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Whey-contaiing food product and method of deflavoring whey proteinRelated Patent Categories: Food Or Edible Material: Processes, Compositions, And Products, Processes, Treatment Of Liquid With Nongaseous Material Other Than Water Per SeWhey-contaiing food product and method of deflavoring whey protein description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060292275, Whey-contaiing food product and method of deflavoring whey protein. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001] The present application is a continuation-in-part application of U.S. patent application Ser. No. 09/939,500, filed Aug. 23, 2001, which was based on, and claimed benefit of, U.S. Provisional Application Ser. No. 60/250,228, filed on Nov. 30, 2000, both of which are hereby incorporated by reference. BACKGROUND OF THE INVENTION [0002] This invention relates generally to the processing of whey protein-containing materials for use in various food products. More particularly, the invention relates to a method of deflavoring whey protein materials in order to make them acceptable in a wide range of foods. [0003] In recent years, whey proteins have become widely used in food products, for the health benefits to be obtained from their use. For example, studies suggest that whey proteins may provide a variety of health benefits such as anti-hypertension activity, immune system enhancement, antimicrobial activity, intestinal health enhancement, and oral hygiene activity. In some applications, the taste of the whey protein materials is not objectionable. However, in some uses, such as dairy analog products, beverages and the like, and especially when the amount of whey protein is increased to the levels associated with such health benefits, the flavors found in whey protein materials may prevent their ready acceptance by the consumer. Thus, in order to extend the uses of whey protein materials, the present inventors wanted to find a method of reducing the flavor components of whey protein materials. However, it was not evident that methods which had been used previously to remove flavor components from other organic materials would be successful in the treating of whey protein materials. Organic materials, since they have complex compositions, must be tested to determine whether any given method of treating them will be satisfactory. [0004] One example of previously employed methods to purify organic materials is found in U.S. Pat. No. 4,477,480, in which the patentees show that starch can be treated with an alkali to remove objectionable flavor components. In a commonly assigned patent, U.S. Pat. No. 4,761,186, ultrafiltration is used to purify starch. In both cases, flavor components are removed from the starch, in the '480 patent by solubilizing the flavor components so that they can be washed out of the relatively insoluble starch. In the '186 patent, ultrafiltration was used to remove the flavor components as permeate, while the insoluble starch remained in an aqueous slurry. By contrast, the present invention separates flavor components from soluble high molecular weight whey proteins. [0005] There are many articles and patents which relate to processing soy materials in order to recover the protein content and which at the same time reduce the flavor compounds to make the proteins more acceptable in food products. However, these previous disclosures were not specifically directed to removal of flavoring compounds and recovering as much of the protein as possible. One example is U.S. Pat. No. 4,420,425 in which protein components of soy are solubilized at a pH of 7 to 11, preferably about 8 and, after ultrafiltration through a membrane having a molecular weight cut off above 70,000, are recovered by spray drying the retained soy proteins. In variants, only a portion of the protein is solubilized at lower pH values and subjected to ultrafiltration with a membrane having a cutoff preferably above 100,000 molecular weight, the product was found to have improved color and flavor. A higher cutoff valve would be expected to result in a loss of valuable proteins. In another patent, U.S. Pat. No. 5,658,714, a soy flour slurry is pH-adjusted to the range of 7 to 10 to solubilize proteins, which are then passed through an ultrafiltration membrane and phytate and aluminum are retained, presumably as solids. While the molecular weight cutoff of the membrane was not given, it is assumed that the pore size was large in order to be able to pass the soluble proteins. Both of these patents contain extensive discussions of the efforts of others in the processing of soy materials; neither teaches or suggests the control of pH during the ultrafiltration process. [0006] In a group of related patents, Mead Johnson Company disclosed processes for solubilizing soy proteins by raising the pH of an aqueous solution of soy materials and recovering the proteins which are said to have a bland taste. The processes are principally directed to concentrating proteins rather than removing flavor compounds. In U.S. Pat. No. 3,995,071, the pH was increased to 10.1 to 14 (preferably 11 to 12) to solubilize soy proteins, after which the pH was lowered to about 6 to 10 and ultrafiltration with a membrane having a molecular weight cutoff of 10,000 to 50,000 Daltons was used to retain the proteins while discarding carbohydrates and minerals. In U.S. Pat. No. 4,072,670, emphasis was placed on removing phytates and phytic acid by solubilizing proteins at a pH of 10.6 to 14 and a temperature of 10 to 50.degree. C. to make the phytates and phytic acid insoluble, then separating them and finally acidifying the solution to a pH of about 4 to 5 to precipitate the soy proteins. In U.S. Pat. No. 4,091,120 soy proteins were solubilized at a pH less than 10, preferably 7 to 9, and ultrafiltration was used to separate the proteins as retentate, while passing carbohydrates as permeate. These patents do not teach or suggest control of the pH during the ultrafiltration process. [0007] The present inventors wanted to remove compounds in soy protein materials which contribute color and flavor and which interfere with the use of soy protein in certain food products such as beverages, dairy analogs, and the like. They found that soy protein-derived materials can be treated successfully, recovering substantially all of the proteins and rejecting the compounds which cause undesirable color and flavor. Moreover, by controlling the pH within the range of about 8.5 to about 12 during the ultrafiltration process, deflavored soy protein materials having improved functional properties can be obtained. Thus, the product is suitable for many food products. Now the present inventors have surprisingly discovered that a related process can be advantageously applied to whey protein materials to remove undesirable flavor components to obtain a deflavored whey protein material which can be incorporated into many different food products. The process can, however, be modified such that it can be operated in a basic or acid pH range. Thus, either basic or acidic deflavored soy protein can be prepared using the process of this invention. SUMMARY OF THE INVENTION [0008] Broadly, the invention is a process for preparing an aqueous whey composition having a whey protein concentration of about 1 to about 50 percent, which is pH-adjusted to solubilize the whey protein content and to release the flavoring compounds. Then the composition is subjected to ultrafiltration, while maintaining pH control, using a membrane capable of retaining substantially all of the protein content of the whey protein material while removing flavoring components as permeate. As noted above, the present inventors have now surprisingly discovered that a method used for deflavoring soy protein materials can be used in a similar manner for deflavoring whey protein materials. The present process, as applied to whey proteins, can be run under either acidic or basic conditions as desired to produce either an acidic or a basic deflavored whey protein material. [0009] The deflavored whey protein materials prepared by the present methods are ideally suited for use in dairy and non-dairy beverages, smoothies, health drinks, confectionary type products, nutritional bars, cheeses, cheese analogs, dairy and non-dairy yogurts, meat and meat analog products, cereals, baked products, snacks, and the like. Preferably the acidic deflavored whey protein is used in acidic food products and the basic deflavored whey protein is used in neutral and basic food products. Thus, by proper selection, one can avoid destabilizing the deflavored whey protein associated with passing it through its isoelectric point. [0010] The present invention provides methods for deflavoring whey proteins. In addition to the removal of off-flavors, the present invention also allows the efficient removal of lactose, thereby allowing concentration of the whey proteins to high levels. Typically whey protein contains about 70 to about 80 percent (dry basis) lactose. Generally, levels of lactose less than about 15 percent (dry basis) can be obtained in the deflavored whey protein. By extensive ultrafiltration/difiltration (i.e., greater than 5 wash cycles and typically in the range of about 6 to 7 wash cycles), the level of lactose can be reduce to less than about 99 percent (dry basis). Moreover, the deflavored whey protein materials can be prepared containing greater than about 50 percent protein (on a dry basis), and preferably about 65 to about 95 percent protein; obtaining higher levels of protein (generally greater than about 85 percent) require extensive ultrafiltration/diafiltration. Thus, it becomes possible to incorporate whey protein in conventional food products at sufficiently high levels (generally sufficient to provide about 2.5 to about 20 g whey protein per single serving size (generally about 25 to about 100 g for solid food products and about 100 to about 300 ml for liquid food products)) to provide health benefits of whey protein. Prior to this invention, incorporation whey proteins at such levels generally resulted in significant off-flavors and, therefore, only very limited acceptance by consumers. Moreover, the removal of lactose may allow the use of such food products by lactose-intolerant consumers; generally, in such cases, at least about 95 percent of the lactose should be removed. [0011] In one aspect, the invention is a method of deflavoring whey protein materials, which method includes preparing an aqueous composition of the whey protein material containing flavoring compounds, adjusting the pH to a basic range of about 8.5 to about 12 or to an acidic range of about 2.4 to about 4 to solubilize the protein content of the whey protein material and release the flavor components, and then passing the pH-adjusted composition adjacent to an ultrafiltration membrane having pores which provide a molecular weight cutoff up to 50,000 Daltons, while maintaining the pH in the same range as to which the aqueous composition was adjusted, thus retaining substantially all of the whey protein content, while passing through the pores the flavor producing compounds. [0012] In another aspect (herein termed the "basic mode of operation"), the invention includes adjusting the pH to the range of about 8.5 to about 12 with an alkali such as sodium, potassium or calcium hydroxides to maintain the solubility of the whey protein content and release the flavor compounds, making it possible to separate such compounds by ultrafiltration. Importantly, the pH in this basic mode of operation is also controlled within the range of about 8 to about 12 during the ultrafiltration process. [0013] In another aspect (herein termed the "acidic mode of operation"), the invention includes adjusting the pH to the range of about 2.5 to about 4 with an edible acid (e.g., citric acid, acetic acid, lactic acid, malic acid, ascorbic acid, fumaric acid, adpidic acid, phosphoric acid, sodium hydrogen sulfate, and the like) to maintain the solubility of the whey protein content and release the flavor compounds, making it possible to separate such compounds by ultrafiltration. The preferred edible acids for use in this acidic mode of operation include phosphoric acid, citric acid, and malic acid. Importantly, the pH in this acidic mode of operation is also controlled within the range of about 2.5 to about 4 during the ultrafiltration process. [0014] Native whey proteins (i.e., undenatured) are generally soluble over a wide range of pH values. Denaturing of such protein, as often occurs during processing (e.g., cheese manufacture, pasteurization, elevated temperature, ultrafiltration, and the like) have decrease solubility (especially around the isoelectric point of about 7.4). Maintaining the pH of the deflavored whey protein in essentially the same range as its ultimate use in a food product allows the maintenance of desired solubility. Using a deflavored whey protein prepared using the basic mode of operation in a neutral or basic food product and using a deflavored whey protein prepared using the acidic mode of operation in an acidic food products avoids modifying the pH of the deflavored whey protein (and passing it through its isoelectric point) and thereby provides maximum solubility in the food product. [0015] In one embodiment, the invention is a method for deflavoring whey protein materials in a continuous process wherein a pH-adjusted aqueous mixture of whey protein materials is passed adjacent an ultrafiltration membrane to separate the flavor components. The pH is maintained at about 8.5 to about 12 for the basic mode of operation or at about 2.5 to about 4 for the acidic mode of operation during the ultrafiltration by the addition of the appropriate amount of an appropriate pH-altering material (i.e., a base or acid depending on the desired mode of operation). The permeate containing flavor components, lactose, minerals, and water is passed adjacent a reverse osmosis membrane to dewater the permeate and the separated water is recycled to join recycled retentate and fresh pH-adjusted whey materials. A portion of the retentate is continually removed and the deflavored whey protein materials recovered. [0016] In a preferred embodiment, the invention is a method for deflavoring whey protein materials in a batch or semi-continuous process wherein a pH-adjusted aqueous mixture of whey protein materials is passed adjacent an ultrafiltration membrane, the permeate is separated for recovery of the flavor components, and the retentate is recycled to join fresh pH-adjusted whey protein materials. Water is added periodically or continuously to replace the water lost to the permeate and to adjust the concentration of whey materials in the combined stream to a predetermined level. If necessary, a pH-altering material (e.g., a base or an acid) can be added to the recycled retentate or added water to control the pH to the desired range during the ultrafiltration process. The process is continued until essentially all of the flavoring compounds have been removed. If desired, the process can also be continued until sufficient levels of lactose removal have been obtained; such reduced lactose materials may be used in food products directed to lactose-intolerant individuals. [0017] In another preferred embodiment, the present invention provides a method for preparing deflavored whey protein material, said method comprising: [0018] (a) preparing an aqueous composition of a whey protein material containing soluble whey proteins and flavoring compounds; [0019] (b) adjusting the aqueous composition of (a) to either (1) a basic pH in the range of about 8.5 to about 12 or (2) an acidic pH in the rang of about 2.5 to about 4; [0020] (c) passing the aqueous composition of (b) adjacent an ultrafiltration membrane having a molecular weight cutoff up to about 50,000 Daltons, while maintaining the pH in the same range as adjusted in step (b), under suitable ultrafiltration conditions wherein the flavor compounds pass through the membrane, thereby deflavoring the whey protein material and retaining substantially all of the soluble whey proteins; and [0021] (d) recovering the soluble whey proteins retained by the ultrafiltration membrane to obtain the deflavored whey protein material. It is generally preferred that any insoluble materials be removed from the whey protein composition prior to the ultrafiltration step. Removal of such insoluble materials (which could include, for example cheese fines, fat globules, and casein aggregates using whey derived from a cheese making process) could be carried out at any time before ultrafiltration step, including before the preparing the initial aqueous solution of step (a). [0022] The ultrafiltration membrane used in the method of the invention will have a molecular weight cutoff up to 50,000 Daltons, preferably 1,000 to 50,000, most preferably about 10,000. Continue reading about Whey-contaiing food product and method of deflavoring whey protein... 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