The Dairy Processing and Products Research Unit

1. The Dairy Processing and Products Research Unit Dr. Peggy M. Tomasula Research Leader USDA/ARS/ERRC/DPPRU 600 E. Mermaid Ln Wyndmoor, PA 19038 215-233-6703

2. Management Units • Crop Conversion Science & Engineering - Kevin Hicks • Dairy Processing and Products – Peggy Tomasula • Fats, Oils, & Animal Co-Products - Bill Marmer • Food Safety & Intervention Technologies – Don Thayer • Microbial Biophysics & Residue Chemistry – Shu-I Tu • Microbial Food Safety – John Luchansky

3. Resources - Unique Facilities • Food, Dairy, & Bioengineering Pilot Plants • Leather Research Tannery • Wool Utilization Research Laboratory • Botulism Research Laboratory

4. Resources - Unique Facilities • Irradiation Laboratories • Cesium-137, Gamma Radiation, 1 Million Curies • Fruit Processing Pilot Plant (BL-2) • Pathogen Compatible Food Processing Suite (BL-2)

5. Resources - Core Technologies - Research Data Systems Unit – Bill Damert - Microscopic Imaging Unit – Peter Cooke - Scientific Information Resources Unit – Wendy Kramer - Magnetic Resonance Spectroscopy Unit – Janine Brouillette - Nucleic Acid Sequencing Unit – Connie Briggs

6. Technology Transfer Partnership Collaborator’s Interests ARS’ Mission Area of Interaction Jerry Crawford, Ph.D. Technology Transfer Coordinator

7. The Dairy Processing and Products Research Unit http://www.arserrc.gov/dp Mission – To apply knowledge of the chemistry of milk to the development of new methods and processes to increase its utilization and safety.

8. Who is the Dairy Processing and Products Research Unit and What Do We Do?

9. The Dairy Processing and Products Research Unit Only group in ARS doing “postharvest” research on milk – farm to table Over 60 years of pioneering research on dairy science, specialized instrumentation, and new process development Perform long term research only Personnel – 13 researchers – chemists, engineers, food scientists, molecular biologists and 13 support scientists

10. Types of Dairy Research at ERRC Dairy Food Processing and Development Dairy Starter Culture/Biotechnology Dairy Food Quality and Preservation Dairy Food Science and Technology Biosecurity of Milk and Dairy Products Support USDA and other action agencies (School Lunch Program, Food for Peace, APHIS, the Military) Share expertise and resources with our stakeholder groups, our customers, and universities through CRADAS, trust agreements, and licenses.

11. Selected Accomplishments: ERRC Dairy Program Reduced lactose and lactose-free milk (Lactaid) and other products

12. Low-fat Mozzarella Cheese ERRC Mozzarella cheese has < 10% fat, melts well and has good texture. Used by the School Lunch Program, sales have reached over 23M pounds with an estimated value of $34.5M.

13. DPPRU Collaborators Universities ARS Athens Beltsville NCAUR Penn State PIADC Other Govt APHIS FDA Natick Foreign CIAD, Mex Moorepark Embrapa, Br. Stakeholder Groups NMPF DFA DMI IDFA Cal Poly Cornell Fort Valley St. Langston North Carolina St Penn State Rutgers University of Arkansas University of Delaware University of Hawaii University of Wisconsin Utah State University Companies Devine Foods EnerGenetics Grande Cheese M&M Mars SMBI Dupont AirLiquide The Dairy Processing and Products Research Unit, ERRC

14. Current Project Titles MolecularBasis for Improved Milk Protein Based Dairy Products Use of Novel Processing Methods to Develop Specialty Cheeses With Unique Functional Properties New and Improved Processes to Foster Utilization of Milk Components Development of Lactic Fermentation Bacteria for the Production of Bioactive Food Ingredients Protein Processing Using High Pressure Gases and Supercritical Fluids Biosecurity of Milk fromthe Farm to the Dairy Processing Plant

15. Processing Methods for Specialty Cheese with Unique Functional Properties Lead Scientist – D. VanHekken; M. Tunick; D. Olson; A. Bricker ; P. Tomasula

16. Why Hispanic-Style Cheeses? Growing Hispanic population in the US and a demand for this style of cheese for use by the food service industry. Functional and textural property data for these cheeses do not exist. No “standard of identity” definitions. Many are fresh style varieties and techniques are needed to extend their shelf-life for sale in the US and ensure their safety.

17. Objectives Establish the properties of 3 selected Hispanic-style cheeses made from raw or pasteurized milk. Determine influence of proteolytic breakdown system on the properties of the cheeses by either starter culture or indigenous microflora. Identify the cheesemaking steps that are key elements in developing the desired characteristics in these cheeses and that meet US standards and retain properties of raw milk cheeses. Develop cheesemaking procedures to extend the shelf life of selected fresh – Hispanic style cheeses. Determine the flavor components and generate flavor profiles to define the cheeses. Identify microorganisms in the raw milk cheeses and evaluate their impact on flavor development.

18. Characterize Hispanic-style cheeses - pasteurized milk Cheeses of interest Soft - Queso Blanco, Queso Fresco, Panela Semi-hard - Asadero, Oaxaca, Menonita/Chihuahua™ Hard - Cotija • Properties of interest - Functional - melt, color change - Textural - TPA, torsion, viscoelastic

19. Soft cheeses Queso Blanco, Queso Fresco, Panela High moisture (45-58%), full fat (18-30%), protein (17-22%), salt 1-3% pH 6.3 Does not melt Good slicing and crumbling properties

20. Queso Blanco acid or rennet set Queso Fresco rennet set, curd finely milled before salting Panela Combination acid and rennet set, CaCl2 added

21. Semi-hard Cheeses Asadero, Oaxaca, Mennonita/Quesadilla/Chihuahua™ medium moisture 40-48%, full fat 18-30% protein 21-30%, salt 0.8-2.3% pH 5.0-5.5 Mesophilic starter cultures, rennet set Excellent melt and slicing properties

22. Asadero add acid whey after rennet Pasta filata step Oaxaca Pasta filata step Mennonita Cheddar step

23. Collaboration with researchers at Centro de Investigacion en Alimentacion y Desarrollo, Cuauhtemoc, (CIAD) Chihuahua, Mexico

24. Functional Properties Examine cooking properties Melting ability Color changes when broiled or baked

25. Meltability

26. Mexican Mennonite cheeses made in Chihuahua, Mexico Raw vs pasteurized milk Cheeses from 13 manufacturers Evaluated: Composition Rheological properties

27. Rheological Properties Shear Rigidity (kPa) Range Average raw 11-52 36 pasteurized 24-72 49

28. Sensory Training panelists at ERRC to identify flavors in fresh Hispanic-style cheeses. Collaboration with MaryAnne Drake, NCSU

29. Sensory Data for a Hispanic Cheese Basic and young flavors Aged flavors

30. Preliminary Composition Data

31. Texture of Chihuahua Cheese How well do the Chihuahua – Chester cheeses cluster

32. Food Safety Focal Points at ERRC Raw Material Interventions • Physical (Irradiation) • Biological (LAB) • Chemical (Na Lactate) • Mechanical (Design change) Fabricate Process Slaughter Finished Product Recovery/Characterization Modeling • Biosensors (Micro. & Immuno) • Nucleic Acid (PCR, PFGE) • Genomics & Proteomics • Predictive Microbiology • (PMP, ComBase, CEMMI)

33. DPPRU Projects Determination of effectiveness of pasteurization in elimination of FMD Virus from milk – with Plum Island Animal Disease Center Evaluation of microbial pathogen food safety of fresh cheeses – Queso Fresco- shelf life studies, and interventions - with Microbial Food Safety RU.

34. ERRC Food Safety Collaborative Projects - Brazil Collaboration with Embrapa Dairy Cattle Center and the Dairy Technology Institute Developing specifications and evaluating safety of soft cheeses. Bacteriocins with activity against Salmonella and Listeria Survey of Food Safety Farm to Slaughter for Salmonella, Listeria, and E.Coli 0157:H7.

35. In Summary The Dairy Processing and Products RU at ERRC maintains a multidisciplinary group of dairy professionals: To respond to the critical needs of our stakeholders To anticipate the needs of the dairy industry by incorporating new ideas in chemistry and biotechnology into processing, for the consumer of tomorrow To ensure the continued quality, utilization and safety of milk and milk products

36. U. S. Whey Products Range $0.37 - $5.00/ kg $1.5-2.0/ kg $1-10/ kg >$500 $0.35-0.50/ kg Modified Wheys WPCs Whey Fractions Lactose Permeate Sweet whey Feed Food Pharma WPIs $5-6.0/kg Calcium Lactose derivatives

37. New and Improved Processes to Foster Utilization of Milk Components Lead Scientist – C. Onwulata; R. Konstance • Objectives • Develop thermal and non-thermal extrusion-based processes • that denature and functionalize milk proteins to create texturized • casein and whey protein ingredients. • Develop process protocols for texturizing milk proteins through • non-extrusion shear processes.

38. Why Extrusion? A twin-screw extruder, with its shearing screws operating at various speeds, uses mechanical and heat energy to cook, mix, pump and ultimately change the texture of dairy products. Low – shear processing – for pasta and doughs High-shear processing – for puffed products

39. Research Approach: Use new extrusion processing techniques to create texturized products based mainly on whey and nonfat dry milk Use other shear –based processes that manipulate the structure of whey proteins with other food ingredients.

40. Potential Products: Simulated Meat Products Meat extenders Functionalized protein products for inclusion in snack foods and meal-replacement bars

41. Protein Processing Using High Pressure Gases and Supercritical Fluids • Lead Scientist – PM Tomasula; MF Kozempel • Objectives • Design a new environmentally-benign process for producing • enriched fractions of the whey proteins • Develop new environmentally-benign processes for dairy • protein modification that utilize supercritical fluids as reac- • tion media and carriers. • Develop new, cost effective technologies for processing • protein fractions into non-food products

42. Why Use Carbon Dioxide? It’s an environmentally benign solvent in large supply; it’s cheap; it’s GRAS; and it can be reclaimed for re-use in the process.

43. Research Approach Use high pressure and supercritical carbon dioxide in new processes: to isolate casein from milk to produce enriched fractions of the whey proteins modify dairy proteins for food applications And Investigate processing of dairy proteins for nonfood applications

44. Potential Products Increased utilization of milk and whey by creation of new protein products New technologies for dairy protein utilization Increased utilization of milk and milk products in nonfood products

45. Development of Lactic Fermentation Bacteria for the Production of Bioactive Food Ingredients Lead Scientist – G. Somkuti Objectives: • Develop lactic fermentation bacteria with the capacity to • overproduce biologically active ingredients from milk • proteins for improving the nutraceutical, functional and • biopreservative properties of dairy foods • Develop techniques for optimized and cost effective • production of milk protein components by microbial • technology and assess their impact on the quality and • marketability of value-added dairy foods.

46. What are Bioactive Peptides? Bioactive peptides are the peptides generated from the native proteins in milk during the digestion process when milk or other dairy products are consumed. However, they are produced in small quantities.

47. Properties of Bioactive Peptides: Antihypertensive Antithrombotic Opioid Immunomodulatory Antitumor Antimicrobial

48. Research Approach: Use lactic fermentation bacteria to produce large quantities of bioactive peptides for the food and pharmaceutical companies.

49. Molecular Basis for Improved Milk Protein Based Dairy Products Lead Scientist – H. Farrell; P. Hoagland; P. Qi; E. Malin Objective – To elucidate the basic milk protein structural motifs responsible for protein-protein interactions in milk and dairy products, especially for lowfat cheeses. Physical-chemical basis for protein functionality is evaluated and computer molecular models are used to augment interpretation of the structural information at the molecular level. Environmental factors influencing protein folding and micelle assembly in vitro are used to predict milk protein secretion in vivo.

50. Molecular Modeling Provides knowledge of the molecular basis for structure/function behavior of dairy products and the ability to predict this behavior. Especially useful in the design of low-fat products where the functionality of the product relies on protein-protein interactions that replace the role of the fat.