Dairy Engineering

Advanced Technologies and Their Applications

Murlidhar Meghwal, Megh R. Goyal, Rupesh S. Chavan, Murlidhar Meghwal, Megh R. Goyal, Rupesh S. Chavan

• Publisher: Apple Academic Press
• Year: 2017
• ISBN:
  9781315341989
• Edition: 1
• Topic: Arte
• Subtopic: Arte culinaria

Written for and by dairy and food engineers with experience in the field, this new volume provides a wealth of valuable information on dairy technology and its applications. The book covers devices, standardization, packaging, ingredients, laws and regulatory guidelines, food processing methods, and more. The coverage of each topic is comprehensive enough to serve as an overview of the most recent and relevant research and technology.

PREFACE 1

The dairy industry includes various activities, such as farming for fodder for cattle; cattle rising and care; milk production; transportation; packaging; and distribution. According to the Ministry of Agriculture—Government of India, there are more than 140 million tons of milk production in the year 2014–2015; and India is the largest milk-producing country in the world. The major milk-based products consumed all over the globe are aarts, amasi, ayran, baked-milk, basundi, bhuna-khoya, blaand, booza, yogurt, butter, butterfat, buttermilk, buttermilk-koldskal, buttermilk-powder, cacik, camel-milk, casein, caudle, chaas, chal, chalap, cheese, clabber, clotted-cream, condensed-milk, cottage-cheese, cream, cream-cheese, crème-anglaise, cuajada, curd, curd-snack, custard, dadiah, daigo, dondurma, fermented milk products, frozen custard, frozen yogurt, infant formula, kefir, khoa, kulfi, lassi, malai, mithadahi, paneer, and whey.

According to latest statistics of the International Dairy Federation 2015, about one billion people in the world live on dairy farms; milk production was estimated at 748.7 million tons in 2011; the gross production value of raw milk produced across the world was 292 billion US$; the trade of milk products equals around 64 billion US$ in terms of value, globally. Around 150 million small-scale dairy households, equivalent to 750 million people, are engaged in milk production, and consumption of dairy products is expected to increase by 20% or more before 2021. It reveals huge potential of this sector.

This book volume provides the technology, suggests devices, standardization, packaging, ingredients, laws and regulatory guidelines, and information on infrastructure to transform raw milk into highly value-added products.

In the food processing industry, dairy industry is the one of the major partners. Dairy industry will be able to use emerging and innovative technologies given in this book to meet the changing demands of a growing and increasingly diverse population. As convenience and health consciousness become more important, consumers are increasingly demanding highlyprocessed and value-added dairy-based foods products such as emulsified salted cheese products, cheese made from plant-based coagulants, value-added khoa, high-pressure processed dairy products, and probiotics. This kind of change in consumption patterns will lead to the development of more innovative and processed foods (especially dairy-based food items), and it will not only affect the domestic market but also will influence the international trade. The increasing size, transportation, internet facility, media, and diversity of the global population have driven demand for a greater variety of dairy-based foods products. The combination of expanding export markets and shifting and increasing domestic consumption will lead to significant changes throughout the dairy manufacturing industry. This book is written for dairy and food engineers. Most of the contributors are by profession engaged in dairy and food processing related production, research, training, and teaching.

The targeted audience for the book is practicing engineers, researchers, lecturers, teachers, professors, dairy and food professionals, students of these fields, and all those who have inclination for the dairy and food processing sector. Hopefully, it covers all people because everybody consumes dairy-based products and food. Because the book not only covers the practical aspect, but also has a lot of basic information and is instructive, students in undergraduate, graduate, and post-graduate courses and post-doctoral researchers will also benefit.

Part I on “Advanced Applications in Dairy Engineering” presents chapters on plant-based coagulants in cheese making: review; rheology of fruit ripple; and role of emulsifying salts in cheese products. Part II is focused on “Process Engineering—Dairy Products,” which has chapters on dairy engineering—milk processing and milk products; aseptic food processing and packaging; high-pressure processing of dairy products; and introspection on mechanization of traditional Indian dairy products. Part III covers “Human Health Benefits from Various Dairy Products” such as the health benefits of milk-derived bioactive peptides and potential human health benefits of probiotics. Part IV on “Food Laws, Acts, Orders and Regulations” covers food laws and their implications and also covers food laws all over the world. This section also provides the details about entrepreneurship and management of food plant.

In order for the book to be useful to engineers, coverage of each topic is comprehensive enough to serve as an overview of the most recent and relevant research and technology. Numerous references are included at the end of all chapters.

My own training and work experience as a dairy and food process engineer and teacher was crucial in conceiving this book on dairy engineering. Also, it was the contributors who did the real great work. Thanks to all contributors for their time and energy to create these scholarly and practical chapters. Their professionalism is appreciated, and they have my utmost appreciation and admiration. My thanks also to Almighty God, whose love and blessings helped me immensely.

—Murlidhar Meghwal, PhD

December 2016

PREFACE 2

https://en.wikipedia.org/wiki/Dairy_farming indicates that dairy farming is a class of agriculture for long-term production of milk, which is processed (either on the farm or at a dairy plant, either of which may be called a dairy) for eventual sale of a dairy product. There is a great deal of variation in the pattern of dairy production worldwide. Many countries which are large producers consume most of this internally, while others (in particular New Zealand) export a large percentage of their production. Internal consumption is often in the form of liquid milk, while the bulk of international trade is in processed dairy products such as milk powder. Most milk-consuming countries have a local dairy farming industry, and most producing countries maintain significant tariffs to protect domestic producers from foreign competition but, the largest dairy exporting country, does not apply any subsidies to dairy production. The milking of cows was traditionally a labor-intensive operation and still is in less developed countries. Small farms need several people to milk and care for only a few dozen cows, though for many farms, these employees have traditionally been the children of the farm family, giving rise to the term “family farm.” Advances in technology have mostly led to the radical redefinition of “family farms” in industrialized countries such as Australia, New Zealand, and the United States.

With farms of hundreds of cows producing large volumes of milk, the larger and more efficient dairy farms are more able to weather severe changes in milk price and operate profitably, while “traditional” very small farms generally do not have the equity or cash flow to do so. The common public perception of large corporate farms supplanting smaller ones is generally a misconception, as many small family farms expand to take advantage of economies of scale and incorporate the business to limit the legal liabilities of the owners and simplify such things as tax management.

Worldwide, the largest milk producer is the European Union with its present 27 member countries, with more than 153,000,000 metric tons (151,000,000 long tons; 169,000,000 short tons) in 2009 (more than 95% cow milk). By country, the largest producer is India (more than 55% buffalo milk), the largest cow milk exporter is New Zealand, and the largest importer is China.

In the United States, the top five dairy states are, in order by total milk production, California, Wisconsin, New York, Idaho, and Pennsylvania. Dairy farming is also an important industry in Florida, Minnesota, Ohio, and Vermont. There are 65,000 dairy farms in the United States. Pennsylvania has 8500 farms with 555,000 dairy cows. Milk produced in Pennsylvania yields annual revenue of about US$1.5 billion. Herd size in the United States varies between 1200 on the West Coast and Southwest, where large farms are commonplace, to roughly 50 in the Midwest and Northeast, where land-base is a significant limiting factor to herd size. The average herd size in the United States is about one hundred cows per farm but the median size is 900 cows with 49% of all cows residing on farms of 1000 or more cows.

A dairy product or milk product is food produced from the milk of mammals. Dairy products are usually high energy-yielding food products. A production plant for the processing of milk is called a dairy or a dairy factory. Apart from breastfed infants, the human consumption of dairy products is sourced primarily from the milk of cows, water buffaloes, goats, sheep, yaks, horses, camels, domestic buffaloes, and other mammals. Dairy products are commonly found throughout the world (see Appendix C at the end of this book volume).

I recall my childhood. I was breast fed by mother till I was 8 years old. It calmed me down from my nervousness and hypertension, and imparted me security in the lap of my mother. Till fifth grade, I never tasted the dairy milk except few drops in an Indian tea. In sixth grade, once a day we were asked to sit on a 1 × 50 m mat and were served one 16 oz glass of milk by American Peace Corps volunteers. I enjoyed drinking not only the milk but also dedication of these volunteers. This milk was prepared from the powder milk that was imported from Europe. What a gesture to the undernourished students in the developing countries!

At the 49th annual meeting of the Indian Society of Agricultural Engineers at Punjab Agricultural University (PAU) during February 22–25 of 2015, a group of ABEs and FEs convinced me that there is a dire need to publish book volumes on focus areas of agricultural and biological engineering (ABE). This is how the idea was born on new book series titled “Innovations in Agricultural & Biological Engineering.” This book on Dairy Engineering: Advanced Technologies and Their Applications is the fourth volume under this book series, and it contributes to the ocean of knowledge on dairy engineering.

The contributions by the cooperating authors to this book volume have been most valuable in the compilation. Their names are mentioned in each chapter and in the list of contributors. This book would not have been written without the valuable cooperation of these investigators; many of them are renowned scientists who have worked in the field of food engineering throughout their professional careers. I am glad to introduce Dr. Murlidhar Meghwal, who is an Assistant Professor in the Food Science and Technology Division, of the Center for Emerging Technologies at Jain University—Jain Global Campus in District Karnataka, India. With several awards and recognitions, including from President of India, Dr Meghwal brings his expertise and innovative ideas in this book series. Also, joining my team is Dr. Rupesh S. Chavan, who is a Senior Executive, Department of Quality Assurance, Mother Dairy Junagadh, Gujarat. He has also worked as Assistant Professor at the National Institute of Food Technology Entrepreneurship and Management, Kundli under the Ministry of Food Processing Industries, India; and In-charge of the International Bakery Research and Training Center. He is a professor/researcher and has specialized in dairy and bakery products. Without their support, leadership qualities as editors of the book volume and extraordinary work on dairy engineering applications, readers would not have this quality publication.

I will like to thank editorial staff, Sandy Jones Sickels, Vice President, and Ashish Kumar, Publisher and President at Apple Academic Press, Inc., for making every effort to publish the book. Special thanks are due to the AAP Production Staff for the quality production of this book.

I request that the reader offers his constructive suggestions that may help to improve the next edition.

I express my deep admiration to my family for their understanding and collaboration during the preparation of this book volume.

One of my college mates (Dr R. P. Singh) at PAU can be distinguished as among top five food engineers in USA. At present, Dr. Singh is a Distinguished Emeritus Professor of Food Engineering Department of Biological and Agricultural Engineering Department of Food Science and Technology University of California Davis, CA 95616, USA. I invite readers to consult him at [email protected], whenever they need. Can anyone live without food or milk?

As an educator, there is a piece of advice to one and all in the world: “Permit that our almighty God, our Creator, provider of all and excellent Teacher, feed our life with Healthy Milk and Milk Products and His Grace—; and Get married to your profession—”

—Megh R. Goyal, PhD, PE,
Senior Editor-in-Chief
December 2016

PREFACE 3

Food is defined as a “substance, whether processed, partially processed or unprocessed, which is intended for human consumption.” Dairy is an integral part of food industry and most of the diets are incomplete without dairy products. Dairy industry is changing rapidly and continuously, thus creating a demand of modern engineering with mechanization. The industry offers a lot of value-added products which include traditional as well as westernized products. Dairy industries thrive day in and day out to meet and fulfill the customer’s needs, but due to changing age groups and eating habits, fulfilling the desires of the customers pose a huge challenge as well as an opportunity to the sector.

The intention of this book is to present knowledge on the dairy engineering, regulations, traditional dairy-based products and long-life products to the different segments of scholars, professors, researchers, and scientists in industries engaged in new product development. An attempt has been made to overcome the non-availability of a book in the field of dairy engineering focusing on the recent advances and emerging trends. This book volume, in short, explores and conveys the key concepts on dairy engineering and dairy products that are presented in four parts.

Part I: Advanced Applications in Dairy Engineering highlights the application of different processing aids including plant-based coagulants in cheese making and role of emulsifying salts in cheese-based products. Fruit ripples and the different factors governing the rheological parameters are also discussed in the subsection. Factors governing the consistency and quality of processed cheese (maturity of natural cheese, pH of cheese melt, type and concentration of emulsifying salts, processing temperature, speed of agitation, duration of heating, rate of cooling, temperature of storage, dry matter content, fat content, presence and concentration of ions, type and concentration of lactose or other sugars, and use of emulsifiers) are also discussed in detail along with the recent advancements in the commercial blends of emulsifying salts available in the market.

Part II: Process Engineering—Dairy Products highlights the application of recent and novel technologies for processing of dairy products including microfluidization, high pressure processing, and advancement in manufacturing of Indian traditional dairy products. The chapter on Dairy Engineering encompasses the different milk processing techniques like thermal (pasteurization, sterilization) or non-thermal techniques (high pressure processing, pulse electric field), and distilled description of the equipments including chillers, centrifugal separator, homogenizer, microfluidizer, pasteurizer (batch and continuous), high hydrostatic processing machine, and pulse electric field setup. Aspects of aseptic processing and packaging are also presented in the subsection highlighting the different techniques for UHT treatment of milk and advancements in the aseptic packaging systems. HPP of milk has attracted attention of the consumers as it has least effect on flavor, color, and nutritional value, simultaneously, very effective in reducing the microbial growth and is presented in depth in the current subs...