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MONOGRAPH
ICE CREAM
Whey and whey protein Whey powder was the first whey knowledge about the applications
products have been used product added to ice cream and and benefits of whey products.
its popularity was associated
successfully in ice cream and This monograph focuses on the
with its cost benefits when compared
other frozen dairy desserts for functional benefits and considerations
to other sources of milk-solids-non-fat
the past six decades. Sweet associated with adding whey
(MSNF). Nowadays, the functional
ingredients to ice cream and frozen
whey, whey protein concentrates properties of the proteins in whey
dairy dessert formulations. It is
(34-89% protein) and whey protein concentrates (WPC) and
intended as a tool to jump-start
protein isolates (90% whey protein isolates (WPI) also
product development. For additional
justify their use in mix formulas.
protein) are among the most information and quicker reach
commonly used whey products. In global markets, the use of whey of your goals, please consult with
Other whey ingredients such as products in frozen dairy desserts your U.S. whey ingredients supplier
has become increasingly common. and/or other publications available
delactosed and demineralized This can be attributed to the greater from the U.S. Dairy Export Council
whey can also be used. availability of high quality functional (www.usdec.org).
whey products and the increased
Cost efficiency and quality
improvement are key drivers
in using whey products. The
nutritional value of whey
products is also an important
reason why an increasing
number of manufacturers,
worldwide, include U.S. whey
products in their formulations.
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e3.10.1
A P P L I C AT IONS MONO GR A P H ICE CREAM
2
e3.10.2
A P P L I C AT IONS MONO GR A P H ICE CREAM
3
e3.10.3
A P P L I C AT IONS MONO GR A P H ICE CREAM
Functionality and Benefits of Whey Products in Frozen Dairy Desserts
4
e3.10.4
A P P L I C AT IONS MONO GR A P H ICE CREAM
ultra-high temperatures or ultra-long
MANUFACTURING OF times can affect whey protein functionality,
FROZEN DAIRY DESSERTS both positively and negatively. Again,
WITH WHEY INGREDIENTS care is necessary when considering these
temperature and time options to maximize
water-binding or gelling characteristics of
Impact of Whey Ingredients on Specific
any given whey ingredient in any given mix.
Manufacturing Steps
Homogenization
Assembly of Ingredients, Mix Preparation Whey proteins help form a stable emulsion
Whey products are added with other at the fat/water interface of the mix and add
liquid and dry ingredients to each individual stability to the serum (non-fat) phase of the
mix. Whey products must be added mix. This is particularly helpful in a mix that
to the mix prior to pasteurization to assure is to be packaged for freezing at another
the microbiological quality and safety of the location at another time.
finished mix. Whey and whey ingredients are
always added during the assembly of mix Freezing (Batch or Continuous;
ingredients. Dry whey should be added -5 to -6C) Distribution (<-28C)
under high shear to the totality of liquid The actual draw temperature from the
Temperatures will fluctuate with specific
ingredients (water, milk, skim milk, cream, freezer is dependent on the mix composition
conditions and hardware used in the
liquid sugar, sweeteners) to prevent lumping and functionality and what needs to be
distribution chain. Whey and whey products
and pre-gelation. Under these conditions, done with the finished frozen dairy dessert.
can offer significant benefits and increase
it is not necessary to pre-blend whey with Normally, the lowest possible draw
stability by managing the transition of
other dry ingredients to aid dispersion. temperature is desirable (greatest amount
ice-to-water-to-ice during freeze/thaw
Under less than high shear conditions of ice made in the barrel of the ice cream
abuse. As ice-to-water-to-ice transition
(normally for small batch sizes), amounts freezer) as long as the finished ice cream can
occurs due to temperature fluctuation
of whey and whey products can be added be handled for whatever purpose (packaged,
during distribution, whey products help
via simple pre-blending with other dry molded, extruded) it is to be used. By
since they add heat shock resistance and
ingredients (such as sugar, corn syrup managing the freezing point of the mix,
maintain the body (bite, chew) and texture
solids or maltodextrin) to improve inclusion of whey products can impact
(smoothness, creaminess) of the frozen
dispersion or through a powder funnel the "draw" temperature and the draw
dairy dessert.
with recirculation through the funnel pump viscosity (weak and fluid versus stiff and
and batch tank. In either high or low shear dry). Weak viscosity may be adequate
preparation, care is necessary to prevent and desirable for molded novelties but
excess foaming (air incorporation) in the unacceptable for extruded novelties
mix. Foaming is not just due to addition of or packaged ice cream. Additionally,
protein-containing ingredients (e.g. cream, whey and whey ingredients can help in
skim, milk, egg solids, etc.). More protein the freezing of many small ice crystals that
and less fat in any given mix increases impact the eating quality of the finished
the potential for foaming. Foaming leads dairy dessert.
to burn-on (in batch and continuous
pasteurizers), low yields, increased costs,
poor freezer performance and other
undesirable effects such as development
of oxidized and/or burnt flavors. Foaming
is easily controlled through properly
engineered mix preparation systems.
Pasteurization (Batch or Continuous)
Pasteurization can potentially impact whey
product functionality in finished mixes.
This is dependent on the specific mix,
composition, whey ingredient(s) used, and
the exact times and temperatures applied
during pasteurization. Typical pasteurization
conditions for frozen dairy desserts do not
impact whey product functionality. However,
if heating systems are uncontrolled, burn-on
can occur which can result in off flavors and
varying functionality from added protein
ingredients such as whey. In some instances,
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e3.10.5
A P P L I C AT IONS MONO GR A P H ICE CREAM
most ice cream mixes. This helps retain Typical starting formulas for full-fat,
FORMULATING WITH the unique functional properties of fat-modified (reduced-fat, low-fat and
WHEY PRODUCTS casein that add body (chew), texture fat-free) and sugar-modified (no-sugar
(smoothness) and resistance to heat added) ice creams using sweet whey, whey
Care is necessary to manage protein shock. The effects of lactose and salts protein concentrates and whey protein
(amount and functionality), lactose and must also be carefully considered. isolate are presented.
salts to insure proper freezing performance
(i.e. maximize creation of large number of
small ice crystals) and eliminate potential
for sandiness defects. This is true in Formulations for Ice Cream using Sweet Whey
super-premium ice creams as well as
nutrient-modified ice creams. Regular Premium Super-Premium
Ingredients Ice Cream Ice Cream Ice Cream
In general, whey products, when applied Milk fat 10.00% 12.00% 16.00%
on a protein-to-protein basis, can replace Milk-solids-non-fat 7.50% 7.50% 6.00%
up to 50% of natural occurring casein in Sweet whey* 2.50% 2.50% 2.00%
Sucrose 12.00% 12.00% 12.00%
Corn syrup 36 DE 6.00% 4.00% 4.00%
Stabilizers and emulsifiers 0.30% 0.25% 0.25%
Total solids 38.30% 38.25% 40.25%
*Reduced-lactose or demineralized whey can also be used.
Reduced-fat, Low-fat and Fat-free Ice Cream Formulations with Whey Protein Concentrates (34-80% protein)
Control Reduced-fat Ice Cream Low-fat Ice Cream Fat-free Ice Cream
with with with
Ingredients WPC 34 WPC 60 WPC 80 WPC 34 WPC 60 WPC 80 WPC 34 WPC 60 WPC 80
Milk fat 5.00% 5.00% 5.00% 5.00% 4.00% 4.00% 4.00% 0.35% 0.40% 0.40%
Milk-solids-non-fat 11.00% 8.90% 9.35% 9.50% 8.00% 9.00% 9.25% 8.25% 8.40% 8.80%
WPC 34 1.10% 2.50% 2.75%
WPC 60 0.65% 1.00% 1.60%
WPC 80 0.50% 0.50% 0.50%
Sucrose 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 13.00% 13.00% 13.00%
Corn syrup 36 DE 5.00% 6.00% 6.00% 6.00% 6.00% 6.00% 6.00% 6.00% 6.50% 6.50%
Maltodextrin 4 or 10 DE 5.00% 5.00% 5.00% 5.00% 5.00% 5.00% 5.00% 5.00% 5.50% 5.50%
Stabilizers and emulsifiers 0.30% 0.30% 0.30% 0.30% 0.30% 0.30% 0.30% 0.70% 0.70% 0.70%
Total solids 38.30% 38.30% 38.30% 38.30% 37.80% 37.80% 37.80% 36.05% 36.05% 36.10%
Mix: approximately 0.59 kg/liter of finished product.
Whey Protein Concentrate 80% (WPC 80) Addition in Premium Ice Cream:
Cost-effectiveness Demonstration (Sample calculations*)
7
e3.10.9
A P P L I C AT IONS MONO GR A P H ICE CREAM
Extruded Novelties: These are novelty
CONSIDERATIONS items that are extruded through shaped
WHEN USING WHEY IN orifices and cut to the proper size and shape.
FROZEN DAIRY DESSERTS Frozen dairy dessert needs to be flowable,
yet stiff enough to extrude and hold a
Selection of the exact amount and type shape. Both WPC and WPI offer significant
of whey ingredients to use is based on the functionality to bind water, stiffen the frozen
following considerations: dairy dessert and help an extruded piece
withstand the physical abuse it must
Final Use of the Mix
undergo during manufacturing.
Retail Packs: Two-, one-, half-liter and
other small packs for home consumption, Molded Novelties: Normally, very fluid (as
where significant freeze/thaw stability is compared to stiff) frozen mix is deposited
necessary due to temperature abuse. WPC into molds, which, in turn, are frozen to
or WPI can add significant freeze/thaw create the molded form. Frozen dairy
stability when distribution abuse is a is limited and varies with a number of
dessert mixes need to be created to
potential concern. factors. Although there must be lactose
withstand air incorporation and freezing,
crystallization in virtually all dairy-based
yet allow flow, rapid hardening (to hold
Bulk Packs: Ten-liter packs or larger for frozen dairy desserts, the amount of lactose
inserted stick, if desired), surface thaw
food service or dip shops, where repeated and the size of the actual lactose crystals
to release items from the molds, and
dipping and sampling can physically punish are critical to detection of sandiness.
secondary treatments (liquid or dry
the finished frozen dairy dessert. Again, By managing the lactose content, both the
coating applications.) If molds are not
WPC or WPI can add physical strength to likelihood of lactose crystallization and
filled adequately, voids are created which
the finished frozen dairy dessert and add the size of the lactose crystals can be
can cause a variety of undesirable defects.
both heat shock resistance and resistance reduced. This simple recommendation can
Sweet whey (or demineralized whey) is
to punishment due to physical abuse of the help prevent sandy defects. Of course, the
typically used.
frozen dairy dessert. lower the lactose content the less likely it
Coated Novelties: Whether a frozen is that the lactose can or will contribute to
Direct-fill Novelties: This is the direct
item is to be coated or not is critical to mix sandiness. The contribution of lactose
filling of cups, cones, push-ups, etc.
ingredient selection and mix formulation. from all dairy ingredients must be known,
Because the ultimate shape of the product
Whey can add significant functional calculated and controlled.
is determined by the package, the frozen
characteristics that assist application and
dairy dessert must be able to flow evenly Sweetness: Whey, particularly sweet whey,
retention of coatings onto the finished
into the package before final hardening, adds some degree of sweetness to the mix.
frozen novelty. Lactose is a desirable
thus concern is given to mix composition, Depending on mix specifics, it may be
ingredient in many compounded novelty
viscosity and processing. Sweet whey possible to reduce sweetness using whey
coatings as it provides sweetness control
is a normal ingredient selection for these for improved consumer acceptability.
and low-cost solids. This includes dry as
direct-filled novelty applications. Draw However, in most instances sweetness from
well as liquid coatings.
temperatures are selected to reflect need the lactose (only 20% as sweet as sucrose)
of the final frozen dairy dessert to flow into Amount and Type of in dairy ingredients can be ignored. If
the package without voids. Mix Ingredients Available sweetness from lactose is to be considered,
Lactose Content: An important factor it must be considered for all mixes that are
is the total lactose content of the mix. To being compared.
minimize lactose crystallization (also known
Bulking Agents, Stabilizers and
as "sandiness" in frozen dairy desserts), it
Emulsifiers: Whey proteins can interact
is advisable to reduce the lactose content
with several large molecular weight bulking
of mixes to below 7.5%. Lactose solubility
agents (starches, starch hydrolysates,
hydrocolloids, etc.) to add or detract from
the performance of a given mix. Thus, care
is necessary when adding WPC or WPI to
specialty mixes with relatively large amounts
of bulking agents. Whereas there is very
little interaction between components
of whey ingredients and added chemical
emulsifiers, there can be significant
interaction between components of whey
and stabilizer gums (e.g. free calcium from
whey and low methoxyl pectin). Such
interactions can result in sticky and/or
gummy frozen dairy dessert if the mix is
over stabilized.
8
e3.10.6
A P P L I C AT IONS MONO GR A P H ICE CREAM
Processing Conditions: Typically,
pasteurization conditions impact very WHEY PERMEATE RECOMMENDATIONS FOR
little on whey protein functionality in mixes. AS AN INGREDIENT IN THE USE OF WHEY PRODUCTS
However, if aggressive (high temperature, SOFT-SERVE ICE CREAM IN FROZEN DAIRY DESSERTS
long time) pasteurization is considered, C.S. Otte,* K. Lim,** K.E. Smith,**
whey protein functionality can be affected, V. Jusuf,* L. Jensen,* S.A. Rankin* When considering using a whey ingredient,
depending on the processing of the specific Department of Food Science* and Center for Dairy note the following:
whey ingredient. Whey products, particularly Research,** University of Wisconsin-Madison, WI Balance the freezing performance of
WPC (with 60 to 85% protein) and WPI may the mix with that of the whey ingredient
become more hydrated during aging and Soft-serve ice cream is smooth, soft and of choice.
can significantly effect mix viscosity and mix has a similar flavor to hard ice cream, Be sure to control total lactose in
performance. Freezer draw temperatures yet contains less milk fat. To reduce formulas to <7.5% of total mix to
become critical. Recommended draw the production cost, whey ingredients minimize lactose crystallization
temperatures are typically those that can be added to replace some of the resulting in sandy ice cream. The
are as low as possible and still allow the milk solids. lower the lactose, the less likely it is
manufacturer to handle the frozen dairy that sandiness will result.
A study was conducted by researchers
dessert as necessary (e.g. for packaged The functionality (including flavor) of
at the University of Wisconsin-Madison
ice cream, extruded novelties, molded the whey ingredient itself and its impact
to determine the influence of whey
novelties, direct-filled novelties, etc). on added flavors should be assessed
permeate on the texture and flavor of
Modern continuous hardening systems for each individual mix.
soft-serve ice cream. In the study, three
maximize the use of whey products by Regulatory limitations: check local
vanilla soft-serve ice creams were made:
quickly freezing the remaining free water legislation for usage limits of all
1) Control with 11.3% nonfat dry milk
as ice. This allows the use of either the ingredients.
2) Replacement of 25% milk-solids-non-
maximum acceptable sweet whey or Consider how the finished food is to be
fat (MSNF) with sweet whey powder
reduces the amount of WPC or WPI 3) Replacement of 25% MSNF with used, distributed and marketed.
needed for any given purpose. whey permeate* Add dry whey to the totality of all liquid
ingredients under high shear or as a
If severe thermal abuse during distribution The mixes were pasteurized (84C for 15 pre-blend (small batch sizes) together
is expected, selecting a proper whey seconds), homogenized (2000/500 psi) with high solubility dry ingredients.
protein product can add significant and aged for 24 hours at 4C. Prior to Minimize foam through a properly
freeze/thaw stability. freezing, 127 ml/L of natural vanilla was engineered batching system. Other
Whey products offer significant mix added to each mix. Each mix was frozen process considerations can be managed
ingredient and yield improvement cost to identical draw temperatures on a through proper formulation.
savings. Whey products play a significant soft-serve ice cream freezer. Economics: When properly formulated
role in reducing ingredient costs and significant savings can be achieved.
Colorimetric tests showed that the whey
improving finished product yields (see Sweet whey may be the most economic
permeate sample was more similar to
sample formulations and cost tables). whey ingredient. However, WPCs
the control than the sample with sweet
and WPIs can be more cost-effective
whey powder. There were no significant
ingredient choices to achieve quality,
differences in the melting rates, fat
consistency and desired nutritional
destabilization and overrun. The trained profile. WPCs and WPIs are multi-
sensory panel showed significant functional ingredients which may
differences in the vanilla flavor intensity help reduce or displace less desirable
and salt flavor intensity of all three ingredients or additives.
products. The consumer panel found no
significant differences in preference. When all product and process
considerations are taken into account,
These results show that sweet whey whey products are viable and valuable
powder and whey permeate can ingredients for use in virtually all frozen
successfully replace a portion of the dairy dessert mixes.
MSNF in soft-serve ice cream while
maintaining consumer satisfaction.
9
e3.10.7
A P P L I C AT IONS MONO GR A P H ICE CREAM
Standard Ice Cream 11% Milk Fat
10
e3.10.10
A P P L I C AT IONS MONO GR A P H ICE CREAM
Mellorine 10% Vegetable Fat
11
e3.10.11
A P P L I C AT IONS MONO GR A P H ICE CREAM
Q: How can WPC 80-85 and WPI, which carry cost Q: Can I use whey or whey ingredients in sorbet? Q: What about frozen yogurt?
premiums to skim milk solids, be cost-effective? A: Yes. A judicious amount of a whey A: Standards for frozen yogurt may, or may
A: Several factors impact the cost- ingredient (limit the lactose content at or not, exist in any given market. Whey
effectiveness of high protein WPC and below 7%) can offer smoother body and products can be added to frozen yogurts
WPI. The key is to know that these highly texture and still retain a low- or no-fat claim. in much the same manner as for standard
functional ingredients can be used at Since sorbets have little or no added dairy ice creams. Rules related to total milk
significantly lower levels (0.50-2.0%) ingredient, added wheys impact is to protein, percent of casein and lactose still
than standard sweet whey (2.0-3.0%). In improve bulk, whipping performance and hold. However, any modification of osmotic
addition, these highly functional ingredients stability. Additionally, whey protein gives pressure on the culture side of mixes
can totally or partially replace other more increased mix viscosity resulting in can result in poor fermentation, flavor
expensive ingredients (hydrocolloid smoother, more refreshing finished and functionality.
stabilizers and some emulsifiers) from products. In non-fruit flavored sorbets Frozen yogurt mix can be processed in
formulas. Finally, because ice cream is sold (e.g. chocolate), whey adds low-cost several ways:
by weight, as well as volume, increased dairy background flavor and appearance 1. Culture the entire ice cream mix. The
yields can be achieved by producing quality (opacity) characteristics. original way of making frozen yogurt is
product at higher overruns. Minor increases not recommended. This approach results
(5-6%) in overrun (producing more finished Q What is gelato? Can whey ingredients
be used successfully? in atypical fermentation leading to bitter
ice cream from a given volume of mix) and tart off flavors.
can return major reductions (10-12%) in A. There is no uniform definition or standard 2. Cold incubation. In some countries
ingredient and process costs when for gelato (Italian for ice cream). However, the addition of live and active bacterial
premium whey products are used. gelato typically refers to ice cream of high cultures to pasteurized and refrigerated
solids (milk fat levels can vary), extremely ice cream mix is allowed. No culturing of
Q: Can whey permeate be used in ice cream and other low overrun, bright, bold colors and strong
frozen dairy desserts? the actual mix is made. Cultures can be
flavors. Again, rules outlined above for added at the flavor tank. The amount and
A: Permeate, which is the by-product of the replacement of milk-solids-non-fat with type of culture determines function
process to make whey protein concentrates whey protein ingredients hold. Remember, and flavor of resulting frozen yogurt.
and isolates, is ultra-high in salts and gelato is ice cream. 3. Partial culturing of dairy ingredients:
lactose. These latter components negatively a. Two-way blend of cultured dairy
affect freezing point of ice cream mix, heat Q: What about whey and whey protein concentrates in
variegating syrups and other ice cream inclusions? (milk fat & milk-solids-non-fat) and
shock resistance and add unusually high uncultured non-dairy ingredients
percent of lactose (which can increase the A: Whey and whey protein concentrates can (sugar, corn syrup, stabilizer, etc).
sensitivity to sandiness) to mixes. Thus, be used where applicable in flavoring swirls, Whey can be added to partially
permeate is typically not recommended for ribbons, etc. and in particulate inclusions replace milk solids-non-fat using
ice cream. If considered, care must be taken. such as baked pieces, candies, etc. that rules noted previously.
are added post-pasteurization; as long b. Two-way blend of cultured mix
Q: Whey flavor is typically a defect of ice cream and as the inclusion has one of the following
other frozen dairy desserts. Does using whey add (a specific percent of the total mix)
characteristics: and remaining percent of uncultured
whey flavor to frozen dairy desserts? Has a pH below 4.7. mix. Again, whey can be used following
A: Whey flavor or other flavor defects Has been baked, roasted, pasteurized or rules for standard ice cream.
called cardboard, oxidized or cheesy in any other way heat treated. c. Two-way cultured dairy (milk-solids-
flavors can be attributed to whey Has a water activity of <0.85. non-fat) and uncultured sugar/dairy
ingredients, particularly sweet wheys. Contains high levels of alcohol (such as blend. Whey ingredients can be used
This defect may occur in low-quality or vanilla extracts and other liquid flavors). as appropriate in either side to partially
poorly processed ingredients. U.S. whey Is a bacterial culture (freeze-dried lactic replace skim milk solids.
ingredients typically have a pleasant dairy acid bacterial) that is pathogen-free. d. Three-way blend of yogurt (milk fat,
flavor which is highly compatible with Is subjected to any other process which milk-solids-non-fat and/or sugar),
frozen dairy dessert mixes. renders the inclusion pathogen-free. uncultured dairy and sugars. Use of
This also holds for functional (e.g. mousse, whey ingredients again is determined
whipping) bases and compounded flavoring by guidelines for standard ice cream.
bases that may contain whey products as
ingredients to be added at the flavor tank
before freezing.