Dried milk protein concentrate is produced from skim milk using a combination of processes such as ultrafiltration (UF), evaporation or nanofiltration, and spray drying. It is well established that dried milk protein concentrate (MPC) that contains 80% (MPC80) and greater protein content (relative to dry matter) can lose solubility during storage as a result of protein-protein interactions and formation of insoluble complexes. Previous studies have shown that partial replacement of calcium with sodium improves MPC80 functionality and prevents the loss in solubility during storage. Those studies have used pH adjustment with the addition of acids, addition of monovalent salts, or ion exchange treatment of UF retentate. The objective of this study was to use carbon dioxide to produce MPC80 with improved functionality. In this study, reduced-calcium MPC80 (RCMPC) was produced from skim milk that was subjected to injection of 2,200 ppm of CO2 before UF, along with additional CO2 injection at a flow rate of 1.5 to 2 L/min during UF. A control MPC80 (CtrlMPC) was also produced from the same lot of skim milk without injection of CO2. The above processes were replicated 3 times, using different lots of skim milk for each replication. All the UF retentates were spray dried using a pilot-scale dryer. Skim milk and UF retentates were tested for ζ-potential (net negative charge), particle size, and viscosity. All the MPC were stored at room (22±1°C) and elevated (40°C) temperatures for 6 mo. Solubility was measured by dissolving the dried MPC in water at 22°C and at 10°C (cold solubility). Injection of CO2 and the resultant solubilization of calcium phosphate had a significant effect on UF performance, resulting in 10 and 20% loss in initial and average flux, respectively. Processing of skim milk with injection of CO2 also resulted in higher irreversible fouling resistances. Compared with control, the reduced-calcium MPC had 28 and 34% less ash and calcium, respectively. Injection of CO2 resulted in a significant decrease in ζ-potential and a significant increase in the size of the casein micelle. Moreover, RCMPC had a significantly higher solubility after storage at room temperature and at elevated temperature. This study demonstrates that MPC80 with a reduced calcium and mineral content can be produced with injection of CO2 before and during UF of skim milk.

Natural cheese is the major ingredient utilized to manufacture process cheese. The objective of the present study was to evaluate the effect of natural cheese characteristics on the chemical and functional properties of process cheese. Three replicates of 8 natural (Cheddar) cheeses with 2 levels of calcium and phosphorus, residual lactose, and salt-to-moisture ratio (S/M) were manufactured. After 2 mo of ripening, each of the 8 natural cheeses was converted to 8 process cheese foods that were balanced for their composition, including moisture, fat, salt, and total protein. In addition to the standard compositional analysis (moisture, fat, salt, and total protein), the chemical properties (pH, total Ca, total P, and intact casein) and the functional properties [texture profile analysis (TPA), modified Schreiber melt test, dynamic stress rheometry, and rapid visco analysis] of the process cheese foods were determined. Natural cheese Ca and P, as well as S/M, significantly increased total Ca and P, pH, and intact casein in the process cheese food. Natural cheese Ca and P and S/M also significantly affected the final functional properties of the process cheese food. With the increase in natural cheese Ca and P and S/M, there was a significant increase in the TPA-hardness and the viscous properties of process cheese food, whereas the meltability of the process cheese food significantly decreased. Consequently, natural cheese characteristics such as Ca and P and S/M have a significant influence on the chemical and the final functional properties of process cheese.

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Four treatments of natural Cheddar cheese with two levels (high and low) of calcium (Ca) and phosphorus (P), and two levels (high and low) of residual lactose were manufactured. Each treatment was subsequently split prior to the salting step of cheese manufacturing processed and salted at two levels (high and low) for a total of eight treatments. The eight treatments included: high Ca and P, high lactose, high salt-in-moisture (S/M) content (HHH); high Ca and P, high lactose, low S/ M (HHL); high Ca and P, low lactose, high S/M (HLH); high Ca and P, low lactose, low S/M (HLL); low Ca and P, high lactose, high S/M (LHH); low Ca and P, high lactose, low S/M (LHL); low Ca and P, low lactose, high S/M (LLH); and low Ca and P, low lactose, low S/M (LLL). After 2 months of ripening, each treatment of natural Cheddar cheese was used to manufacture processed cheese using a twin-screw Blentech processed cheese cooker. All of the processed cheese food formulations were balanced for moisture, fat and salt. Texture and melt-flow characteristics of the processed cheese were evaluated with different techniques, including texture profile analysis (TPA) for hardness and melt profile analysis. There was a considerable increase in cheese hardness for the processed cheeses prepared from high Ca and P content, and high S/M natural cheeses compared with low Ca and P content and low S/M natural cheeses. Moreover, definite decrease in flow rate and extent of flow was observed for processed cheeses manufactured from high Ca and P content, and high S/M natural cheeses than that of low Ca and P content and low S/M natural cheeses. No considerable trend was observed in hardness and melt-flow characteristics for the processed cheeses manufactured from high and low residual lactose content natural Cheddar cheeses. This study strongly demonstrates that the characteristics of natural cheese (calcium and phosphorus content, lactose content and salt-in-moisture content) used in processed cheese manufacture have a significant impact on processed cheese functionality.