UNIT 14 METHOD OF MANUFACTURE OF

SPRAY AND ROLLER DRIED

MILK POWDER AND VALUE
ADDED PRODUCTS
Structure
14.0 Objectives
14.1 Introduction
14.2 Production of Milk Powder
• Standardization
• Preheat treatment
• Condensing
• Homogenization
• Drying

14.3 Manufacture of Spray Dried Milk Powder

• Foam Spray Drying

14.4 Manufacture of Roller Dried Milk Powder

14.5 Malted Milk Food
• Manufacture of Malted Milk

14.6 Infant Milk Food and Infant Formula

• Virtues of Human Milk

• Production of Infant Milk Food and Infant Formula

14.7 Dairy Whitener

• Quality Attributes

14.8 Let Us Sum Up

14.9 Key Words
14.10 Some Useful Books
14.11 Answers to Check Your Progress

14.0 OBJECTIVES
After reading this unit you should be able to:
• Describe the manufacturing process of spray and roller dried milk powders
• Describe various value added products like infant food and infant formula,
malted milk foods and dairy whitener

14.1 INTRODUCTION
Today, the production of dried milks and milk products has become important segment
of dairy industry due to their longer shelf life, requiring lesser storage space and
lower shipping costs. Dry milk provides a means of preserving the excess milk
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supply during the flush season for use during the lean season. Value added dried
Dried Milks dairy products like malted milk foods, infant food and infant formula and dairy whitener
are convenient ready to use products having wide acceptance.
The production of dried milks to a greater extent, is now being governed by the
market requirement and to some specialised use of such products. Considerable
quantities of dried skim milk powders are being used in the preparation of
“Reconstituted and Recombined Milk”. Milk powders are also used extensively in
the manufacture of ice cream, bakery products, confectionary products, cottage
cheese and in other cheese varieties. The greatest proportion of milk powder is
utilized in confectioneries such as milk chocolate, caramels, soft sweets, coatings,
biscuits and cakes. In these products, milk powder has a special effect on the quality
of particular products: it improves consistency, taste, and flavour, as well as nutritional
value and shelf life.
However, the suitability of dried milk for different uses depends upon certain quality
attributes of the powder. Some types of skim milk powders are found to be better
suited for reconstitution purpose while certain other kinds are more suitable for
bakery products. Therefore, attempts have been made to classify milk powder
suitable for different end uses on the basis of certain attributes.

14.2 PRODUCTION OF MILK POWDER

Milk destined for the production of powder must be of high chemical, organoleptical,
and bacteriological quality. Acidity of milk must be below 0.15% (expressed as
lactic acid), otherwise the solubility of the milk powder is reduced. Stored raw milk
is not good even when it is kept under refrigerated conditions because it may lead to
an increase in free fatty acidy in the resultant dried milk causing many fold increase
in lipolysis in the powder produced from such milk. High bacterial counts increase
the susceptibility of fat to oxidation during storage of the powder. Oxidation of milk
fat reduces the shelf life of the resulting milk powder. Fat oxidation is accelerated by
the presence of metals such as copper or iron. Care must be taken that all equipments,
pipelines and accessories coming into contact with milk and cleaning solutions are
made of stainless steel exclusively.
The basic operations in milk powder production consists of receiving and selecting
milk, filtration/clarification, cream separation/standardization, preheat treatment,
condensing, homogenisation, drying, packaging and storing of powder. Production
of skim milk powder differs slightly from whole milk powder production.
i. Standadization
The objective of standardization is to adjust the ratio of milk fat and total solids to
the level required in the final product. Production of skim milk powder differs slightly
from whole milk powder production. For skim milk powder, it is necessary to reduce
fat in skim milk to less than 0.1%.
ii. Preheat Treatment
The preheating of milk before condensing in the manufacture of dried milks is done
for the production of safe and better stable milk powders and also for inducing in it
other desirable attributes. Pasteurization at 72oC for 15 s is sufficient to address the
safety requirements associated with processing of raw milk, though, higher
temperatures and longer holding times may be necessary to meet requirements relating
to thermoduric pathogens and specific food spoilage organisms. For milk powder
solubility, which mostly depends on the state of the milk protein system, the high
44 temperature short time (HTST) regime is more convenient when compared to
prolonged thermal treatment at low temperatures, and has the same microbiological Method of Manufacture
of Spray and Roller
effect. The temperature most frequently used is in the range of 88-95oC for 15-30 Dried Milk Powder and
sec. HTST regimes with direct or indirect heating are also used with temperatures Value Added Products
ranging up to 130oC.
Preheat treatment contributes significantly to the shelf life of dried milks (e.g. whole
milk powder) primarily through development of antioxidant or reducing substances.
The formation of reactive or free sulphydryl groups, resulting from the heat treatment
of milk, are responsible for preventing oxidized flavour development by acting as
free radical scavengers, and thus as antioxidants. Products of Maillard reactions
also contribute to the overall antioxidant effect in milk powders.
Milk may be heat-treated at temperatures to achieve various levels and types of
protein denaturation, according to final product requirements. Skim milk powder is
commonly graded according to the amount of undenatured whey protein nitrogen
present in non-fat milk solids expressed by the whey protein nitrogen index (WPNI),
which is defined as the amount of undenatured whey protein nitrogen measured in
mg/g powder. Table 14.1 shows the heat classifications for skim milk powders as
was introduced by the American Dry Milk Institute (ADMI) in 1971.
Table 14.1 Heat classification of skim milk powders and associated heat
treatments
Class of powder WPN Index Typical heat treatment
(mg/g powder) conditions for milk
Low heat Not less than 6.0 75oC, 20 s
Medium heat Above 1.5, but below 6 85 -105oC, 1-2 min
High heat Not more than 1.5 120-135oC, 2-3min

iii. Condensing
For spray drying, the milk is concentrated in multiple effect evaporators to 40-50 %
total solids. For roller drying, the milk is concentrated to 18% total solids. Further
concentration for spray drying would increase viscosity and cause difficulties during
atomisation of the milk. During roller drying, a higher concentration of milk would
form a thicker layer on the rollers, followed by inhibited drying and intensive irreversible
changes to proteins, lactose and fat. Evaporators use much lesser thermal energy
than driers for removal of equivalent amount of moisture from milk.
iv. Homogenization
Homogenization is not an obligatory operation in milk powder manufacture, but is
usually applied to decrease free fat content. Higher free fat content in powder is,
however, demanded in certain confections. Homogenization also helps to prevent
clumping of fat during reconstitution and improves the keeping quality of powder.
Homogenization is conducted after evaporation, or in partly concentrated milk, the
concentration rate being not more than 3:1. At higher concentration, homogenization
destabilizes milk proteins, thus decreasing powder solubility. The customary
homogenization is 2500 to 3000 psi at 62.8 to 76.7oC.
v. Drying
Though a number of drying systems are available, practically only spray drying and
roller drying are commercially used in dairy industry. Since the product quality and
process economy are much better and are being constantly improved, spray drying
has the highest potential today and in the foreseeable future.
45
Dried Milks Check Your Progress 1
1) What is the importance of drying of milk and milk products?
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2) Why the milk should be of high quality for the production of milk powder?
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3) List the basic operations in milk powder production.
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4) Why preheat treatment is given to milk prior to evaporation?
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5) How are powders heat-classified?
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6) To what extent, milk is concentrated before drying and why not to higher levels?
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 ................................................................................................................... Method of Manufacture
of Spray and Roller
................................................................................................................... Dried Milk Powder and
Value Added Products
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7) Why and how the homogenization is done during the manufacture of milk
powder?
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14.3 MANUFACTURE OF SPRAY DRIED MILK

POWDER
The predominant method of drying milk and milk products is spray drying. The
condensed milk from the evaporator is pumped to a balance tank and from there
passed through a filter and introduced into drying chamber with or without preheating.
The solubility of skim milk powder is not affected up to a preheating temperature of
80°C. Feeding cold concentrated milk to the drier may result in sticking to the
chamber causing more burnt or scorched particles in the final powder. Either a
pressure nozzle or spinning-disc is used for atomising the concentrate into fine droplets
and exposing to a current of hot air in the spray-drying chamber. Due to increased
surface area, and to the high latent heat of water evaporation (2.26 MJ/kg), sprayed
particles release their moisture quickly, thereby causing an immediate temperature
drop of the incoming air. While the inlet temperature reaches up to 215oC, the
temperature in the chamber drops down almost instantly to the temperature of outlet
air (about 95oC in one stage drying). Residual moisture is one of the most important
properties of milk powder both from a quality and an economic point of view. The
outlet temperature is usually used as the parameter by which the final moisture of the
product is controlled. The outlet temperature depends on a large number of factors.
The chamber design, the residence time of milk particles in the chamber, the final
desired moisture content in the powder and the design of powder collecting systems
controlling the air inlet and outlet temperatures. Dry product is taken away immediately
after drying. The powder coming out of the drier is preferably cooled to 30°C by a
secondary air stream before packaging and storage. Cooling is done to prevent
clumping, sticking and heat-damage to the product. Prolonged heating causes
staleness in non-fat dry milk and jeopardizes the flavour and keeping quality of dried
milks. On prolonged exposure of the powder to heat, the fat has a tendency to melt
and oil off. The fat thus becomes the continuous phase. Some of it covers the surface
of the dried milk particles and is exposed to air and light and becomes subjected to
oxidation.
In two-stage drying, it is also important to control the intermediate moisture, i.e. the
moisture of the powder at exit from the drying chamber because it influences many
other properties including solubility index, particle density, bulk density, agglomeration,
etc. Because there is some gain in moisture content during pneumatic conveying and
blending and to a lesser extent during storage, it is normal to produce powder from
the dryer of lower moisture content than that called for by the specification so that
47
the final powder remains within specification.
Dried Milks Spray drying has numerous important advantages compared to other drying
techniques: The whole process proceeds very rapidly; air residence time in the
chamber is up to 30 seconds. Because of this and because drying is accomplished
at lower drying temperatures, the product has excellent properties.
Certain disadvantages of spray drying include very large size of the drying chamber,
expensive equipment, high electricity and steam consumption and low bulk density
of the dried product. However, the bulk density of milk powder obtained by spray
drying is still higher than that of roller-dried powder. Because of high investment
cost, Spray drying installation is economically justified only for large capacities, over
100,000 kg of raw milk per day. Today there are specialized drying plants with
modern facilities, producing 18 tons/hour of powder.
FOAM SPRAY DRYING
Foam spray drying can be accomplished by forcing the gas into liquid through the
pump before atomising nozzle supplying the drier. Air is commonly used as the added
gas for making foam spray non-fat dry milk. Nitrogen is commonly used for making
foam dried whole milk. Foam spray drying provides a means of using most
conventional spray drying equipment for drying liquids up to a maximum of 60%
totals solids as compared to 50% on a particular drier, for obtaining an instant type
powder and provides a procedure for increasing the capacity of conventional
equipment and profits as well. Foam spray drying gives more uniform particle size in
the dried product. Foam spray dried powder has improved dipersibility, but poor
sinkability due to occluded air when reconstituted in water. However, the foam
spray milk powder has lower bulk density and hence higher packaging, storage and
transportation costs.

14.4 MANUFACTURE OF ROLLER DRIED MILK

POWDER
The most used construction of roller drier in the dairy industry is an atmospheric
double drum drier made of cast iron. The product at 74-85oC is pumped into the
reservoir between the two drums. Milk is continuously brought to the heated surface
of the rollers where it is dried. Since the drum speed, on an average at 14-19 rpm,
is normally constant, the principal adjustment is the steam pressure during operation.
This should be changed with care to maintain desired 3.0-4.0 % moisture in the
powder. The temperature of the milk reaches almost the temperature of steam during
drying. After being dried, milk is continuously scraped off the roller by sharp knives
in the form of a thin film. Dry film, scraped off by the knives, falls on a spiral conveyer
that is along the side of each roller. In this procedure, the film is broken into smaller
particles and transported to the hammer milk for pulverizing. The powder is usually
sifted through a system of sieves to be classified according to particle size. The
product is usually packed in 25 kg kraft bags with a plastic liner reasonable impervious
to moisture vapours.
The quality of roller dried milk powder depends on many factors. Higher drum
temperature or slower speed will cause scorching of the product despite insufficient
drying. In addition to the temperature and duration of drying, the temperature and
concentration of milk feed, the thickness of the milk layer over the rollers, and the
uniformity of the milk feed play a major role.
Direct contact of the pre-concentrated milk with the hot drum surface results in
some irreversible changes in the milk. Caramelization of lactose, Maillard’s browning
48 reactions, and denaturation of proteins are the most important changes affecting the
quality of roller dried milk powder. Products of the Maillard type reactions Method of Manufacture
of Spray and Roller
(interactions of lactose with the amino groups of lysine) may cause a scorched flavour Dried Milk Powder and
of the powder. Denaturation of proteins decreases the solubility of the powder. In Value Added Products
spite of these negative effects, roller drying process is used for the following
advantages of this process:
• Relatively low capital and operating costs
• Relatively smaller floor space requirement
• Economical processing, easy operation and maintenance
• Suitable for processing smaller quantities of milk
• Production of dried milk with longer storage life
• Advantageous in some applications: such as in the production of certain
confectioneries or bakery products.
Roller drying is most often used for nonfat milk. Roller dried milk is also used in feed
blends industry.
Check Your Progress 2
1) What are the advantages of spray drying process?
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2) Why powder should be cooled immediately after spray drying?
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3) What are the advantages of foam drying of milk powder?
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4) What are the disadvantages of roller drying process?
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Dried Milks ...................................................................................................................
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5) What are the advantages of roller drying process?
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14.5 MALTED MILK FOODS

Malted milk food is a product containing milk solids, malt extract and cereal grain
flour. Malted milk food was first developed in 1883 by William Horlicks of Racine,
Wisconsin, U.S.A. The product was commercially marketed in 1887. This product
gained favourable attention from the medical profession and public due to its nutritive
value, convenience, digestibility and palatability.
Only a small fraction of milk produced in India has found its place in malted milk
manufacture. Though a potential market exists in the country for malt based milk
beverages, very few factories have under taken its production. Considerable high
cost of these products has largely been responsible in inhibiting its use by common
people.
MANUFACTURE OF MALTED MILK
The preparation of malted milk consists of combining milk with the mash liquor
resulting from a mash of barley malt and wheat flour. Barley malt not only supplies
the malt flavour, but also contains diastase, which converts starch into sugar. Briefly
the process may be divided into the following stages:
i. Production of mash liquor: The malted barely is sieved to remove dust and
other foreign matter. It is then crushed using in line roller mill and mixed with
high-grade wheat flour. Usually about 2.5 times as much dry barley malt is
used as wheat flour. The mix is conveyed to mash tanks, where water at 40°C
is continuously added to prepare uniform slurry. The slurry is continuously heated
and stirred and the temperature gradually increased to 70°C within about 40
min. The slurry is held at 70°C for about 35 min. During this process the whole
of the starch is hydrolysed by diastase, present in malted barley, into maltose,
dextrin and malto-dextrins, while the complex cereal proteins are converted
into simpler protein substances. The slurry temperature is gradually raised to
78°C and held at this temperature for about 20 min to stop further activity of
enzymes and also to achieve maximum cereal solids (28-30%). The mash is
passed through centrifugal separator to remove the insoluble husk and to obtain
clear liquor, known as ‘wort’.
ii. Mix preparation: The wort derived from the mashing section is mixed with
predetermined quantities of standardised milk, diluted and pasteurised (85°C)
malt extract, sugar, salts, minerals and vitamins in a mix preparation tank. Milk
solids increase nutritional value of the product by providing high quality fat,
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proteins, minerals and vitamins. Milk fat enhances flavour and energy level of
 final product. Malt extract provides desired level of colour and typical Method of Manufacture
of Spray and Roller
caramelised flavour to the finished product. Salts are added to optimise product Dried Milk Powder and
pH to improve digestibility, enhance flavour and to provide essential salts, Value Added Products
especially calcium. The percentage contribution of each ingredient depends
upon final formulation of the product.
iii. Evaporation and drying: The mix at about 26% solids is concentrated in the
vacuum evaporator until one half to two-thirds of the water content has been
removed. The product is then transferred to a steam jacketed evaporator
provided with stirring gear, where a high vacuum is maintained, agitation being
constant in order to facilitate the removal of the water and to prevent excessive
caramelisation. The concentrated mass with an average of 80% solids is finally
dried within a level of 2% moisture to a sponge-like, swollen mass usually in a
vacuum tray drier. Dried product is cooled in an air-conditioned room to avoid
moisture pick up, scrapped off the trays and milled into fine powder. The milled
product is conveyed to inline mixers to mix salts, dry vitamins and minerals and
then packed in bottles or refill packs.
Malted milk powder will dissolve freely in hot or cold water or milk, the resultant
beverage being very palatable besides possessing an agreeable odour and flavour
derived from the hydrolysed cereal starch used in its manufacture.
iv. Spray Drying of Malted Milk: The malted milk food is generally prepared
by tray-drying method under vacuum that is essentially a batch operation and
hence adds to the cost. Spray drying method will reduce the cost of product
owing to high volume of continuous and automated operation. Thus the production
of good quality, low cost malted milk food with improved physical
characteristics like better dispersibility and wettability appears to be better
proposition for the dairy industry to consider, than continuing of with the
traditional tray-drying method. The concentrate from first stage evaporation at
an average 50% solids is atomized using either rotary or nozzle atomising system.
Malt-milk based food products are highly hygroscopic, due to high level of
added or process converted sugars. Proper drying of these products is possible
using modified design of three stage dryers, preferably having an air-broom
system. In view of product quality and hygienic standards, spray-drying process
is a potential future technology for drying malt-milk based food products to
meet local as well as international requirements.
Check Your Progress - 3
1) What is malted milk food? Describe its virtues and limitation.
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2) During the manufacture of malted milk food, describe the production of mash
liquor.
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Dried Milks ...................................................................................................................
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3) Describe the evaporation and drying process during the manufacture of malted
milk food?
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14.6 INFANT MILK FOOD AND INFANT FORMULA

Breast milk is the best milk for infant feeding. There is no true substitute to the
human milk for the feeding of infants. Apart from providing right proportion and
quality of nutrients required for the growth, it also helps in protecting the newborn
against infective agents in its new environment. But, there are mothers, who either
can’t or prefer not to feed breast milk to their babies. This led to the development of
infant milk food and infant formula with the modification of cow/buffalo milk as an
alternative to human milk. The pattern of bottle-feeding in the modern world is a
sequel to industrial growth and urbanisation. The substitute of breast milk serves as
a saver of precious life during vulnerable stages of infancy in the event of lactation
failure, insufficient milk secretion and in case of mothers inflicted with transmittable
diseases, like tuberculosis, breast cancer etc. Today nearly 1,85,000 tonnes of infant
food and infant formula are manufactured in India. There are at least 14 different
brands of infant food and infant formulas presently available in the country made
from bovine milk.
i. Virtues of Human Milk
Followings are the virtues of human milk unlike in bovine milk (Table 14.2):
• Protein content is much lower (1.0 %) in human compared to 3.5 % in cow
milk and 4.0% in buffalo milk.
• Ratio of casein to whey proteins is much lower (4:6) in human milk compared
to (4:1) in cow milk.
• Due to higher proportion of whey proteins (which are richer in essential amino
acids) the nutritive value of human milk protein is much higher.
• Concentration of vitamin E, D and K is much higher in human milk and it also
contain taurine (a special protein present only in human milk) which help in the
absorption of calcium.
• Phosphorous to calcium ratio (Ca:P) is much higher (2:1) in human milk
compared to 1:2 in cow milk
• Size of the fat globules is smaller compared to cow or buffalo milk which help
in the formation of softer curd leading to better digestibility in the infant.
• Caseins micelle size is smaller and calcium content is much lower in human
milk. This helps in easier digestion and faster absorption due to the soft curd
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formation compared to cow or buffalo milk.
• Polyunsaturated fatty acids are present relatively in larger quantity in human Method of Manufacture
of Spray and Roller
milk fat. Dried Milk Powder and
Value Added Products
• The larger proportion of lactose helps in the proper development of brain
constituents and greater energy (40%) of the total energy is supplied by lactose
which is the easiest form of energy.
• It puts much less load on kidneys to discharge their functions due to lower
calcium, sodium, potassium and chloride; it has built-in immune bodies.
• The other most valuable component present in human milk in much larger quantity
is the lysozyme, an anti-microbial component, which is present at a concentration
300 times higher than cow milk.
• Other anti-infective properties of human milk are due to secretory
immunoglobulin A, the bifidus factor and lactoferrin. These protect the child
further from undesirable infection.
• Due to higher concentration of lactose in human milk the pH in the intestine is
much lower reading to prevention of growth of pathogenes.
• It allows selective types of microflora to grow in the intestine, which do not
permit the infectious bacteria associated with diarrhea to grow.
Table 14.2 Composition of human and cow milk

Sl. No. Components Human milk Cow milk

Per 100 ml
1 Water (g) 87.1 88.1
2 Proteins (g) 0.9 3.3
3 Casein (g) 0.31 2.60
4 Whey proteins (g) 0.57 0.70
5 Fat (g) 3.8 4.1
6 Lactose (g) 7.0 4.5
7 Ash (g) 0.21 0.72
8 Calcium (mg) 28 120
9 Magnessium (mg) 4 10
10 Sodium (mg) 17 50.6
11 Potassium (mg) 55 145
12 Phosphorus (mg) 14 82

The technological advancement for the production of infant formula has gone a long
way in manufacture of variety of infant formulas for dietary management of normal,
pre-mature infants, and infants born with variety of nutritional as well as physiological
disorders. Both nutritionists and biochemists have provided ample knowledge for
the technocrats to manufacture infant formula having similarities in general
characteristics to that of human milk. Considerable scope, however, exists for
enhancing the bio-protective attributes of infant formula. These attributes are vital
for establishing a healthy microflora in the intestinal tract and potentially play an
important role of protecting the infant against enteric infections.
ii. Production of Infant Milk Food and Infant Formulas
Food manufacturers, world over, have developed wide range of infant formulations
to meet the nutritional requirements of different category of infants.
i) Standard Formulation: This formulation is based on bovine milk and work as
supplement or replacement of human milk for feeding of normal healthy infants. 53
Dried Milks The nutritional requirements of infants through such formulations are met mainly
by coarse adjustments of Protein: Fat: Carbohydrate ratios as a broad
compositional simulation to human milk. These formulations are also fortified
with general minerals and vitamins. They are generally referred to as first
generation formulas developed to meet the general energy and nutritional
requirements of infants born normally with out any physiological disorders.
ii) Nutritionally improved formulations: Nutritionally superior formulations have
been developed for easy adaptability. These formulations bear varying degree
of chemical and biochemical similarity with human milk and are referred to as
humanised or maternalised formulas. Apart from similar gross compositional
profile these formulations also incorporate comparable ratios of whey protein:
Casein; saturated: polyunsaturated fatty acids; calcium: phosphorus and sodium:
potassium. Such formulations closely approach the nutritional qualities of human
milk and, therefore, are easily adaptable by the infantile system without causing
great physiological stress on the under-developed organs.
iii) Specialised formulations: This group of formulas are specific products for
the dietary management of infants with variety of nutritional and physiological
disorders that are associated with the early stages of life. Certain infants for
example, are born with disorders of enzyme insufficiency to digest milk proteins
or carbohydrates present in standard formulations. Such infants require proteins
to be present on the formulation in pre-digested form that is easy to digest or a
low lactose diet or lactose free diet. Specialised formulations consisting of pre-
digested or hydrolysed proteins, hydrolysed lactose, low fat formula etc. fall
into this category. These formulations are designed to have minimum load on
the under-developed digestive system. Such formulations are sold under specific
brand names depending upon their applications.

14.7 DAIRY WHITENER

Majority of people take tea or coffee in India. The availability of milk for this purpose
all the time is difficult particularly in the absence of refrigeration facilities in many
households. Dairy whitener is widely used as a substitute for fresh milk, cream or
evaporated milk in tea, coffee, cocoa or drinking chocolate and is also suitable for
adding to foods like soups, sauces, puddings and cereal dishes. The Dairy whitener
should possess good whitening ability good dispensability, feathering resistance and
emulsion stability. These are produced in fluid, condensed and dried forms and
differ widely in their formulation. Their production has gone up during the last two
decades because of their acceptability as a convenient, shelf stable and ready to
reconstitute product.
i. Major Ingredients of Dairy Whiteners
Protein: Protein serves multifunction in whiteners. It provides whitening power,
imparts body, has feathering resistance, and improves flavor by contributing a flavor
of its own and by reducing the acridity of the tannic acids. It also forms complexes
with the tannins in the coffee and improves the taste and lessens the astringents
mouth feel. The amount of protein used in the formulation should be enough to
completely envelop the fat globules with a hydrophilic membrane, as the total surface
area of globules is very large owing to their larger size that is 0.7 –1.0 micron.
Fat: Fat is the Main constituent of dairy whitener. It imparts whitening power,
body, and viscosity to the product. The whitening effect produced in coffee, primarily
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as a result of light reflected from the surface of the fat globules. The milk fat though
quite bland in taste imparts richness/smoothness to the dairy whitener.
Sugar: Sugar imparts sweet taste and improves body. It also reduces freezing Method of Manufacture
of Spray and Roller
points of the emulsion and contributes to the caloric value. Dried Milk Powder and
Value Added Products
Stabilizing salts: Certain phosphate and citrate salts improve the colloidal solubility
of proteins. The use of phosphate salts is particularly desirable when the water used
for manufacture, is high in calcium or magnesium. Such salts are usually used at
0.10- 0.15% based on total fluid weight .The disodium or dipotassium salts of
phosphoric acid are most commonly used, although other sodium and potassium
phosphates are suitable. The use of deionized water may obviate the need for these
salts.
ii. Quality Attributes
The sole purpose of coffee/ tea whitener is the development of a desirable color
change in tea /coffee. Whitening is also influenced by processing parameter. Whitening
ability can be improved by processing condition that produce smaller fat globules
and produce more interactions between the fat, emulsifiers and casein, which align
at the fat water interface. These interaction and small globules will reflect more light,
producing more of the whitening effect in tea / coffee. In addition to whitening, dairy
whitener should also impart body, mouth feel and flavor to the beverages or food to
which it is added such as coffee/ tea or cereal dishes. Good dairy whiteners must
have sufficient whitening power, emulsion stability, instant solubility and feathering
resistance in beverage or food for which it is especially formulated. For example
coffee whiteners should have the ability to withstand the high temperature (80-900C)
and low pH (4.6 –5.2) of coffee solution. The emulsion stability of coffee whitener
is also affected with ionic concentration of calcium coming from coffee and hard
water.
Check Your Progress - 4
1) Why breast milk is the best milk for infant feeding?
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2) What has been the need to develop infant milk food and infant formula?
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3) Give the gross chemical composition of human milk.
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Dried Milks ...................................................................................................................
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4) What are the characteristics of standard formulation for infants?
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5) Describe Nutritionally superior formulations for infants.
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6) What are the uses of dairy whitener?
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7) What are the requirements of good dairy whitener?
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14.8 LET US SUM UP

Dried milk products are the most important segment of the dairy industry today.
These have higher keeping quality. Dried milks provide means of utilizing surplus
milk during flush season, while in lean season these may be reconstituted and used
to make-up the market shortage of milk. The production of dried milks to a greater
extent, now being governed by the market requirement and to some specialised use
of such products. The basic operations in milk powder production consists of
receiving and selecting milk, filtration/clarification, cream separation/standardization,
preheat treatment, condensing, homogenisation, drying, packaging and storing of
powder. Production of skim milk powder differs slightly from whole milk powder
56
production.
The predominant method of drying milk and milk products is spray drying. Residual Method of Manufacture
of Spray and Roller
moisture is one of the most important properties of milk powder both from a quality Dried Milk Powder and
and an economic point of view. The outlet temperature is usually used as the parameter Value Added Products
by which the final moisture of the product is controlled. In two-stage drying, it is also
important to control the intermediate moisture, i.e. the moisture of the powder at
exit from the drying chamber Dry product is taken away immediately from the spray
drier after drying. Spray drying has numerous important advantages compared to
other drying techniques. The spray dried product has excellent properties. However,
because of high investment cost, spray drying installation is economically justified
only for large capacities, over 100,000 kg of raw milk per day. Today there are
specialized drying plants with modern facilities, producing 18 tons/hour of powder.
Foam spray drying can be accomplished by forcing the gas into liquid through the
pump before atomising nozzle supplying the drier. Foam spray dried powder has
improved dipersibility, but poor sinkability and lower bulk density due to occluded
air.
The most used construction of roller drier in the dairy industry is an atmospheric
double drum drier made of cast iron. The temperature of the milk reaches almost the
temperature of steam during drying. After being dried, milk is continuously scraped
off the roller by sharp knives in the form of a thin film. The product is usually packaged
in 25 kg kraft bags with a plastic liner reasonably impervious to moisture vapours.
Direct contact of the pre-concentrated milk with the hot drum surface results in
some irreversible changes in the milk. Caramelization of lactose, Maillard’s browning
reactions, and denaturation of proteins are the most important changes affecting the
quality of roller dried milk powder. In spite of these negative effects, roller drying
process is used for a number of advantages of this process.
Malted milk food is a product containing milk solids, malt extract and cereal grain
flour and is appreciated due to its nutritive value, convenience, digestibility and
palatability. Its manufacturing process consists of: production of mash liquor, mix
preparation and evaporation and drying
Infant milk food and infant formula are prepared with the modification of cow/buffalo
milk as an alternative to human milk. The substitute of breast milk serves as a saver
of precious life during vulnerable stages of infancy in the event of lactation failure,
insufficient milk secretion and in case of mothers inflicted with transmittable diseases.
Various formulations meeting the requirement of different infants are available.
Considerable scope, however, exists for enhancing the bio-protective attributes of
infant formula
Dairy whitener is widely used as a substitute for fresh milk, cream or evaporated
milk in tea, coffee, cocoa or drinking chocolate and is also suitable for adding to
foods like soups, sauces, puddings and cereal dishes. The Dairy whitener should
possess good whitening ability, feathering resistance and emulsion stability.

14.9 KEY WORDS

Reconstituted milk : It is the milk prepared by reconstitution of
milk powder in water.
Recombined Milk : It is the milk prepared by reconstitution of
milk powder in water and addition of milk fat
followed by homogenisation.
Whey protein nitrogen index : It is defined as the amount of undenatured
(WPNI) whey protein nitrogen measured in mg/g
powder. 57
Dried Milks Maillard’s reaction : It is Interaction of lactose with the amino
groups of lysine of milk proteins resulting into
browning, flavour defect, loss of available
lysine, lowered nutritional value, reduced
digestibility, antioxidant activity and reduced
solubility in milk powders

14.10 SOME USEFUL BOOKS

Caric, M. (1994) Concentrated and dried dairy products, VCH Publishers, Inc.,
New York.
De, S. (2001) Outlines of Dairy Technology. 16th impression. Oxford University
Press, New Delhi.
Early, R. (1998) The Technology of Dairy Products. Blackie Academic &
Professional, U.K.
Hall, C.W. and Hedrick, T.I. (1966). Drying of Milk and Milk Products, The AVI
Publishing Co. Westport, Connecticut.
Lampert, L.M. (1975) Modern Dairy Products. Third Addition. Chemical Publishing
Company, Inc., New York.
Robinson, R.K. (1994), Modern Dairy Technology, Volume-1, Advances in Milk
Processing 2nd Ed., Champman & Hall, London.
Spree, E. (1998) Milk and dairy product technology. Marcel Dekker, Inc., New
York.

14.11 ANSWERS TO CHECK YOUR PROGRESS

Your answers should include the following points.
Check Your Progress 1
1) i. Longer shelf life, lesser storage space and lower shipping costs of dried
products.
ii. Dried milk provides a means of preserving the excess milk supply during
the flush season for use during the lean season.
iii. Used extensively in the manufacture of ice cream, bakery products,
confectionary products, cottage cheese and in other cheese varieties.
2) i. Acidity of milk must be below 0.15% lactic acid otherwise the solubility
of the milk powder is reduced.
ii. High bacterial counts increase the susceptibility of fat to oxidation during
storage of the powder.
3) Receiving and selecting milk ? filtration/clarification ? cream separation/
standardization ? preheat treatment ? condensing ? homogenisation ? drying ?
packaging ? storing of powder.
4) For the production of safe and better stable and different heat classified milk
powders.
5) Classification of powders or heat basis.
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 Type of Heat WPN Index (mg/g powder) Method of Manufacture
of Spray and Roller
Low heat Not less than 6.0 Dried Milk Powder and
Medium heat Above 1.5, but below 6 Value Added Products
High heat Not more than 1.5

6) i. For spray drying, the milk is concentrated in multiple effect evaporators

to 40-50 % total solids, while for roller drying, the milk is concentrated to
18% total solids.
ii. Further concentration for spray drying would increase viscosity and cause
difficulties during atomisation of the milk.
iii. During roller drying, a higher concentration of milk would form a thicker
layer on the rollers, inhibit drying and cause intensive irreversible changes.
7) i. To decrease free fat content and prevent clumping of fat during
reconstitution.
ii. Conducted after evaporation or in partly concentrated milk, the
concentration rate being not more than 3:1.
iii. Customary homogenization is at 2500 to 3000 psi at 62.8 to 76.7oC.
Check Your Progress 2
1) i. Whole process proceeds very rapidly; air residence time in the chamber
is up to 30 sec.
ii. Lower residence time and lower drying temperature, yields product with
excellent properties.
iii. Suitable for large scale production
2) i. To prevent clumping, sticking and heat-damage to the product.
ii. Prolonged heating causes staleness in non-fat dry milk and jeopardizes
the flavour and keeping quality of dried milks.
iii. On prolonged exposure of the powder to heat, the fat has a tendency to
melt and oil off. Some fat covers the surface of the dried milk particles ?
oxidation.
3) i. Increase the capacity of conventional equipment and profits as well.
ii. An instant type powder — improved dipersibility
iii. More uniform particle size in the dried product.
4) Caramelization of lactose, Maillard’s browning reactions and denaturation of
proteins. Products of the Maillard type reactions may cause a scorched flavour
of the powder. Denaturation of proteins decreases the solubility of the powder.
5) Relatively low capital and operating costs, relatively smaller floor space
requirement, economical processing, easy operation and maintenance, suitable
for processing smaller quantities of milk, production of dried milk with longer
storage life and advantageous in some applications.
Check Your Progress 3
1) i. A product containing milk solids, malt extract and cereal grain flour.
ii. High nutritive value, convenience, digestibility and palatability.
iii. A potential market exists in the country for malt based milk beverages.
iv. Considerable high cost.
2) Malted barely is crushed and mixed with high-grade wheat flour ? mashed with
water ? temperature gradually increased to 70°C ? Starch hydrolysed by
diastase into maltose, dextrin and malto-dextrins, while the complex cereal 59
Dried Milks proteins converted into simpler protein substances ? Heat treatment at 78°C/
20 min ? passed through centrifugal separator to remove the insoluble husk.
3) i. Concentrated in the evaporator until one half to two-thirds of the water
content removed.
ii. Transferred to a steam jacketted evaporator provided with stirring gear,
where high vacuum is maintained, agitation being constant to facilitate the
removal of the water and to prevent excessive caramelisation.
iii. Dehydrated to a sponge-like, swollen mass usually in a vacuum tray drier.
Check Your Progress 4
1) i. Provides right proportion and quality of nutrients for infant,
ii. Helps in protecting the newborn against infective agents in its new
environment.
2) i. There are mothers, who either can’t or prefer not to feed breast milk to
their babies.
ii. Serve as a saver of precious life during vulnerable stages of infancy in the
event of lactation failure, insufficient milk secretion and in case of mothers
inflicted with transmittable diseases.
3) Composition of Human milk.
Components Human milk (g/100 ml)
Water 87.1
Proteins 0.9
Casein 0.33
Whey proteins 0.57
Fat 3.8
Lactose 7.0
Ash 0.21

4) i. Coarse adjustments of Protein : Fat : Carbohydrate ratios as a broad

compositional simulation to human milk.
ii. Fortified with general minerals and vitamins.
iii. Meet the general energy and nutritional requirements of infants born
normally with out any physiological disorders.
5) i. Apart from similar gross compositional profile, comparable ratios of whey
protein: Casein; saturated: polyunsaturated fatty acids; calcium: phosphorus
and sodium: potassium.
ii. Varying degree of close similarity of chemical, biochemical and nutritional
qualities to human milk.
iii. Easily adaptable by the infantile system without causing great physiological
stress on the under-developed organs.
6) Widely used as a substitute for fresh milk, cream or evaporated milk in tea,
coffee, cocoa or drinking chocolate and is also suitable for adding to foods like
soups, sauces, puddings and cereal dishes.
7) i. Sufficient whitening power, emulsion stability, good dispensability, instant
solubility and feathering resistance in beverage or food for which it is
especially formulated.
ii. Impart body, mouth feel and flavor to the beverages or food to which it is
added.
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