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After pasteurization, other optional ingredients such as vitamins and minerals are added to the milk. The milk then undergoes a two-part moisture-removal process. The first part involves being pumped to an evaporator where it is concentrated in a series of steps to around 40-50% total solids. Omitting evaporation of the milk prior to drying is not economically feasible because the demand for energy would be severely increased. For example, the energy used in multiple effect evaporators with steam compression is about 10 times lower than in spray drying. Omission of evaporation would also result in an inferior quality milk powder because evaporation produces large powder particles that contain less occluded air, which results in an extended shelf-life. The second part involves drying in either a spray dryer or on a roller dryer. Additional optional processing steps include instantizing. After processing, cooled milk powders are sifted and sent to blending and storage silos. Milk powders are then sampled, packed, check weighed and palletized as required for shipping. SPRAY DRYING Spray drying involves atomizing concentrated milk into a hot air stream (180o 200oC). The atomizer may be either a pressure nozzle or a centrifugal disc. By controlling the size of the droplets, the air temperature, and the airflow, it is possible to evaporate almost all the moisture while exposing the solids to relatively low temperatures. Spray drying yields milk powders with excellent solubility, flavor and color. This is the most common procedure for manufacturing milk powders.
The spray drying process is typically a two-stage process that involves the spray dryer at the first stage with a static fluid bed integrated in the base of the drying chamber. The second stage is an external vibrating fluid bed. Product is moved through the twostage process quickly to prevent overheating of the powder. Powder leaves the dryer and enters a system of cyclones that simultaneously cools it. ROLLER DRYING Roller drying involves direct contact of a layer of concentrated milk with the hot surface of rotating rollers. This method is not used often because of the adverse affects the heat has on milk components. Heat often causes irreversible changes such as lactose carmelization, Maillard reaction and protein denaturation. Roller drying typically results in more scorched powder particles and poorer powder solubility than spray drying. INSTANTIZING The process of instantizing results in a milk powder with improved reconstitution properties. Instantizing is attained by agglomeration, a process of increasing the amount of air incorporated between powder particles. During reconstitution, the air is replaced by water. Incorporated air enables a larger amount of water to come into contact immediately with the powder particle during reconstitution. With whole milk powder and buttermilk powder, a small amount of lecithin is typically applied during agglomeration. Lecithin is a natural phospholipid that improves the ability of high-fat products to dissolve in water. Lecithin also occurs in milk fat.
There are two basic types of agglomeration processes: The rewet process, where the instantization is carried out after the powder is obtained in dry form, and the straight-through process, where instantization is accomplished during drying.
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Standardization
Heat treatment
(Minimum 72 C for 15 seconds or comparable)
o
Evaporation
(Concentrate in a 3-6 effect evaporator to 40-50% total solids.)
Drying/Optional Instantizing
(Final moisture: 2.5-3.5%)
Cool
Sieve
Pack
Store
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INSTANTIZING-REWET PROCESS
Milk powder
Agglomeration
Fluid-bed drying
(Final moisture: 2.0 - 4.0%)
Cool
Sieve
Pack
Store
19
INSTANTIZING-STRAIGHT-THROUGH PROCESS
Concentrated milk
Fluid-bed drying
(Final moisture: 2.0 - 4.0%)
Cool
Sieve
Pack
Store
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PLANT SURVEYS Each plant survey is conducted by experienced, highly trained dairy inspectors who make detailed checks on more than 100 items. Only plants that meet these requirements are granted approval status and are eligible for grading and quality control services. Some of the items on a dairy inspectors list include: 1. The plant surroundings must be clean to prevent bacterial contamination and maximize product safety. 2. Areas such as the raw milk grading room, receiving line, manufacturing area and warehouse supply room must have adequate lighting. 3. Facilities must be of sound construction. 4. Incoming raw product is graded on a regular basis. 5. Incoming milk must be regularly analyzed to ensure high quality and product safety. 6. All processing equipment must be kept sanitary and in excellent working condition to assure the buyer that the milk powder is protected from contamination. INSPECTION AND GRADING Final product is sampled by USDA inspectors. A computer program is used to select samples randomly and these samples are pulled from storage in the presence of the USDA inspector. The inspector examines each sample to determine compliance to the grade standard or contract specification and stamps packages with the official acceptance stamp or grade mark. They also issue certificates for product that complies with the standard or specification. After inspection, dairy 22
products are packaged under stringent, U.S. government regulated standards. LABORATORY SERVICE Laboratory service consists of analytical and quality control tests, including all chemical and bacteriological determinations essential for grading. PERSONNEL The men and women who perform these services are experienced and well trained. Many inspectors and graders have college degrees in dairy manufacturing or food science, and have held responsible jobs in the dairy industry.