COMPOSING A DAIRY PRODUCT

The present invention relates to a method for production of a dairy product. More specifically, in the method of present invention base elements of milk, such as fat, carbohydrates milk proteins are mixed with multiple predetermined mixtures comprising vitamins and trace minerals and optionally additional ingredients. Furthermore, the present invention relates to a system for composing a dairy product using the method of present invention.

There are three main processes in the industry for the production of dairy products, more specifically infant formula. These are integral spray drying, semi-integral spray drying and dry blending, of which dry blending is the most commonly used. Dry blending is an operation in infant formula manufacturing, wherein individual powdered components (amongst others an infant formula base powder) comprising the various ingredients are blended and subsequently mixed with vitamin- and minerals powdered components.

An infant formula base powder or milk product comprises of at least milk, protein, fat and carbohydrates. The production process starts with the main ingredient being milk, e.g., goat, cow, sheep, camel, yak, soy milk, a milk protein source (such as whey protein) from goat, cow, sheep, camel, yak, soy, or a (enzymatically) hydrolysed protein source, and a fat source being a vegetable fat blend, a structured lipid such as OPO, or fat from mammal milk origin or a combination thereof, and a carbohydrate source, such as, lactose, a hydrolysed starch derivate such as maltodextrin or glucose syrup, potato- or com starch, in liquid or powder state. The mixture will be first pasteurized, followed by evaporation, and subsequently spray dried to obtain for instance an infant formula base powder. These methods for production of an infant formula are well known in the art.

The difference between cow and human milk are amongst others the quantities of lactose, proteins, minerals and fat. Also the compositions and bioavailability of proteins, minerals and fat are different. In order to produce a mammalian milk (not being human milk) suitable for consumption by human infants, the protein, fat, mineral and vitamin content requires adjustments. Since there are various infant formulas available on the market, with each infant formula having their own composition that differs from one another, the amount of ingredients, fats vitamins and minerals that need to be added to the base powder during the production process may also strongly differ.

Infant formula manufacturers often have a hard time managing their inventory, more specifically managing stock keeping units, which can easily range above one hundred, up to several hundreds of recipes, leading to a complex storage management. Furthermore, enabling the development and production of all these recipes requires complex and laborious operation. For product development, each different recipe requires a full product development cycle, including recipe calculations, and all need to be checked individually against prevalent, local legislation and meet local nutritional requirements. For procurement, all different product composition demand a large array of ingredients that need to be purchased, managed and of which availability has to be secured and checked by quality control prior to production. For production it means that many different recipes/producl imply short productions runs, which makes it more difficult to have stable production runs, which leads to the challenge to obtain a product that is always within specification and compliant with (food) legislation per jurisdiction (e.g. EU, US, etc) ln addition, the use of many stock keeping units also means more frequent cleaning of the production and processing lines, resulting in more downtime.

It is an object of the present invention, amongst other objects, to address the above need in the art. The object of present invention, amongst other objects, is met by the present invention as outlined in the appended claims.

Specifically, the above object, amongst other objects, is met, according to a first aspect, by the present invention by a method for production of a dairy product, wherein the method is comprised of the steps of:

a) providing a mixture of base elements of said dairy product, wherein said base elements are milk, fat, carbohydrates, and optionally additional milk protein and water- and/or fat soluble ingredients;

b) providing a composition A comprising vitamins, a composition B comprising trace minerals, and a composition C comprising at least 5% - 35% potassium, based on the total weight of the composition C;

c) mixing of the compositions A, B and C to obtain the dairy product, wherein the amount of the vitamins and minerals in said compositions A and B, and the amount of C used in the mix depend on if said dairy product is a goat milk based product or a cow milk based product.

The present invention provides a method for the production of a dairy product, wherein the various components and their compositions of a (e.g. dry blended) dairy product, more preferably an infant formula, are calculated and prepared to match and be compatible in order to be combined optimally to deliver the desired products within specifications of the food product.

According to the invention, the dairy product is comprised of at least milk of mammalian origin (but not human), enriched with fat and carbohydrates. The milk may also be a protein source from milk. Optionally, an additional milk protein source (such as whey protein) from goat, cow, sheep, camel, yak, soy, or a (enzymatically) hydrolysed protein source can be added as base element to the mixture of step a. The fat source can be a vegetable fat and/or oil (blend) or fat from mammal milk origin or a combination thereof. The carbohydrate source can be lactose, maltodextrin, potato- or com starch.

According to another preferred embodiment, the present invention relates to the method, wherein in step c) the mixing of the compositions A, B and C is to obtain the dairy product, wherein the amount of the vitamins and minerals in said compositions A and B, and the amount of C used in the mix further depend on the type of product being manufactured. Different requirements are needed for dairy product supporting the different stages in infant development, e.g. infant formula suitable for infants of 0-6 months, follow-up formula suitable for infants of 6-12 months, and growing up milk suitable for infants of 12-36 months of age.

According to yet another preferred embodiment, the present invention relates to the method, wherein wherein in step c) the mixing of the compositions A, B and C is to obtain the dairy product, wherein the amount of the vitamins and minerals in said compositions A and B, and the amount of C used in the mix further depend on local regulatory requirements on nutritional product composition.

In the method of present invention there may be a difference in composition A, B and C when producing a dairy product based on goat/cow milk, the dairy product also may need to differ is specification/content due to the different legislation in respect to food products in for instance Europe in comparison to other parts of the world (Global - Codex). This thus means that the amount of composition A, B and C to be used for the production of a specific dairy product may differ because it needs to comply with legislation per jurisdiction.

The method of present invention drastically reduces the number of stock keeping units, i.e. using pre-mixes (or pre-blends) comprised of vitamins, trace minerals and minerals, while remaining the potential to produce a large number of different dairy products from these units. Depending on the ratio/portions of composition A, B and C, a great variety of different dairy products are obtained from only a limited number of stock keeping units. Furthermore, the method of present invention is beneficial for stability-vulnerable ingredients, such as vitamins. In addition, keeping vitamins and minerals separated as long as possible in a separate pre-mix is beneficial for product stability; and is therefore preferred over having pre-mixes wherein vitamins and minerals are combined.

The method of present invention has the advantage for the final product to shorten the time-to-market due to limitation of the variation within recipes, and less considerations regarding the use of separate ingredients. Dosing in the final product is more precise because a larger amount of the premixes are added, instead of small portions of individual ingredients and components. The method is more cost effective due to the limited number of different base powders and premix recipes. Because variation within recipes and pre-blends is limited, there will be a reduction in analytical costs in batch test and release of the finished product. It will also enable slock production of micronutrient pre-blends resulting in less stock keeping units, less storage, lower procurement costs, thereby creating more flexibility in supply chain management. The method of present invention will result in that there will be less down-time of the production facility because of cleaning of the production machines and that fewer cleaning steps can be involved.

According to a preferred embodiment, the present invention relates to the method, wherein the composition A is comprised of 10% - 30% choline, 0.5% - 2.5% niacin, 2% - 15% taurine, 5% - 25% vitamin C, 4% - 10% hydrolysed starch derivate or lactose, 0.5% - 2.5% vitamin E, 0.001% - 0.1 % vitamin D3, 0.01% - 0.5% vitamin A, 0.01 % - 2.5% L-carnitine, 0.2% - 1% pantothenic acid, 0.1% - 7.5% inositol, 0.001% -0.2% biotin, 0.01% - 0.2% folic acid, 0.001% - 0.2% vitamin Kl, 0.01% - 0.5% vitamin Bl, 0.01% - 0.5% vitamin B2, 0.01% - 0.5% vitamin B6, and 0.00001% - 0.2% vitamin B12„ based on the total weight of the composition A.

According to another preferred embodiment, the present invention relates to the method, wherein the composition B is comprised of 0.1% - 4% iron, 0.5% - 2.5% zinc, 0.01 % - 1% manganese, 1% - 7% hydrolysed starch derivate or lactose , 0.1% - 1% copper, 0.01% - 1% iodine and 0.001%- 1% selenium, based on the total weight of said composition B.

According to yet another preferred embodiment, the present invention relates to the method, w'herein said composition C is further comprised of at most 35% calcium, at most 20% phosphorous, at most 5% magnesium, at most 30% hydrolysed starch derivate or lactose, at most 10% sodium and at most 20% chloride, based on the total weight of said composition C.

According to another preferred embodiment, the present invention relates to the method, further comprising the step of determining the amount of composition A, composition B, and composition C to be mixed in order to obtain the dairy product that corresponds with a dairy product content specification. In case the dairy product is a product for the EU market, the composition C comprising the minerals as indicated above, is present in the dairy product due to food legislation in the EU.

According to a preferred embodiment, the present invention relates to the method, wherein in case the dairy product is a goat milk based product, the composition A is comprised of about 25% choline, about 0.7% niacin, about 5% taurine, about 7% vitamin C, about 5% hydrolysed starch derivate or lactose, about 1% vitamin E, about 0.02% vitamin D3, about 0.1% vitamin A, about 1.4% L-carnitine, about 0.5% pantothenic acid, about 4.5% inositol, about 0.002% biotin, about 0.015% folic acid, about 0.01% vitamin Kl, about 0.1 % vitamin Bl, about 0.1% vitamin B2, about 0.05% vitamin B6, and 0.0002% vitamin B 12, based on the total weight of the composition A, and wherein the composition B is comprised of 0.1% - 4% iron, 0.5% - 2.5% zinc, 0.01% - 1% manganese, 1% - 7% hydrolysed starch derivate or lactose, 0.1% - 1% copper, 0.01% - 1% iodine and 0.001 % - 1% selenium, based on the total 'eight of said composition B. According to yet another preferred embodiment, the present invention relates to the method, wherein the dairy product is a cow milk based product, the composition A is comprised of 12% to 26% choline, 0.5% - 2% niacin, 5% - 12.5% taurine, 5% - 25% vitamin C, 6% - 9% hydrolysed starch derivate or lactose, 1% - 2.5% vitamin E, 0.001% - 0.005% vitamin D3, 0.1% - 0.25% vitamin A, 0.01% - 2% L-carnitine, 0.2% - 1% pantothenic acid, 0.2% - 2% inositol,

0.001% -0.1% biotin, 0.01% - 0.1 % folic acid, 0.05% - 0.5% vitamin Kl, 0.01% - 0.5% vitamin Bl, 0.01% - 0.5% vitamin B2, 0.01% - 0.5% vitamin B6, and 0.00001% - 0.2% vitamin B12, based on the total weight of the composition A, and wherein the composition B is comprised of 0.1% - 4% iron, 0.5% - 2.5% zinc, 0.01% - 1% manganese, 1% - 7% hydrolysed starch derivate or lactose , 0.1% - 1% copper, 0.01% - 1% iodine and 0.001% - 1% selenium, based on the total weight of said composition B.

According to another preferred embodiment, the present invention relates to the method, wherein vitamins and/or minerals are encapsulated with a carrier material, wherein the carrier material is selected from the group consisting of a hydrolysed starch derivate, sucrose, starch, mannitol, or a mixture of corn starch and sucrose, preferably glucose or glucose syrup solids. The compositions comprised of (trace) minerals, vitamins can be prepared by encapsulation or immobilization of the sensitive nutrients, stability-vulnerable ingredients on a carrier material, in order to protect these ingredients and separated them from each other by means of this

encapsulation, to avoid or prevent degradation or oxidation and thereby loosing their nutritional value. Sensitive nutrients can be for example vitamins or minerals that are vulnerable towards oxidation, degradation, etc.

According to a preferred embodiment, the present invention relates to the method, wherein the encapsulated mineral is one or more selected from the group consisting of iron, zinc, manganese copper, iodine and selenium.

According to yet another preferred embodiment, the present invention relates to the method, wherein the encapsulated vitamin is one or more selected from the group consisting of choline, niacin, taurine, vitamin C, vitamin E, vitamin D3, vitamin A, L-carnitine, pantothenic acid, inositol, biotin, folic acid, vitamin Kl, vitamin Bl, vitamin B2, vitamin B6, and vitamin B 12. Encapsulated vitamins as indicated above have the advantage it result in an improved homogeneity and stability of these vitamins in the composition of present invention.

According to a preferred embodiment, the present invention relates to the method, wherein the compositions A, B and C are powders.

The present invention, according to a second aspect, relates to a dairy product obtained according to the method of present invention.

According to a preferred embodiment, the present invention relates to the dairy product, wherein the dairy product is a dry powder or a liquid, wherein the product is selected from the group consisting of an infant formula, follow-on formula, growing-up milk, children’s nutrition, maternal nutrition, elderly nutrition, sports- and performance nutrition, recovery nutrition, supplements, meal replacers, and clinical nutrition, preferably an infant formula.

Additional products could be envisaged for groups of consumers with specific needs, not limited to performance nutrition for amateur and professional athletes, maternal nutrition, elderly nutrition, and clinical nutrition. Such products are commonly available as instant powder, to be dissolved in warm water prior to consumption. For example, a liquid milk formula based on the composition of present invention can be obtained by dissolving of dry powder of the composition in water. The dairy product can also be a ready-to-feed liquid formulation, packed in an aseptic packaging, such as an aseptic pouch or aseptic bottle. As alternative, sterilized, ready-to-drink formula (sold as liquid) is another possible dairy product format.

The present invention, according to a third aspect, relates to a system for composing a dairy product, wherein the system is comprised of a number of containers for holding composition A, composition B and composition C, a mixing device that is operatively connected to the containers for mixing the compositions A, B and C into a determined dairy product composition, wherein the system further comprises an output configured for supplying a composed diary product, an input configured for receiving a dairy product order, a processor that is connected to the input and configured for determining said dairy product composition of the received dairy product order, wherein the dairy product composition comprises a composition A comprising vitamins, a composition B comprising trace minerals, and a composition C comprising minerals.

Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which:

- Fig. 1: Shows an embodiment of the method of present invention.

Production process 2 (Fig. 1) of a dairy product according to an embodiment of the method of present invention starts with the supply of fresh milk 4. In the illustrated embodiment, in the first processing sub-stage I, the milk is first pasteurized 8, and optionally cream 10 is separated in separation step 12. Evaporation step 14 results in (skimmed) milk concentrate 16.

In second processing sub-stage 11, concentrate 16 can optionally be provided with water soluble ingredients 18, such as protein, carbohydrates and/or minerals and/or can optionally be provided with fat-soluble ingredients 20, such as milk and/or vegetable fat, fat soluble vitamins. This results in a product that is comprised of base elements (milk and/or a protein source from milk, fat carbohydrates) and optionally added ingredients such as additional protein, minerals and/or processing agents, for example. After (wet) blending 22, the mixture will be pasteurized 24, homogenized 26, and subsequently spray dried 28 to obtain an infant formula base powder 30. Next, in the illustrated embodiment of the present invention in third processing sub-stage III, building blocks A, B and C 32a, 32b, 32c are added to the dairy product mixture to obtain the final dairy product that corresponds with the dairy product content specification.

Optionally, additional complementary ingredients 34 can be added to the product. After (dry) blending 36 the intended finished product 38 is produced. It will be understood that alternative and/or additional (sub)-processing steps can be envisaged in conformity with the present invention.

Example - stage 1 infant formula (0-6 months) for the European market (compliant EU legislation)

A stage 1 infant formula dairy product suitable for infants up to six months is produced according to the method of present invention.

An infant formula base making up about 92.5 wt% based on the total weight of the dairy product, the infant formula base is composed of 30 - 50% demineralized whey powder, 20 - 30% vegetable oils, 10 - 30 % lactose, 5 - 20% skimmed milk, 0 - 5% whey protein concentrate, and 0 - 2% minerals. The infant formula based is mixed with;

About 0.42 wt% of Building Block A based on the total weight of the dairy product, composed of 23.2% choline, 1.03% niacine, 9.6% taurine, 8.3% glucose syrup solids,

7.61 % vitamin C, 0.003% vitamin D3, 0.52% vitamin E, 0.11% vitamin A, 0.46% L-carnitine, 0.55% pantothenic acid, 0.5% inositol, 0.003% biotin, 0.018% folic acid, 0.008% vitamin Kl, 0.09% vitamin Bl, 0.10% vitamin B2, 0.08% vitamin B6, 0.0001 % vitamin B12, the remainder being comprised of counter ions (in case the nutrients are added as salts) and/or carrier materials.

About 0.32 wt% of Building Block B based on the total weight of the dairy product, composed of 1.2% iron , 1% zinc, 0.02% manganese, 0.12% copper, 1.75% glucose syrup solids, 0.02% iodine, 0.005% selenium, the remainder being comprised of counter ions (in case the nutrients are added as salts) and/or carrier materials;

About 0.42 wt% of Building Block C based on the total weight of the dairy product, composed of 23.8% potassium, 25.5% glucose syrup solids, 5% sodium, 13% chloride, the remainder being comprised of counter ions (in case the nutrients are added as salts) and/or carrier materials;

And about 6.36 wt% of optional ingredients based on the total weight of the dairy product; 4% GOS powder (70% premix), 1% AA powder (10% premix), 1% DHA powder (12% premix), 0.25% L-phenylalanine (50% premix), 0.1% nucleotides, 0.01 % L-tryptophan.

This example shows an embodiment of the invention. It will be understood that other examples can also be envisaged in accordance with the present invention. The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.