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Casein and Caseinate: Methods of Manufacture: Anand Rangrao Sarode Pravin D Sawale
Casein and Caseinate: Methods of Manufacture: Anand Rangrao Sarode Pravin D Sawale
Casein and Caseinate: Methods of Manufacture: Anand Rangrao Sarode Pravin D Sawale
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Sarode A.R., Sawale P.D., Khedkar C.D., Kalyankar S.D. and Pawshe R.D. (2016) Casein and Caseinate:
Methods of Manufacture. In: Caballero, B., Finglas, P., and Toldrá, F. (eds.) The Encyclopedia of Food and
Health vol. 1, pp. 676-682. Oxford: Academic Press.
Skim milk
Pasteurizationa
Heat
Washing
Dewatering
Drying
Tempering
Grinding
Grading
Blending
Bagging
a
Figure 1 Manufacture of the various types of caseins. Milk for the manufacture of rennet casein for nonfood use is not pasteurized.
separator so that the fat in the skim milk is reduced to less than solution, and at the IEP of casein (about pH 4.6), maximum
0.05%. Achieving the microbiological standards for edible precipitation occurs. At this pH all the calcium is solubilized.
casein also requires the pasteurization of either or both the Not only is the calcium from the caseinate molecule removed,
milk and the curd. Heat treatment tends to produce a higher but the calcium phosphate is also liberated in its soluble
yield of casein. Some researchers hold that the heat treatment form. This allows the plant to wash the soluble salts from
of milk for casein manufacture causes slight insolubility and the curd in order to achieve low ash content in the final
other defects. product.
Ideally, all the casein in a sample of milk would be precip-
itated simply by adding enough acid to bring the pH value
Separation to 4.6. However, the reaction between the acid and the
To extract the casein from milk, it is first separated by means of caseinate complex is not instantaneous, and the pH tends to
centrifuges to produce cream and skim milk. Skim milk can rise slowly with time. Therefore, ample time should be allowed
thus be considered to be the raw material from which casein for achieving equilibrium conditions. When casein is precipi-
products are made. tated from skim milk by the direct addition of acid, the tem-
perature and pH of precipitation and the mechanical handling
of the curd during its formation are very important in deter-
Precipitation mining the subsequent properties of the curd.
power in stabilizing the micelles in milk, and the result is the Washing of Casein Curd
formation of a three-dimensional gel network or coagulum of
The washing of casein curd is one of the most important steps
casein in the presence of calcium ions. This reaction is essential
in casein manufacture as most quality improvement in casein
for the manufacture of virtually all cheeses and in the produc-
is achieved through efficient washing. Large portions of lac-
tion of rennet casein.
tose, minerals, and acids are trapped within the curd, which
prevents their ready removal during washing of the curd. It is
Acid coagulation
necessary to allow sufficient holding time during each washing
Casein precipitated by acid usually includes the name of the
stage in order to permit the diffusion of these whey compo-
acid in its description, as with hydrochloric acid casein and
nents. The diffusion rate depends on the size and permeability
lactic acid casein. Any of the acid precipitation processes can be
of the curd particles and the purity, amount, and rate of move-
used to produce edible casein. The choice of the method for
ment of the wash water. Smaller size and better permeability of
reducing the pH of skim milk to precipitate casein is governed
the curd particles are important for efficient washing. Three
by the cost of acid. The lactic fermentation process is attractive
separate washes of casein curd are required with contact times
in terms of its cost effectiveness. For lactic acid casein, the
of 15–20 min each. As soon as the whey is removed the wash
pasteurized skim milk is cooled to 22–26 C and inoculated
water should be added in equal quantity to the whey that has
with a 0.5% starter of mixed lactic starters and incubated for
drained off. The curd should be well stirred in the wash water,
14–16 h, during which time the pH reduces to 4.6, producing a
either by rakes or by mechanical agitators, but care should be
coagulum. The coagulum is cooked to 50–55 C to create a
taken not to break the curd into fine particles. Firm and friable
curd firm enough for subsequent processing. The acid and heat
curd particles are required to avoid creation of excessive fines.
help in the syneresis of whey.
Rubbery and plastic curds cannot be washed effectively. Effi-
The use of mineral acids has the advantage of completely
cient washing can be achieved through the removal of as much
continuous operation with no holding time for coagulation.
whey as possible at the whey off stage. The temperature and pH
Hydrochloric acid is a superior coagulating agent. When sulfuric
of wash water are important factors affecting quality of casein.
acid or hydrochloric acid is used to precipitate curd, it should be
diluted before being added to the skim milk; otherwise, the local
action of the acid may injure the curd, even though the agitation Temperature of wash water
is rapid. Within reasonable limits, the more dilute the acid the Casein curd acts like a sponge in the water, contracting to expel
better the quality of the casein produced. water when heat is applied (termed as syneresis) and relaxing
when the water temperature is lowered. Heating leads to hard
Temperature of precipitation and rubbery curd, while cold water softens it and causes the
The kind of curd formed is sensitive to heat. Curd precipitated at curd to be fragile and readily broken. The temperature of the
temperatures below 35 C is very soft and fine, and conse- first wash should be the same as the precipitation temperature
quently, it is slow to settle and difficult to wash without loss. in order to produce good curd shrinkage. With lactic casein,
Precipitated at temperatures between 35 and 38 C, the curd is higher temperatures (70 C or above) are necessary at some
coarse, provided stirring is not too fast. Stirring is necessary to stage of washing to reduce the bacteria, which multiply during
distribute the acid uniformly, but rapid stirring at temperatures the incubation of milk with starter. The temperature of the
below 38 C produces a curd so fine that it settles very slowly final wash water should be adjusted to 32–40 C for better
during drainage and washing, and it may be lost to some extent expulsion of water during subsequent pressing.
in the whey and washings. The curd can be made firm either
by heating to a temperature above 38 C or lowering the pH pH of wash water
to 4.1. Curd precipitated at about 43 C has a texture resembling The pH of the water should be around 4.6 for the first two
chewing gum, being stringy, lumpy, and coarse, containing prac- washings to avoid the formation of a gelatinous layer over the
tically no fine particles, and separating cleanly from the whey. curd particles in excessively acid water, as well as the softening
High-grade casein, which is low in ash and readily soluble, and dispersion of the curd in alkaline waters. The gelatinous
is made by the grain-curd process in which the pH and tem- layer, if formed over the curd particles, inhibits the drainage of
perature are closely controlled. The best product is made by the salts and lactose from the curd. Making the pH of the wash
use of hydrochloric acid, but lactic and sulfuric acids may be water the same as that of casein helps maintain the equilib-
used successfully. The temperature of the skim milk should be rium. Dilute sulfuric acid is preferred for this purpose because
held close to 35 C for hydrochloric acid curd. The pH 4.1 is casein is much less soluble in this acid than it is in hydrochloric
adjusted by adding dilute acid slowly with continuous stirring. acid. The third wash should be given with neutral water.
It produces a granular curd that is easy to drain and wash.
Pressing of Casein Curd
Draining of Whey
The efficient pressing of washed casein curd is important for
After precipitation, curd gets settled. Whey should be removed minimizing the energy required for the removal of the remain-
from contact with the curd as soon as possible. The longer the ing water by drying. Inadequate pressing leads to the formation
curd remains in contact with the whey, the more difficult it is to of lumps of curd on subsequent grinding. It also produces a
wash out acids, salts, whey protein, and lactose, as the freshly hard, impervious surface that resists the escape of moisture from
broken curd tends to anneal itself, thereby enclosing these the inside, a condition known as case hardening. The mechan-
constituents within a protein film. ical removal of water is cheaper than thermal vaporization.
The batch pressing operation is usually an overnight operation manufacturing costs for improving the value of milk proteins,
(not less than 12–15 h) with 34 kg cm2 pressure. The propor- related to that of dried milk, and also elevated the status of
tion of water in washed curd and its ease of removal depend on casein for both industrial and food uses. These plants are also
the type of curd made. The appropriate pH and a temperature of highly labor-saving, because a large casein plant, with contin-
41 C produce a firm, friable curd that drains and presses well. uous hydrochloric acid precipitation and a capacity of
The final moisture content is usually 55–60%. 14 000 l h1, requires only one person to operate it. The sys-
tems are designed to accurately measure pumping rates in
order to ensure a constant flow of milk and acid, mixing acid
Milling and Drying of Casein
with skim milk at controlled temperatures of 25 C or lower.
Pressed curd is prone to microbial attack and, therefore, should This ensures equilibrium conditions before coagulation
be shredded and dried as promptly as practicable. Pressing begins, automatic regulation of steam injection to achieve the
produces particles of uniform size and surface for drying. coagulation temperature, and a holding tube capable of
Uneven drying leads to large particles or lumps that dry on obtaining complete coagulation and a well-settled curd, all of
the outside, forming a hard, impervious outer surface that which lead to less than 1% losses of casein in whey.
prevents the diffusion of the remaining moisture from the After precipitation, casein curd is concentrated by passage
interior of the particles. over stationary, inclined and fine mesh screens, which remove
The ground curd is spread on trays. It should be spread between 70% and 90% of the whey. Several dairy companies
evenly, and no more than 0.9–1.1 kg of curd should be placed have installed and are successfully operating roller presses and
on a tray of 75 75 cm. The bottom tray on each truck should lately decanters for removing the whey. Hydrocyclones may be
have a finer mesh than the others, or it should be covered with employed to recover fine particles from whey and wash water.
a cloth to catch fine particles that may sift through the other For continuous washing of casein curd, the most common
trays. The proper control of the temperature and humidity of procedure now adopted is a counter flow which reduces both
the air coming in contact with the curd are essential for the the volume of water needed and the loss of casein fines; the
efficient drying of casein. The inlet air temperature of 52–57 C technique involves as many as five washing stages. These stor-
is suitable for any type of curd. Once started, drying should not age tanks are of sufficient capacity to permit an average holding
be interrupted until the moisture content is about 8%. Properly time of 20–30 min. Continuous curd pressing is done in
dried casein has the same fine, granular characteristics as the mechanically driven roller presses, by belt, or by passing the
properly ground curd from which it is made. material through decanters, where water is sufficiently expelled
for subsequent economical drying.
There are a number of types of equipment for the drying of
Tempering, Grinding, Sieving, and Bagging of Casein
casein. The most widely used in recent years is a vibratory type
Tempering: It is the holding of casein for a period of 24 h to allow of drier. The curd passes through a mill to reduce it to even-
efficient cooling, hardening, and even distribution of moisture sized particles, which then travel by means of a vibratory action
throughout the batch. Casein shows variation in moisture con- over trays of perforated stainless steel, transferring to succes-
tent during a day’s run, as it comes from the drier. The most sively lower trays. The heated air flows through the beds of
efficient tempering consists of recirculating the dried casein by curd from the bottom to the top, thus encountering layers of
pneumatic conveyers. It has the advantage that the air used for curd of increasing water content and providing improved effi-
the transport of the casein assists in cooling the curd. ciency of heat utilization.
Grinding: The casein must be cooled before grinding
because warm casein is plastic and causes ‘burn on’ of the
rollers. Grinding and sieving are necessary to produce the high- Method of Manufacture of Caseinates
est proportion of the product in the size range desired by the
buyer. The grinding is completed by roller mills, pin mills, or The caseinate is prepared from freshly precipitated acid casein
hammer mills. For the production of 60- and 80-mesh casein, curd or from dry acid casein by reaction with dilute alkali
pin mills are much more efficient than hammer mills. solutions (Figure 2). Sodium caseinate is the most commonly
Sieving: The grinding operation is followed by sieving into used form of casein, and it is used in wide range of processed
various mesh sizes, and then bagging. Common mesh sizes are food products as a source of protein, and for their physico-
30–40 mesh casein, 60-mesh casein, and 90-mesh casein. chemical, nutritional, and functional properties. Next to
Bagging: The casein is packed in sacks or bags of 100 or sodium caseinate, calcium caseinate is common and finds its
200 lb capacity, as prescribed by the grade classification of the use in both pharmaceutical preparations and as a food ingre-
casein. Burlap sacks lined with closely woven cloth or heavy dient. It functions as supplier of both calcium and protein. The
papers, or three-ply paper bags may be used for bagging of specifications for this product vary with its end use, but they
caseins. frequently include a limitation of calcium content to within
the range of 1.0–1.5%.
Starting materiala After the final casein wash, the curd is dewatered to about 45%
solids and then mixed with water (to 25–30% solids) prior to
entering the colloid mill. The temperature of the emerging
Mixing with water slurry, which has a pasty consistency, should be below 45 C,
because it has been observed that milled curd can
Wet milling reagglomerate at higher temperatures.
Drying
Sodium Caseinate
The homogeneous sodium caseinate solution is usually spray-
The manufacture of sodium caseinate consists of the formation dried in a stream of hot air. In order to ensure efficient atom-
of a casein suspension, solubilization of casein using sodium ization of the sodium caseinate solution, the solution must
hydroxide, and drying the sodium caseinate produced. have a constant viscosity as it is fed to the drier. It is common
practice to minimize the viscosity by preheating the solution to
a temperature of 90–95 C just prior to spray drying. Care
Casein Suspension and Solubilization should be taken to minimize the time for which the caseinate
solution is at high temperature.
The main difficulties experienced in the conversion of acid
casein to sodium caseinate are as follows:
(a) The very high viscosity of sodium caseinate solution of Other Caseinates
moderate concentration limit the solids content for spray
drying to 20%. The manufacture of potassium and ammonium caseinates is
(b) The formation of a relatively impervious, jelly-like, viscous very similar to that of sodium caseinate, although, in the case
coating on the surface of casein micelles impedes their of ammonium caseinate, a lot of the ammonia is evaporated
dissolution on the addition of alkali. To overcome the from the solution during the drying process. A solution of
former difficulty, it is essential that the pH and tempera- sodium caseinate, like those of potassium and ammonium
ture are controlled during conversion, because these influ- caseinates, has a straw-like color, and it is completely different
ence viscosity. The latter challenge can be overcome by in appearance from milk. Solutions of calcium caseinate, on
reducing the particle size by passing the casein and water the other hand, are very white and opaque (even whiter than
mixture through a colloid mill prior to the addition of milk), and they are less viscous than solutions of the other
alkali. caseinates. Calcium caseinate solutions are produced by
adding a slurry of lime (calcium hydroxide) in water to a casein usually to a somewhat higher pH (7.5–9.5, or higher) than
curd–water mixture, and the combined slurries react at a rela- that used for edible applications.
tively low temperature (<45 C) until the neutralization is
completed. Use of higher temperatures before neutralization
is likely to result in the precipitation or coagulation of the Water Absorption and Viscosity
partly reacted calcium caseinate, with the probable dumping Casein products can absorb substantial amounts of water, and,
of the contents of the reaction vessel. All caseinate powders as a result, they can modify the texture of dough or baked
have a white appearance. products, serve as the matrix former in cheese-type products,
produce specialized plastic materials, or increase the consis-
tency of solutions such as soups. They are good film-formers
Composition of Casein and Caseinates
and find use in whipping and foaming applications, and in
emulsions of fats or oils in water.
The typical composition of casein and caseinates is shown in
Table 1. The caseins produced from lactic, sulfuric, or hydro-
chloric acid precipitation are almost indistinguishable from one Melting Properties
another. The rennet casein differs from acid casein particularly
in ash content and pH. During the acidification process, the Casein exhibits melting properties that are unique among pro-
calcium and inorganic phosphate, which are associated with the teins. Following limited proteolysis, casein becomes thermo-
casein micelles in milk, are dissolved and leached from the curd plastic and flows when heated. A similar affect can be achieved
leaving only the organic phosphorus and a small residue of by chelating of some of the calcium ions present. These phe-
calcium. Rennet casein contains about 3% calcium and approx- nomena are the basis for the melting of natural cheeses and the
imately 1.4% phosphorus. Sodium and calcium caseinates are production of process or imitation processed cheeses. A struc-
spray-dried products, their moisture content is much lower than ture must exist before a substance can be said to melt. With
that of the caseins, and their protein content is higher. With a caseins, this structure may be obtained by precipitation with
pH in the range 6.5–7.0, sodium caseinate usually contains calcium, acid, or the addition of rennin. Casein does not form
1.2–1.4% sodium, whereas the calcium content of calcium thermal gels and has little functionality in applications that
caseinate is in the range 1.3–1.6% (Table 2). require temperature set.
High heat stability and the ability to melt are the two
properties of caseinates that make them difficult to replace in
Properties of Casein and Caseinates many food applications. The demand for casein for use in
products such as cheese analogs (processed cheese,
Solubility
mozzarella cheese) depends on the formation of a protein
Acid and rennet casein are insoluble in water. Virtually all matrix from calcium caseinate, which undergoes thermo-
applications of casein products require them to be dissolved melting similar to its processed cheese counterpart.
first. Consequently, before use, acid casein must be dissolved
using an alkali to produce a solution with a pH of 6.5 or
higher. For nonfood, technical applications, acid casein may Whipping/Foaming Ability
be dissolved in other alkalis, such as borax or ammonia, Caseinates generally produce higher foam overruns, but they
also produce less stable foams than egg white or whey protein
Table 1 Composition of casein products concentrates. The excellent surfactant property of the
amphiphilic casein is also responsible for its use in whipped
Acid Rennet Sodium Calcium
toppings, cake mixes, and ice cream.
Parameters casein casein caseinate caseinate
Further Reading Swaisgood HE (2003) Chemistry of the caseins. In: Fox PF and Sweeney PLH (eds.)
Advanced dairy chemistry – 1, proteins, 3rd ed., pp. 139–201. New York: Kluwer
Carie M (1994) Casein. In: Concentrated and dried dairy products, pp. 199–225. Academic/Plenum.
New York: VCR Publishers, Inc. Wang J, Su J, Jia F, and Jin H (2013) Characterization of casein hydrolysates derived
Fadaei V (2012) Milk proteins-derived antibacterial peptides as novel functional food from enzymatic hydrolysis. Chemistry Central Journal 7: 62–66.
ingredients. Annals of Biological Research 3(5): 2520–2526. Whiteley P, Shattock P, Knivsberg AM, et al. (2013) Gluten- and casein-free dietary
Frisher H, Meisel H, and Schlimme E (2011) OPA method modified by use of N, intervention for autism spectrum conditions. Frontiers in Human Neuroscience
N-dimethyl-2-mercaptoethylammonium chloride as thiol components. Fresenius’ 6: 344–350.
Journal of Analytical Chemistry 330: 631–633.
Mocanua AM, Moldoveanub C, Lucia Odochianb L, Cristina MP, Apostolescua N, and
Neculauc R (2012) Study on the thermal behavior of casein under nitrogen and air
atmosphere by means of the TG-FTIR technique. Thermochimica Acta 546: 120–126. Relevant Websites
Pedersen L, Parlar S, Kvist K, Whiteley P, and Shattock P (2014) Data mining the
ScanBrit study of a gluten- and casein-free dietary intervention for children with http://ajpendo.physiology.org/content/300/3/E610 – American Journal of Physiology.
autism spectrum disorders: behavioural and psychometric measures of dietary http://journal.chemistrycentral.com/content/7/1/62 – Chemistry Central Journal.
response. Nutritional Neuroscience 17(5): 207–213. http://www.nutritionj.com/content/11/1/35 – Nutrition Journal and BioMed Central.
Southward CR (1994) Utilization of milk components: casein. In: Robinson RK (ed.) http://scholarsresearchlibrary.com/archive.html – Archives of Applied Science Research
Modern dairy technology. Advances in milk processing, vol. 1, 2nd ed., Journals.
pp. 375–432. London, UK: Chapman Hall.