Abstract:
A process for making a stable flavored milk product which meets the CFR regulations for milk and a dry powder for use in the process. The product is a flavored, non-agglomerated powder containing flavoring, color, Kappa and/or Iota carrageenan, and the milk proteins, casein and lactalbumin. The powder, when added to water, makes a stabilized liquid syrup with no wasteful foam during processing. Addition of the water based syrup to milk requires less aggitation than adding powders directly to milk, this resulting in less foaming and waste. The process provides for adding the liquid phase stabilization system to milk prior to homogenization to produce a stable, flavored milk drink.

Description:
CROSS-REFERENCE INFORMATION 
     This application is a continuation-in-part of U.S. Ser. No. 07/733,349, filed Jul. 22, 1991 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to a dry non-agglomerated flavored, blended powder for mixing with water and sweetener to produce a syrup which is added to milk prior to pasteurization to make a stable, flavored milk drink. 
     Presently there are Federal Specifications for milk, low fat milk and skim milk. The requirements Br milk are set forth in 21 C.F.R. Ch.1, §131 et sec. The contents of 21 C.F.R. §131 110 and 21 C.F.R. §131.143 are as follow: 
     §131.110 Milk 
     (a) Description 
     Milk is the lacteal secretion, practically free from colostrum, obtained by the complete milking of one or more healthy cows. Milk that is in final package form for beverage use shall have been pasteurized or ultrapasteurized, and shall contain not less than 81/4 percent milk solids not fat and not less than 31/4 percent milkfat. Milk may have been adjusted by separating part of the milkfat therefrom, or by adding thereto cream, concentrated milk, dry whole milk, skim milk, concentrated skim milk, or nonfat dry milk. Milk may be homogenized. 
     (b) Vitamin Addition 
     Optional 
     (1) If added, vitamin A shall be present in such quantity that each quart of the food contains not less than 2000 International Units thereof within limits of good manufacturing practice. 
     (2) If added, vitamin D shall be present in such quantity that each quart of the food contains 400 International Units thereof within limits of good manufacturing practice. 
     (c) Optional Ingredients 
     The following safe and suitable ingredients may be used: 
     (1) Carriers for vitamins A and D. 
     (2) Characterizing flavoring ingredients (with or without coloring, nutritive sweetener, emulsifiers, and stabilizers) as follows: 
     (i) Fruit and fruit juice (including concentrated fruit and fruit juice). 
     (ii) Natural and artificial food flavorings. 
     (d) Methods of Analysis 
     Referenced methods are from &#34;Official Analytical Chemists,&#34; 13th Ed. (1980), which is incorporated by reference. Copies may be obtained from the Association of Official Analytical Chemists, 2200 wilson Blvd., suite 400, Arlington, Va. 22201-3301, or may be examined at the Office of the Federal Register, 1100 L. St. NW., Washington, DC 20408. 
     (1) Milkfat content--&#34;Fat, Roese-Gottlieb Method-Official Final Action,&#34; Section 16.059. 
     (2) Milk solids non fat content--Calculated by subtracting the milk fat content from the total solids content as determined by the method &#34;Total Solids, Method I-Official Final Action,&#34; section 16.032. 
     (3) Vitamin D content--&#34;Vitamin D-Official Final Action,&#34; sections 43.195-43.208. 
     (e) Nomenclature 
     The name of the food is &#34;milk&#34;. The name of the food shall be accompanied on the label by a declaration indicating the presence of any characterizing flavoring, as specified in §101.22 of this chapter. 
     (1) The following terms shall accompany the name of the food wherever it appears on the principal display panel or panels or the label in letters not less than one-half the height of the letters used in such name: 
     (i) If vitamins are added, the phrase &#34;vitamin D added&#34;, or &#34;vitamin A and D&#34; or &#34;vitamins A and D added&#34;, as is appropriate. The word &#34;vitamin&#34; may be abbreviated &#34;vit.&#34;. 
     (ii) The word &#34;ultra-pasteurized&#34; if the food has been ultra-pasteurized. 
     (2) The following terms may appear on the label: 
     (i) The work &#34;pasteurized&#34; if the food has been pasteurized. 
     (ii) The word &#34;homogenized&#34; if the food has been homogenized. 
     (f) Label declaration 
     When used in the food, each of the ingredients specified in paragraphs (b) and (c)(2) of this section shall be declared on the label as required by the applicable sections of Part 101 of this chapter. 
     [47 FR 14360, Mar. 15, 1977, as amended at 47 FR 11822, Mar. 19, 1982; 49 Fr 10090, Mar. 19, 1984; 54 FR 24892, Jun. 12, 1989] 
     §131.143 Skim Milk 
     (a) Description 
     Skim milk is milk from which sufficient milkfat has been removed to reduce its milkfat content to less than 0.5 percent. Skim milk that is in final package form for beverage use shall have been pasteurized or ultra-pasteurized, shall contain added vitamin A as prescribed by paragraph (b) of this section, and shall contain not less than 81/4 percent milk solids not fat. Skim milk may be homogenized. 
     (b) Vitamin addition 
     (1) Vitamin A shall be present in such quantity that each quart of the food contains not less than 2000 International Units thereof within limits of good manufacturing practice. 
     (2) Addition of vitamin D is optional. If added, vitamin D shall be present in such quantity that each quart of the food contains 400 International Units thereof within limits of good manufacturing practice. 
     (c) Optional Ingredients 
     The following safe and suitable ingredients may be used: 
     (1) Carriers for vitamins A and D. 
     (2) Concentrated skim milk, nonfat dry milk, or other milk derived ingredients to increase the nonfat solids content of the food: Provided, That the ratio of protein to total nonfat solids of the food, and the protein efficiency ratio of all protein present, shall not be decreased as a result of adding such ingredients. 
     (3) When one or more of the optional milk derived ingredients in paragraph (c)(2) of this section are used, emulsifiers, stabilizers, or a combination of both, in an amount not more than 2 percent by weight of the solid in such ingredients. 
     (4) Characterizing flavoring ingredients (with or without coloring, nutritive sweetener, emulsifiers, and stabilizers) as follows: 
     (i) Fruit and fruit juice (including concentrated fruit and fruit juice). 
     (ii) Natural and artificial food flavoring. 
     (d) Method of Analysis 
     Referenced method are from &#34;Official Methods of analysis of the Association of Official Analytical Chemists,&#34; 13th Ed. (1980), which is incorporated by reference. Copies may be obtained from the Association of Official Analytical Chemists, 2200 Wilson Blvd., Suite 400, Arlington, Va. 22201-3301, or may be examined at the Office of the Federal Register, 1100 L. St. NW., Washington, DC 20408. 
     (1) Milkfat content--&#34;Fat, Roese-Gottlieb Method-Official Final Action,&#34; Section 16,059. 
     (2) Milk solids not fat content (or total nonfat solids content)--Calculated by subtracting the milkfat content from the total solids content as determined by the method &#34;Total Solids, Method I-Official Final Action,&#34; section 16.032. 
     (3) Vitamin D content--&#34;Vitamin D-Official Final Action,&#34; sections 43.195-43.208. 
     (e) Nomenclature 
     The name of the food is &#34;Skim milk&#34; or alternatively &#34;Nonfat milk&#34;. The name of the food shall appear on the label in type of uniform size, style, and color. The name of the food shall be accompanied on the label by a declaration indicating the presence of any characterizing flavoring, as specified in §101.22 of this chapter. 
     (1) The following terms shall accompany the name of the food whenever it appears on the principal display panel or panels of the label in letters not less than one-half of the height of the letters used in such name: 
     (i) The phrase &#34;vitamin A&#34; or &#34;vitamin A added&#34;, or, if vitamin D is added, the phrase &#34;vitamins A and D&#34; or &#34;vitamins A and D added&#34;. The word &#34;vitamin&#34; may be abbreviated &#34;vit.&#34;. 
     (ii) The word &#34;ultra-pasteurized&#34; if the food has been ultra-pasteurized. 
     (iii) The phrase &#34;with added milk solids not fat&#34; if the food contains not less than 10 percent milk-derived nonfat solids. 
     (2) The following terms may appear on the label: 
     (i) The work &#34;pasteurized&#34; if the food has been pasteurized. 
     (ii) The work &#34;homogenized&#34; if the food has been homogenized. 
     (f) Label Declaration 
     When used in the food, each of the ingredients specified in paragraphs (b)(2) and (c)(2), (3), and (4) of this section shall be declared on the label as required by applicable sections of Part 101 of this chapter. 
     The Specifications require that the products have specific minimum amounts of milk solids non-fat and final protein levels and a minimum protein efficiency ratio. The Specifications also allow certain flavorings, colorings, emulsifiers, sweeteners and stabilizers to be added as optional ingredients, as long as the ratio of protein to total solids and the protein efficiency ratio of all protein present in the final product is not decreased below the minimum specified by law. 
     A present method for making chocolate milk, for example, allows the addition of nutritive sweeteners to the chocolate milk. However, this addition often dilutes the milk to the point where the finished product is below the legal limits on milk solids non-fat and protein. Accordingly, a principal advantage of the present invention is that it allows the dairy to adjust its milk solids non-fat and protein level to meet the Federal Specification for milk. The syrup-powder blend corrects this problem by having additional milk solids non-fat and protein in the blend and thus the final product is up to the legal requirements to be called a milk product. 
     Another advantage of the present invention is that by making a syrup blend first, better hydration of the stabilizers occurs which makes the finished product much more uniform because of better suspension of the cocoa particles. An indirect benefit of increasing the protein level in the finished drink is that the stabilizers react more completely and thus cause the finished drink to be more stable. 
     Stabilization is defined as the ability to suspend non-soluble particles, such as the flavoring, cocoa, in the milk to provide a homogeneous color and flavor. Stabilizers or suspending agents such as carrageenans, are used to suspend or stabilize the flavoring in the liquids and keep the flavoring from separating. 
     Suspending agents, such as carrageenans, both Kappa and Iota carrageenan, react with milk proteins to form a web-like structure throughout the milk. Furthermore, a better reaction has been observed by the inventors by using only selected milk proteins, e.g., isolated casein milk protein or isolated lactalbumin protein. Cocoa particles or other insoluble flavoring materials are then trapped upon this webbing throughout the milk. This allows for a homogeous flavored milk. 
     TYPICAL PRIOR ART PROCESS 
     In the prior art processes for suspending flavorings in milk, carrageenan is introduced as a powder and is very difficult to mix in the milk because of its inherent &#34;gumminess&#34;. Severe agitation is needed to disperse the carrageenans. Agitation causes excess foaming and protein denaturization. The damaged proteins lessen the functionality of the carrageenan and the excess foaming must be disposed of. The disposal also is a problem because it can overload sewer systems and waste disposal plants. 
     The actual suspension reaction takes place during pasteurization, since the carrageenans are activated by temperatures above 160° F. The prior art process results from a reaction between the carrageenans and all milk proteins to form the web, even though some proteins are not as effective as others in forming the reactor. 
     An example of a current manufacture of chocolate milk is as follows: 25 lbs. of cocoa powder, 275 lbs. of sugar, and 5 lbs of carrageenans are added to 500 gallons of raw milk and vigorously agitated. This agitation creates tremendous foaming. This foam is removed and disposed of creating loss of product. The resulting mixture is then pasteurized forming the carrageenan-protein webbing with the insoluble cocoa particles trapped therein. 
     ADVANTAGES OF THE PRESENT INVENTION 
     By first blending the dry ingredients into a water based syrup, the amount of air which is incorporated into the finished product when the syrup is mixed with the liquid milk is greatly reduced as compared to adding all of the materials directly into the milk. This allows for easy processing of the product, more even flow through the pasteurizing equipment, and greatly reduces the number of micro particles of air which occur during the homogenization process. The reduction of air particles in the product improves the long term stability and appearance of the product in the finished containers or milk bottles. Also, since there is less air in the product, the filling procedure is made more reliable and accurate and reduces the number of short filled containers. This process also results in less foam in processing, resulting in less waste left in processing and storage equipment, which reduces waste being disposed of down the sewer, with resulting drop in sewer treatment expense. 
     Also, by making up a syrup and adding the syrup to the milk the syrup materials go into the solution in the milk much faster than if all dry material were added to the milk. This greatly reduces the total mixing time a dairy must use and thus cuts down on the overall mixing, processing and filling time in the dairy. 
     Another advantage of the dairy making a syrup prior to mixing a flavoring with the milk is that the color and flavor of the final product is enhanced because of the greater reaction time of the powder with the water and sweeteners during the heating process of the syrup. When the solids are added to the milk as is presently done, only approximately one minute of time is used in the heating stage of the milk which is not enough to develop all of the natural flavor and color of the cocoa. 
     Another advantage of the present system is that is incorporates those milk proteins that most efficiency react with the stabilizers. 
     Use of consumer chocolate syrups or agglomerated cocoa mixes conventionally sold in grocery stores to the public do not result in a stable product when mixed with milk because they do not contain carrageenan. Thus, these products are not useful to a commercial dairy and are not relevant to this invention. 
     A critical factor in commercially manufactured flavored milks is that particle suspension is critical over long periods of time. This is difficult to achieve with present procedures and it is this problem that the present invention attacks. 
     These and other objects and advantages will become apparent to those versed in the art from the following description. 
     SUMMARY OF THE INVENTION 
     The invention comprises a flavored, non-agglomerated powder containing flavoring, color, stabilizers, and flavor carriers and fillers and further comprises a water based stabilized liquid syrup containing Kappa and/or Iota carrageenan, flavors, preferably cocoa, milk proteins and milk sugar. The invention also comprises a process of making a flavored milk by adding this liquid phase stabilization system to milk prior to homogenization to produce a stable, flavored milk without foaming. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention provides for the introduction of a liquid phase stabilization system to the milk. This stabilization system is comprised of several preferred ingredients. 
     Our liquid stabilization product contains the following: 
     Lactose 
     Lactalbumin 
     Casein (it may be precipitated by calcium, sodium, or magnesium) 
     Water 
     Carrageenan (it may be comprised of either Kappa or Iota carrageenan or both) 
     It may contain the following: 
     Sugars (defined as nutritive sweeteners 
     Salt 
     Vitamins 
     All other optional ingredients as provided by the Code of Federal Regulations, Title 21, §131 titled Milk and Cream This would include but is not limited to: 
     
         ______________________________________Cocoa Powder       Artificial ColorsArtificial Flavors Natural ColorsNatural Flavors    ChocolateThickening Agents  Fruit and Fruit Juices______________________________________ 
    
     It may not contain any ingredient, chemical or food that is not permitted for use in milk in the United States. 
     For example, many commercial flavoring syrups contain hydrogen peroxide as an ingredient to sterilize the bacteria loads found in chocolate. However, these types of syrups are not within the scope of our invention because hydrogen peroxide is not permitted in milk in the United States as defined by the Code of Federal Regulations. 
     The essence of our invention is to place the stabilization system into a liquid phase by adding the following essential ingredients into a water solution: 
     lactose (from about 70 to 80%, preferably about 75.40% by weight), 
     casein (from about 0 to 14.07%, preferably about 8.10% by weight), 
     lactalbumin (from about 7.28 to 35% preferably about 13.25% by weight), 
     carrageenan (from about 2 to 8% preferably about 3.25% by weight. 
     In the liquid system after it has been prepared, the milk protein level must be at least 2.97% by weight with a protein efficiency ratio (PER) of at least 2.7 to comply within the Code of Federal Regulations (CFR). The milk solids non-fat must be at least 8.25% by weight. 
     The following equation provides the proper amount of protein and protein efficiency in the liquid stabilization system. The percentages listed are percentages by weight of the liquid stabilization system: 
     Lactalbumin must be at least 0.594% of the system. 
     Casein cannot be more than 2.376% of the system. 
     The combined protein must be at least 1.46% of the system. As the lactalbumin level rises, the amount of casein decreases; so the amount of casein necessary is: 
     Casein=2.97% minus the percentage of lactalbumin of total system 
     Lactalbumin=2.97% minus the percentage of casein of the total system: 
     Lactose=5.28% of the total system 
     Carrageenan=0.25% of the total system 
     Water=91.50% of the total system 
     Following are examples of our invention: 
     EXAMPLE No. 1 
     An example of the aforestated system for making standardized flavored milk is as follows: 
     
         ______________________________________Water              15        GallonsKappa Carrageenan  0.34      lbs.Isolated casein milk protein              2.0       lbs.Isolated lactalbumin protein              2.04      lbs.Granulated lactose 8.76      lbs.______________________________________ 
    
     These ingredients are blended together in a lightening mixer for two (2) minutes and form a stabilized liquid system. The system is added to 82.5 gallons of raw milk with a fat content of 4.25%. Fifty (50) pounds of granulated sugar is then added to the stabilized milk. Fifteen (15) pounds of seedless strawberry puree is added to the stabilized, sweetened raw milk. The puree contains about 50% solids by weight. 
     The foregoing mixture of ingredients is pasteurized at 185° F. for twenty-two (22) seconds and then quickly cooled. The result is 105 gallons of product that meets the standards of 21 C.F.R. §131 et sec. for milk with a fat content of 3.25% and is flavored strawberry. The flavoring will not settle out, nor will the fat separate from the solids. Moreover, the product will be shelf stable until the milk sours. This is an example of a stabilized, flavored, sweetened milk product which meets CFR requirements. 
     EXAMPLE NO. 2 
     In another example for making chocolate skim milk, the following ingredients are combined: 
     
         ______________________________________Water               15        GallonsKappa and Iota carrageenan               0.25      lbs.Isolated casein milk protein               0.8       lbs.Isolated lactalbumin milk protein               3.63      lbs.Granulated lactose  8.76      lbs.Granulated sugar    60.00     lbs.Cocoa               10.00     lbs.______________________________________ 
    
     The foregoing ingredients are mixed together in a lightening mixer for two (2) minutes resulting in a liquid sweetened flavored stabilization system which is then added to 82.5 gallons of raw skim milk. The product is then ultra high pasteurized, resulting in a stable, homogeneous chocolate skim milk that will have cocoa particles suspended throughout and which will not separate and settle to the bottom of the container. 
     In the foregoing examples, the lactose is necessary since it produces superior flavor in the end product. Furthermore, lactose, when blended with the milk proteins and carrageenan, provides a better dispersion in the water to form a liquid stabilization system. 
     In the examples, the vigorous agitation of the products occurs when the solid ingredients are added to the water to create the liquid stabilization system. Agitation at this point in the process does not cause foaming, and therefore, no product waste or loss. Also, at this point in the process other optional ingredients and nutritious sweeteners as permitted by 21 C.F.R. §131 et seq. may be added to raw milk, which has been standardized for solids and fats content as specified by the 21 §C.F.R. §131. This results in little foam production. 
     The flavoring and color material include cocoa solids, natural flavors, artificial flavors, salt, and natural and artificial colors. 
     Specific flavor ingredients are the following: 
     
         ______________________________________Natural processed cocoa              Natural root beer flavorsCocoa processed with alkali              Artificial root beer flavorsMalt               Natural coffee flavorsVanillin           Artificial coffee flavorsVanilla            Natural raspberry flavorsSalt               Artificial raspberry flavorsArtificial chocolate flavors              Orange juiceNatural chocolate flavors              Apple juiceNatural orange flavors              Grape juiceArtificial orange flavors              Natural grape flavorsNatural strawberry flavors              Natural banana flavorsArtificial vanilla flavors              Artificial banana flavorsArtificial egg nog flavors              Natural cherry flavorsNatural egg nog flavors              Artificial cherry flavors______________________________________ 
    
     specific coloring ingredients are as follows: 
     
         ______________________________________Red #40        Yellow #5     AnnattoBlue #1        Caramel color CarmineYellow #6      Tumeric       Beet colorGrape skin extract______________________________________ 
    
     The stabilizers are selected from the group consisting of Iota and Kappa carrageenan and mixtures thereof. 
     Fillers can include nutritive sweeteners, milk derived ingredients, and mixtures thereof. 
     ALTERNATIVE EMBODIMENT 
     In this embodiment of the invention, the product comprises a dry non-agglomerated, flavored blended powder which consists of about 15 to about 60% by weight dsb of a flavoring or color material, preferably about 36% flavoring material, about 2 to about 6 percent stabilizer, preferably about 5% stabilizer, and fillers to 100%. 
     The dry, non-agglomerated, flavored, blended powder mix can contain dry acids and buffers, such as citric acid and sodium citrate, to adjust the pH to any desired level. 
     The aforestated powder mix is stored by the diary and mixed on a daily or other routine, as needed, basis. Approximately 8 to 11% by weight of the non-agglomerated flavored, blended, powder product is mixed with about 34 to 37% high fructose syrup having about 71% fructose and about 55 to 58% by weight water. The process of mixing is as follows: 
     1) Approximately 15 gallons of water should be metered into processing vat. Heat water to 80° F. 
     2) Add 71 pounds of liquid high fructose corn syrup of about 71% fructose and mix well for approximately 3 to 5 minutes. 
     3) Add 18 pounds of powder to high fructose corn syrup and water mixture. heat the product until the product is well mixed (mixing will take approximately 15 minutes and heating should raise product to approximately 90° F. to 100° F.). 
     When the syrup is to be mixed with milk, from about 23 to about 25 gallons of syrup is mixed with about 82 to about 80 gallons of whole milk to produce a syrup mix. The mixing procedure is as follows: 
     1) Raw milk should be standardized for proper butterfat before mixing and stored at 35° F. It is standardized to about between 0.25 of 1% to 4.2% butterfat. 
     2) After the syrup has been properly mixed and reaches a temperature of 90° F., it should be pumped into the raw standardize for butterfat milk. 
     3) This mixture of milk and syrup should be allowed to mix under good agitation for 5 to 10 minutes until the temperature of the mix is about 40° F. 
     4 ) After the product has mixed well it is ready to pasteurize. 
     The syrup mix then is passed through a pasteurizer under the following conditions: 
     1) If a high temperature short time pasteurizer is used the milk-syrup mixture should be pumped to the pasteurizer at a temperature of approximate 40° F. 
     2) the pasteurizing temperature should be set at between 166° F. to 186° F. with the total holding time at these temperatures to be from a minimum of 17 seconds to a maximum of 120seconds. 
     3) The product does not have to homogenized, but if desired, a total pressure of 500 to 1000 p.s.i. is all that is required. 
     4) The product is then cooled to 40° F. and pumped from the pasteurizer to a holding tank for bottling. 
     If vat pasteurization is desired, the following procedures should be used: 
     1) The desired amount of prestandardized butterfat milk should be pumped into a pasteurizing vat or kettle. The milk should begin to be heated at this point. 
     2) Syrup should be added to his warm milk and mixed well. Heating should continue. 
     3) The product should be heated to about 140° F. to 160° F. and held at the temperature for about 30 to about 35 minutes, preferably about 30 minutes. 
     4) The product can be pumped to the homogenizer with the total pressure set at between 500 to 1000 p.s.i. 
     5) The product should then be pumped to a holding tank for bottling. 
     This invention is intended to cover all changes and modifications of the example of the invention herein chosen for purposes of the disclosure which do not constitute departures from the spirit and scope of the invention.