dairy foods webinar presentation

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 (ptong@calpoly.edu, 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