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D A I R Y F O O D S , D A I R Y F O O D S . C O M
PRESENTS
Phillip S. Tong, Ph.D. Professor of Dairy Science Dairy Products Technology Center, California Polytechnic State University
Pete Kondrup General Manager Westby Cooperative Creamery
D A I R Y F O O D S , D A I R Y F O O D S . C O M
U.S. YOGURT PRODUCTION
0
1,000,000,000
2,000,000,000
3,000,000,000
4,000,000,000
5,000,000,0004.7 billion pounds in 2013
Pounds
D A I R Y F O O D S , D A I R Y F O O D S . C O M
YOGURT PLANTS IN THE UNITED STATES, 2004 TO 2013
020406080
100120140160
04 05 06 07 08 09 10 11 12 13
51 new yogurt plants from 2004 to 2013
D A I R Y F O O D S , D A I R Y F O O D S . C O M
YOGURT PLANTS, BY REGION
Region 2009 2010 2011 2012 2013
Atlantic 47 50 55 58 65
Central 31 36 40 37 43
West 31 34 35 36 37
U.S. total 109 120 130 131 145
D A I R Y F O O D S , D A I R Y F O O D S . C O M
Phillip S. Tong, Professor
Dairy Products Technology Center
California Polytechnic State University
San Luis Obispo ([email protected], 805-756-6102)
Dairy Foods Webinar . . .
Challenges and Opportunities in High-Protein Yogurts and other Cultured Products
Challenges and Opportunities in High-Protein Yogurts and other Cultured Products Consumer Interest in High Protein
High Protein in Cultured Dairy Products – Technical Approaches
Future Challenges and Opportunities
What do consumers want?
McCarthy, D., Dairy Management, Inc., 2014
How will population change? By 2020?
33%
45% Increase
McCarthy, D., Dairy Management, Inc., 2014
Protein and Wellness
McCarthy, D., Dairy Management, Inc., 2014
www.wheyoflife.org
Health Halo of Dairy History of Fermented milk
Pottery shards in Poland suggest strained fermented milks (7000 BC) Basis of lactase persistence
1900: Dr. Ilya Metchnikoff (1845-1916) Novel Prize Medicine (1908) Consuming yogurt and longevity
http://www.nature.com/news/archaeology-the-milk-revolution-1.13471
Yogurt (Turkey) Labneh (Lebanon) Kumiss (Asia) Kefir (Czech Republic) Skyr (Iceland) Lassi (India) Doogh (Iran) Ymer (Denmark) Calpis (Japan)
What is Greek Yogurt? • Health halo of yogurt (good for you)
• Gut health, dairy wholesomeness • . . . delivery system for other nutrients
• Convenient (availability, portability, no preparation, shelf life) • Tastes good • PROTEIN !!! ???
What is Greek Yogurt? • Legally - No Legal Definition for “Greek” Yogurt • Market/Trade
• “Generally” 1.5 – 2.5X protein content of conventional yogurt • Regular: 8-9 gms per 8 oz (3-4% w/w) • “Greek”: ~15-20 gms per 8 oz (6-9%w/w)
• ~ 50% Lower lactose level in final product • Shorter ingredient list • Sensory (compared to traditional yogurt)
• Viscous . . . pasty • Smooth, creamy . . . . Chalky, grainy texture • Less acid taste
Proliferation of High Protein (“Greek, Asian, Australian, Icelandic ”) Style Yogurts
Rapid growth of Greek (high protein) Yogurt
Source: AC Nielsen
Manufacture of “higher protein” yogurt Protein Concentration pre- or post-fermentation?
• Concentrated (“strained”) post fermentation to increase protein while reducing water, lactose and minerals • Bags • Mechanical separator • Membrane filtration
• Concentrated protein prior to fermentation (no acid whey) • Formulation with WPC/MPC/NFDM
• no post fermentation concentration • No acid whey generated
Higher calcium content • Ultrafiltration of milk
Higher protein cultured milks -Considerations • Concentration (straining) post fermentation
• Acid whey handling/usage • Micro-nutrient loss (minerals – Na, Ca) in whey drainage • Loss of probiotics • Fat level limitations (heavy vs. light phase for centrifugal separation?)
• Concentration/Formulation pre-fermentation • Buffering capacity of high solids • Fermentation time • Total acidity to final pH (taste?) • No acid whey, less/no micro-nutrient loss • Viscosity control during thermal processing • Texture control (chalkiness)
Cottage Cheese Daisy Low Fat Cottage Cheese Because it has just 90 calories and 13 grams of protein per 1/2-cup serving, you can enjoy low-fat, 100% natural cottage cheese without giving up the creamy, delicious taste.
Interests in High Protein
Future Cultured Milks? Dairy Technology . . . • Process & Ingredient Technology
• High pressure homogenization (7,000 – 10,000 PSI) Ingredients
• Micellar casein concentrates (native caseins) • Modified (reformed) casein micelles (minerals) • Casein/Whey protein blends • Increased functional proteins for simple (clean) labels • Lactose free • Culture technology (health, shelf life, viability) • Packaging (communication, ease of use)
Future Cultured Milks? Dairy Technology . . . • Products
• Fat content (from skim to > whole milk?) • Drinkable, spoonable, spreadable, sliceable
• Formulated vs. Separation Processes • Pre- vs. Post Fermentation
• Protein focus over process ? • Sensory Quality • Yield • Acid Whey • Culture viability (total count?) • Flexibility to handle wider range of fat content?
Consumer Interest in High Protein
High Protein in Cultured Dairy Products – Technical Approaches
Future Challenges and Opportunities
Challenges and Opportunities in High-Protein Yogurts and other Cultured Products
Westby Cooperative Creamery Westby, Wisconsin
Pete Kondrup – General Manager
• 110 Years (since 1903)
– One of the oldest family dairy farm cooperatives in WI & USA
• 175 Patron-Member Farms – Growth from 115 farms in 10 years – Most in WI, some in MN – Approx.10,000 cows milked
• 125+ million pounds of milk – Growth from 85-mil. in 10 years – Conventional & Organic (r-BST-free) – <30 million pounds production
• Growth from 11-mil. in 10 years. – New Distribution Center in 2012 – SQF Quality Certification
• 125 Employees – Growth from 45 in 10 years – 2/12 hour production shifts
• Product Production
– 40% Cottage Cheeses • Only manufacturer in WI
– 20% Sour Creams & Dairy Dips • Regular and Lite
– 40% Yogurts • Started in 2007 • Standard 70% • Other “Styles” 30% • Conventional & Organic
• Product Volume by Channel – 45% Private Label – 35% Ingredients – 10% Food Service – 10% Westby Brand
• $55-million Total Revenues
Yogurts
• Standard & Greek-Style & Any-Style
• Conventional & Organic • Regular & Lite
• Retail, Private Label,
Food Service, Ingredient
Greek Yogurt Strained, Filtered, or Fortified?
• No standard of identity. • Clean label. • Cost of capital. • Disposal of
whey-permeate. • Consumer driven. • We are looking at
manufacturing more specialized high protein yogurts.
Cultured Dairy Food Products
Cottage Cheese
Simply – a fresh, soft, dairy cheese.
New Cottage Cheese Developments at Westby
• Cottage cheese
as ingredient. • Probiotic? • Increase protein. • Flavors. • Could be the next
“Greek Yogurt”
A product & brand
business development company …
… creating new product differentiation and brand preference in the category of
Ready-to-Eat -- Refrigerated Dairy Foods.
Steve King – President
© ™ 2014 3D Dairy Foods – all content and ideas expressed are copyrights and trademarks.
Cottage Cheese
Soft Small Cheese Curds
Soft Small Cheese Curds in Creamy Sauce
Fat Free, <150 Calorie, Gluten Free, High Calcium, High Protein.
Soft Small Cheese Curds in Creamy Sauce
Fat Free, <150 Calorie, Gluten Free, Calcium (15% DV), Protein @ 14g (28% DV)
Plus -- Natural Vitamins -- A B1 B6 C D E @ 20%+ DV of each
NutriDairi™ Soft Small Cheese Curds
in Creamy Sauce
14g Protein + Calcium + Natural Vitamins
Fat Free <150 Calories Gluten Free
Plus – Flavors for the Family
A dairy-nutritious choice™
TM trademark of 3D Dairy Foods © 2014 3D Dairy Foods (NutriFusion is a trademark of NutriFusion, LLC)
NutriDairi™
Soft Small Cheese Curds in Creamy Sauce
• Every meal occasion/use.
– Flavors for toppings, dips, spreads, snacks, desserts, side-dishes, breakfast, recovery.
• Every consumer demographic. – Age, gender, socio-econ., geo-locale
Two Trademarked New Product Categories
NutriDairi™ Dessert
NutriDairi™ Snack
TM trademarks of 3D Dairy Foods © 2014 3D Dairy Foods
Two Trademarked New Brands
Cheeserts™ NutriDairi™ Dessert Flavors are pudding/pie/dessert (5oz product/6oz cup): Vanilla Custard, Cookie Créme, Strawberry Shortcake, Key-Lime Cream, Lemon Cheesecake, Crème Bruleé, Tiramisu Lulu, French Nougat, Butter-Cream Frost.
Cheenaks™ NutriDairi™ Snack Flavors are fruit/nut (5oz product/6oz cup):
Berry Blast, Apple Burst, Banana Boom, Mellon Munch, Ginger Pear, Pecan Peach, Peanutty-Buttery, PB & Jelly, Honey-Almond, Coconut Chill.
TM trademarks of 3D Dairy Foods © 2014 3D Dairy Foods
Smile for goodness in a dairy-nutritious choice™
TM trademarks of 3D Dairy Foods © 2014 3D Dairy Foods
7 Trademarked New Product Categories
NutriDairi™ Dessert NutriDairi™ Snack NutriDairi™ SaladTop NutriDairi™ CheeseDip NutriDairi™ SideCup NutriDairi™ SunUpCup
NutriDairi™ ReCuvCup
Each is a dairy-nutritious choice™ that defines a meal occasion/use.
TM trademarks of 3D Dairy Foods © 2013 3D Dairy Foods
12 Trademarked New Brands TM trademarks of 3D Dairy Foods © 2014 3D Dairy Foods
Cheeserts™ NutriDairi™ Dessert
Cheenaks™ NutriDairi™ Snack
Cheetops™ NutriDairi™ SaladTop
Cheedips™ NutriDairi™ CheeseDip
Cheemacs™ NutriDairi™ SideCup
Cheetots™ NutriDairi™ SideCup
Cheevegs™ NutriDairi™ SideCup
Cheesoops™ NutriDairi™ SideCup
Cheebles™ NutriDairi™ SunUpCup
Cheerays™ NutriDairi™ SunUpCup
Cheejoes™ NutriDairi™ SunUpCup
Cheerevs™ NutriDairi™ ReCuvCup
60+ Product Flavors
Cheddar Bacon, Asiago Tomato
Cheesy Avocado Olé, Smokey Gouda Goody
Key Lime Cream, Crème Brulee
Banana Boom, Melon Munch
Nacho Mucho, Pizza Cheezza
Cool-Tot Cheddar, Parmesan Dijon Dill
Butter Corn Salsa, SourCream 3Bean
Cheezo Gazpacho, Cheezi Broccoli Breezi,
Honey-Butter Oatmeal, ButterMilk Kasha
Orange Halo, Cranberry Crisp, Mango Mist
Creamy Cappuccino, Vanilla Frappé
Raspberry Rip, Blueberry Blitz
Smile for goodness in a dairy-nutritious choice™
TM trademarks of 3D Dairy Foods © 2014 3D Dairy Foods