labeling.The formulations in this manual are onlyprovided for demonstration purposesand as a starting point for productdevelopment efforts.Reference Manual for U.S. Whey and Lactose Products7


THE U.S. DAIRYEXPORT COUNCILUSDEC is an independent, non-profit, tradeassociation. The mission of USDEC is to unifythe U.S. dairy industry’s international marketdevelopment efforts so the United Statescan be a more responsive supplier tointernational customers. USDEC workswith U.S. suppliers to help them maximizeall the benefits the industry has to offer:size, efficiency, consistency, high quality andstate-of-the-art technology.USDEC’s activities fall into three broadcategories: providing on-going service totrade partners; bringing potential buyersand sellers together to facilitate trade;and educating and supporting U.S.dairy exporters.The U.S. Dairy Export Council providessupport to international buyers of dairyproducts by:• Working closely with trade partners andend-users around the world to developnew alliances.• Providing information about U.S. suppliers,their products and capabilities.• Supporting end-users and the trade withconferences and technical seminars aimedat providing training and guidance on theuse of U.S. products.• Furnishing applications and usage ideasfor U.S. dairy ingredients.• Helping drive the sale of U.S. productsby creating and supporting in-store andfoodservice promotions.• Creating point-of-sale materialshighlighting the benefits of purchasingU.S. dairy products.The U.S. Dairy Export Council facilitatescommunication between international buyersof dairy products and U.S. suppliers by:• Acting as a central contact point forinternational buyers and U.S. exporters,matching prospective buyers andpotential sellers.• Compiling and maintaining comprehensivelists of buyers and sellers, which areavailable to overseas customersand members.• Circulating product inquiries frominternational buyers to a concentratedlist of U.S. suppliers to generateprice quotations.• Hosting international buying delegationsto familiarize end-users with the size andscope of the U.S. industry.• Coordinating trade missions andparticipating in trade shows in overseasmarkets to help U.S. suppliers betterunderstand the market needs.The U.S. Dairy Export Council providessupport to the U.S. dairy industry by:• Educating and informing U.S. dairysuppliers of the opportunities availableinternationally and advising them ofthe requirements of the internationalmarketplace so they can offer productsthat meet end-user specifications.• Representing the U.S. dairy industry ininternational trade policy forums to reducetrade barriers for U.S. products.• Taking a proactive role with theInternational Dairy Federation to developworldwide technical standards and helpingexporters meet regulatory requirements.• Researching, analyzing andcommunicating information ontrends in dairy production, consumptionand trade.The Council’s headquarters are located inArlington, Virginia (near Washington, D.C.),and can be contacted at:U.S. Dairy Export Council2101 Wilson Boulevard, Suite 400Arlington, Virginia 22201 USAPhone: 1-703-528-3049Fax: 1-703-528-3705www.usdec.orgIn addition, USDEC has set up a number ofinternational offices with representatives inMexico, Brazil, Korea, Japan, China, Taiwan,Southeast Asia, Europe and the Middle East.For a full list of international offices andcontact information, please contact theU.S. Dairy Export Council or checkwww.usdec.org.8 Reference Manual for U.S. Whey and Lactose Products


DAIRY MANAGEMENT, INC.Formed in 1995, Dairy Management Inc ṬM(DMI) is the domestic and internationalplanning and management organizationthat builds demand for U.S.-produceddairy products on behalf of America’s dairyfarmers. DMI along with international,state and regional organizations managethe American Dairy Association, theNational Dairy Council and the U.S. DairyExport Council.Since 1997, DMI, on behalf of America’s dairyfarmers, has been inviting food formulatorsand dairy processors and cooperatives inthe United States to “Do it with dairy. TM ”Our “Do it with dairy” program was designedwith the primary goal of changing the U.S.domestic market’s perception of dairyingredients. The program’s original missionwas to promote dry ingredients, anddemonstrate the functional and nutritionalbenefits these ingredients offer in developingnew and/or improved food and beverageproducts. In 2002 the program was expandedto include cheese and milkfat ingredients.The “Do it with dairy” program offers premierservices that help food companies excel inthe marketplace. DMI has brought togethersome of the best food technologists,researchers and dairy ingredient specialistsin the U.S. to develop and offer solutionsto some of the industry’s toughest fooddevelopment challenges. Our technicalsupport system helps U.S. food and beveragemanufacturers make formulation decisionsmore quickly and easily. Members of the DMItechnical support team made contributionsto this manual.I am pleased to have participated inmaking this manual available to you.I hope you will find it a valuable resource ofcomprehensive technical informationto meet your product developmentneeds along with specific applicationssolutions. Providing this type of technicalassistance is part of the mission of DMI.I am grateful to the many subject-matterexperts who authored the various sections ofthis manual, and hope you will find it usefulin your professional activities.William C. Haines, Ph.D.Vice President, Business to Business MarketingDairy Management, Inc.DMI’s headquarters are located inRosemont, Illinois (near Chicago, IL),and can be contacted at:Dairy Management Inc ṬM10255 West Higgins Road, Suite 900Rosemont, Illinois 60018-5616 USAPhone: 1-800-853-2479Fax: 1-847-803-2077www.dairyinfo.comwww.doitwithdairy.comReference Manual for U.S. Whey and Lactose Products9


AMERICAN DAIRY<strong>PRODUCTS</strong> INSTITUTEAmerican Dairy Products Institute (ADPI), thenational trade association of the processeddairy products industry, was formed in April,1986, through a merger of the 61-year oldAmerican Dry Milk Institute and the 15-yearold Whey Products Institute. In April 1987, theInstitute expanded the scope of its activitieswhen the Evaporated Milk Associationmerged into the American Dairy ProductsInstitute. Actions were initiated to establisha cheese division within the AmericanDairy Products Institute, and successfulculmination of this effort occurred February6, 1997. Current Institute membershipincludes manufacturers of evaporatedand dry milks, cheese and whey products,firms that provide supplies and services toprocessors, and many companies that utilizethese processed dairy products. While themajority of our members are located in theU.S., we have many international membersas well—currently from 16 countries.ADPI’s business purpose is to become themost effective communicator of the positiveattributes and benefits for the dairy productswe represent. Our business purpose must beexecuted to the benefit of our members, theircustomers and consumers.ADPI provides a variety of services tomembers, representing its members ingovernmental affairs, consumer affairs andproduct standards of identity. Our goal is toprovide our members complete informationabout the industry from processing toutilization. ADPI provides standards for drymilks which can be found in the ADPI Bulletin916, “Standards for Grades of Dry MilksIncluding Methods of Analysis,” and for wheyproducts which can be found in the ADPIBulletin W-16, “Whey & Whey Products—Definitions, Composition, Standard Methodsof Analysis.” These publications and othermaterials can be ordered from:American Dairy Products Institute116 North York StreetElmhurst, IL, 60126 USAPhone: 1-630-530-8700Fax: 1-630-530-8707www.adpi.orgThe Chief Executive Officer isJim Page and he can be reached at:jjpage@adpi.org.For technical assistance, please contactDan Meyer at:dmeyer@adpi.organd for accounting/statistics, please contactSteve Griffin at:sgriffin@adpi.org.10 Reference Manual for U.S. Whey and Lactose Products

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