Post Farm-gate Dairy Research in Australia
Strengthening and Growing Dairy Manufacturing
Dr Lesley MacLeod CEO
Why do we need post farm-gate dairy R&D?
Milk is a perishable product it requires processing for commercial sale
Dairy ind...
Dairy Processing
Major Milk Uses
Cheese
Drinking Milk
Milk Powders
Butter
Consumer Products
Specialised Ingredients
What are the challenges for post farm-gate
dairy R&D?
Australia exports 40% of it’s milk production
Australia is well rega...
Requirements for Export growth
Production efficiency -to complete on
international market
Shelf life extension – to meet e...
Where is post farm-gate dairy R&D happening?
65% carrying out
dairy R&D
84% carrying out
‘near dairy’ R&D
5% not carrying
...
Who is doing post farm-gate dairy R&D?
Universities
ANU, Ballarat; Curtin; Deakin; Edith Cowan;
Flinders; SAUni, UQ; UTas;...
Key post farm-gate R&D technologies?
Have we lost our way - funding and resources?
Over last decade
Constrained milk supply has caused rationalisation in
proce...
Australian Industry and R&D working together?
Australia last out of 33 countries compared for business collaboration with ...
Australian Dairy industry is innovative…
Australian dairy has
Collectively invested in commercially focussed post
farm-gat...
What is going on in post farm-gate dairy R&D
in Australia?
Process Efficiency /Productivity
Waste Stream Valorisation
Wast...
Realising Current potential – adding value
Powder Technologies Platform
Developed (DIAL, Monash, NIZO, INRA, UQ, NCDEA)
• ...
Producing powders more efficiently and more
sustainably
Powders Performance
• Process optimisation: Evaporation & Spray Dr...
Producing higher value powders
What are the powder characteristics required for:
A reconstituted liquid that matches the f...
Troubleshooting powder performance
Microstructural changes during rehydration of “Aged” MPC
Case study: Infant Formula
Process optimisation
A critical mass of expertise in drying and evaporation
including the manuf...
Dairy Science vs. Dairy Industry
Protecting existing potential - quality & safety
Factors that contribute to milk quality
• Natural milk composition: prote...
Protecting existing potential - quality & safety
Spores(DIAL, CSIRO, UQ, UniTas)
Developing rapid analytical methods to de...
Case Study -Spores
New insights and resources for
spore analysis
• Many bacteria can form heat resistant
spores that survi...
Developing new potential -innovative
technologies
New Processing Technologies Platform
Developed (DIAL, CSIRO, U Melb, Mon...
Anti-fouling technologies
Fouling of heat exchangers & equipment
surfaces during thermal processing
(Uni Melb ARC Hub)
Fou...
Non thermal shelf life extension
Short shelf life of liquid
dairy products: Milk, whey,
concentrates
• Carbon dioxide can ...
Case Study: Shelf life and transport
Issue:
 Long transport distances within Australia and
to export destinations
 Prefe...
Developing new potential -innovative science
Curd Microstructure (Uni Melb ARC Hub)
Identifying the physical properties of...
Developing new potential -innovative science
Tribology (UQ, ARC Hub)
Use of advanced rheological techniques in conjunction...
Demonstrating consumer health and nutritional
benefits.
Child diet study reveals a
need for more dairy
Australian children...
Developing new potential - capability
CSIRO
Milk compositional understanding Microstructure
impact on digestive functional...
International dairy R&D networks
Australian dairy does not have to invent everything
• Technology scanning
• Fast followin...
People and Capability -
delivering the opportunity science creates
Last year,
7 Masters level and 23PhD level students par...
Innovation = Research & Development +
Exploitation
Successful Innovation is commercially led responsive and adaptable
Tech...
Dairy research and innovation – the final
frontier
Support R&D
Collaborate with a supply chain view
Celebrate and embrace ...
Thank You
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Post-farmgate Dairy Research in Australia - DIAA Vic Conf May 2014

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Dr Lesley MacLeod, DIAL CEO, presents "Post-farmgate Dairy Research in Australia" at the DIAA Victoria Conference on May 7th 2014.

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Post-farmgate Dairy Research in Australia - DIAA Vic Conf May 2014

  1. 1. Post Farm-gate Dairy Research in Australia Strengthening and Growing Dairy Manufacturing Dr Lesley MacLeod CEO
  2. 2. Why do we need post farm-gate dairy R&D? Milk is a perishable product it requires processing for commercial sale Dairy industry relies on an integrated supply chain where post farm gate processing adds value Export Retail Out of home eating DistributionMarketingImport Processing/ ManufacturingMilk Production Feed Production Supplements Irrigation $4B $12B $3B
  3. 3. Dairy Processing Major Milk Uses Cheese Drinking Milk Milk Powders Butter Consumer Products Specialised Ingredients
  4. 4. What are the challenges for post farm-gate dairy R&D? Australia exports 40% of it’s milk production Australia is well regarded for product quality and integrity Global demand in developing markets is growing faster than capacity of exporters to supply Markets for dairy products will continue to be volatile Competitive intensity will continue to grow with domestic supermarket dominance and export competition Regulatory and sustainability agendas will increase Value add will compete with commodity Agility, responsiveness and sustainable cost competitive manufacturing will drive growth
  5. 5. Requirements for Export growth Production efficiency -to complete on international market Shelf life extension – to meet export supply chain requirements Product performance –robust high quality product formulation for traditional products New product functionality – based on understanding market and consumer preferences quality and performance requirements
  6. 6. Where is post farm-gate dairy R&D happening? 65% carrying out dairy R&D 84% carrying out ‘near dairy’ R&D 5% not carrying out dairy R&D but capable 23% with pilot facilities 85% with Laboratory Facilities 60 Research Centres
  7. 7. Who is doing post farm-gate dairy R&D? Universities ANU, Ballarat; Curtin; Deakin; Edith Cowan; Flinders; SAUni, UQ; UTas; RMIT, Monash; Swinburne; Adelaide; Melbourne; UNSW; UWestSyd; Wollongong; VU Government departments State and Federal Agriculture, Industry, Innovation, Research Dairy companies MG; Fonterra; Bega; Parmalat; Warrnambool; Lion; Mondelez; Burra; Norco; SME’s Private supply companies Tetrapak; GEA; Healthlinx; TGR; Syntek; Ballantyne; Research organisations DA;TIAR; CSIRO; DIAL; Baker IDI; Dairy Futures CRC
  8. 8. Key post farm-gate R&D technologies?
  9. 9. Have we lost our way - funding and resources? Over last decade Constrained milk supply has caused rationalisation in processing capacity and reduced investment in new processing technology Proportion of foreign ownership in dairy processing has increased creating potential to lock up R&D as companies look to overseas support Market pressures have increased competitiveness forced companies to require more rapid returns on R&D investment While there is a significant investment in dairy R&D it has decreased significantly over the last 10 years and dairy company investment in Australia has been less than 0.5% of sales revenue
  10. 10. Australian Industry and R&D working together? Australia last out of 33 countries compared for business collaboration with higher education or public research agencies 4% of Australian large firms collaborated compared to 40% in Japan or 30% in UK
  11. 11. Australian Dairy industry is innovative… Australian dairy has Collectively invested in commercially focussed post farm-gate R&D as a collective endeavour in Dairy Innovation Australia Embraced a government focus on food and national coordination of food R&D with centres of excellence such as the Dairy Futures CRC and the Dairy Innovation ARC Transformational Research Hub, FIAL, Mondelez Open Innovation centre Individually invested in processing upgrades and new greenfield sites eg.MG; Burra; Fonterra; Norco Used M&A to deliver new technology delivering innovations faster WCB + Friesland; MG+Danone; Burra+ Itochu; Tatura +Tatua/ Mead Johnson
  12. 12. What is going on in post farm-gate dairy R&D in Australia? Process Efficiency /Productivity Waste Stream Valorisation Waste stream treatment Energy Reduction Water – Reduction, Recycling & Energy Nexus Yield Increase Supply Chain Cost New processing technology Technology for Product/ Market Growth Product structure and performance Milk compositional analysis and performance Health and nutritional performance Packaging development and performance Product design technology Sensory and consumer science Shelf life extension Product Profitable Sustainable Growth
  13. 13. Realising Current potential – adding value Powder Technologies Platform Developed (DIAL, Monash, NIZO, INRA, UQ, NCDEA) • Preheat, evaporation and drying simulation • Viscosity measurement • Energy use and optimisation • High solids drying (skim) • Stickiness assessment • Drying Process simulator Under Development (Monash, UQ, Syd, NIZO) • Crystallisation in Fluid Beds • Drying profile selection • Powder characterisation library • Atomisation selection • Nano-structured Dairy Powders
  14. 14. Producing powders more efficiently and more sustainably Powders Performance • Process optimisation: Evaporation & Spray Drying (Monash; Sydney) • Product characterisation to support functional advantages (e.g. solubility) (UQ) • Technology transfer of optimisation knowledge to all processors (DIAL) Combining lower temperature spray drying and more efficient evaporation generating high quality commodity powders from high solids liquids. Demonstrated to deliver: • >5% dryer capacity increases • Reduced energy use • Project NPV Risk adjusted $21M • Project IRR 23% • Minimal Capital outlay
  15. 15. Producing higher value powders What are the powder characteristics required for: A reconstituted liquid that matches the functionality of the starting material ? Long shelf life as a dry powder ? High water-solubility with minimal heat & shear ?
  16. 16. Troubleshooting powder performance Microstructural changes during rehydration of “Aged” MPC
  17. 17. Case study: Infant Formula Process optimisation A critical mass of expertise in drying and evaporation including the manufacturing optimisation of complex nutritional powders. Modelling & International Networks Sophisticated software models developed with international collaborators to predict the outcomes of process changes during evaporation and drying. Powder Library DIAL’s large reference collection of dairy powders can assist in relating processing conditions to product functionality. Product characterisation Powder flow properties, particle size and solubility. DIAL can help with stickiness of lactose rich powders Pilot Plant Pilot scale evaporator and drying equipment can be accessed at Monash University
  18. 18. Dairy Science vs. Dairy Industry
  19. 19. Protecting existing potential - quality & safety Factors that contribute to milk quality • Natural milk composition: protein, fat, lactose, minerals, whey proteins • Seasonal variation, feed • Microbial hygiene: Microbial growth can reduce shelf life and accelerate spoilage • Farm, Transport, Processing • Environmental origin or biofilms • Health of the dairy cow: Mastitis, leading to high Bulk Milk Cell Count (BMCC) and other compositional changes in milk • Enzymes, pathogens, milk spoilage • Minor chemical contaminants: antibiotics, cleaning chemicals
  20. 20. Protecting existing potential - quality & safety Spores(DIAL, CSIRO, UQ, UniTas) Developing rapid analytical methods to detect identify and track spore species to aid control of spore levels in Australian dairy products. Estimated direct losses in market opportunities of $6.7M in cheese and powders. • Novel and rapid identification methods • Tests to enable strategic and specific spore control in dairy products Microbial milk quality(CSIRO, DIAL) Fundamental factors that influence dairy product quality include numbers and types of microorganisms in raw milk, survivors of processing (conditions applied), post processing contamination • Science based information for effective strategies for the management of the microbial quality of raw milk Platform for reducing quality risk by management of spore formers) Platform for accelerated ripening; quality control and NPD
  21. 21. Case Study -Spores New insights and resources for spore analysis • Many bacteria can form heat resistant spores that survive pasteurisation, spray drying or UHT treatment • 700 dairy product samples analysed • New method of 16S rDNA analysis capable of distinguishing sub-types within Bacillus licheniformis and subtypes of the Geobacillus genus • Miniaturised spore test • Modelling studies: when and where do biofilms form and when do they release new spores?
  22. 22. Developing new potential -innovative technologies New Processing Technologies Platform Developed (DIAL, CSIRO, U Melb, Monash ,UQ, U SA,) • High value UHT products • Cheese yield optimisation • Ultrasound for lactose crystallisation • Novel separation technologies (electro dialysis) • Ultrasonic separation for milk and whey components • Modelling membrane separation processes • CO2 shelf life extension • Anti fouling coatings for membranes • Anti fouling coatings for heat exchangers
  23. 23. Anti-fouling technologies Fouling of heat exchangers & equipment surfaces during thermal processing (Uni Melb ARC Hub) Fouling is a Critical Concern for Membranes (Uni SA) Fouling results in a large flux decrease + increased operating costs (CIP, membrane replacement) Time (s) Normalizedheattransfer coefficient:U* Food safe coatings reduce fouling in thermal processing
  24. 24. Non thermal shelf life extension Short shelf life of liquid dairy products: Milk, whey, concentrates • Carbon dioxide can extend the shelf life of dairy products 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08 0 10 20 30 40 50CFU/ml Time (Days)
  25. 25. Case Study: Shelf life and transport Issue:  Long transport distances within Australia and to export destinations  Preference for long life commodity products for export: Powders and cheese New trends - new product formats  Liquid milk and liquid nutritional drinks – UHT formats  Fresh dairy and fresh liquid milk – longer shelf  “Natural” flavour R&D platforms for shelf life extension  UHT &ESL expertise and pilot plant  Formulation and NPD  Modified atmosphere storage;  Concentration  Sensory Science
  26. 26. Developing new potential -innovative science Curd Microstructure (Uni Melb ARC Hub) Identifying the physical properties of curd microstructure that determine sensory, textural and macroscopic features of cheese during manufacture. • Tools to analyse the functional properties of cheese • Capability to predict and control quality, consistency and functional properties of cheese Adjunct Starter Cultures (UQ ARC Hub) Using adjunct cultures to control and manipulate cheese structure and sensory properties. • Tools to identify, select and characterise adjunct cultures Platform for new products (flavour; texture; reduced salt/ fat; functional food transfer) Platform for accelerated ripening; quality control and NPD Fat = red; Protein = green
  27. 27. Developing new potential -innovative science Tribology (UQ, ARC Hub) Use of advanced rheological techniques in conjunction with sensory analysis to characterise the physical properties of dairy products during production, over shelf life and during consumption. • Provide objective, cost effective, rapid assessment tools Health and Nutrition (DHNC) To enhance the commercial value proposition of dairy products by demonstrating related consumer health and nutritional benefits. Platform for new products to meet consumer demand (flavour; texture;) Platform for information for product messaging, NPD, regulatory submissions
  28. 28. Demonstrating consumer health and nutritional benefits. Child diet study reveals a need for more dairy Australian children older than 4 years did not reach recommendations for dairy intake, consuming ≤ 2 servings per day which has important implications for intakes of key nutrients such as calcium (Baird et al., 2012). Dairy foods increase muscle synthesis Developing evidence to show that dairy foods and fractions may be helpful in maintaining healthy muscles and preventing age related muscle loss which leads to reduced mobility and increased risk of falls. Dairy linked to reduced diabetes in Australian men The study revealed that men with the highest level of dairy had a 47% reduced risk of diabetes compared to the lowest consumers of dairy (Grantham et al., 2012).
  29. 29. Developing new potential - capability CSIRO Milk compositional understanding Microstructure impact on digestive functionality Microencapsulation Segregation of milk fat globules, casein micelles Ultrasound technology Powder Drying &UHT capability High Pressure Processing Health & Nutrition Food Safety Victoria University Engineering packaging solutions Membrane technologies, design and manufacture Dairy Food component analysis Swinburne University Ultrasonics for milk component separation Monash Spray drying modelling Powder technology University of Sydney Spray drying technologies Evaporation Queensland University Sensory science & Flavour chemistry Microbiology, genomics Powders structure and performance Melbourne University Cheese structure and production Dairy protein chemistry Ultrasound technology Membrane processing Anti fouling technology Sensory & consumer science RMIT Health & Nutrition Formulation Biosensors UTasmania Microbial predictive models Curtin Sonocrystallisation Whey utilisation Lactose chemistry DIAL NCDEA Dairy Training
  30. 30. International dairy R&D networks Australian dairy does not have to invent everything • Technology scanning • Fast following • Smarter investment BUT we do need credibility to play in the international R&D market and capability to develop and adopt R&D and technologies from global sources Reading University Massey University Auckland University Wisconsin University Cornell University NIZO (Netherlands) INRA (France) Moorepark (Ireland)
  31. 31. People and Capability - delivering the opportunity science creates Last year, 7 Masters level and 23PhD level students participated in DIAL co-funded projects and will contribute to a growing highly skilled work force for the Australian food industry. 17post-doctoral researchers across DIAL’s university partner organisations contribute to advances in dairy science and technology and are training to be the food scientists of tomorrow. DIAL alone strategically collaborates with 15Australian research organisations Effective adoption of science and innovation to improve industry sustainability and global competitiveness
  32. 32. Innovation = Research & Development + Exploitation Successful Innovation is commercially led responsive and adaptable Technology Transfer Represents A Major Hurdle In Exploitation RESEARCH is the creative driver for innovation Grows knowledge capability and resources DEVELOPMENT is the commercial lens applied to creativity Identifying opportunity and adapting research for adoption EXPLOITATION is commercially led response to market, consumer and customer demand Adopting creativity to catalyse opportunity
  33. 33. Dairy research and innovation – the final frontier Support R&D Collaborate with a supply chain view Celebrate and embrace our successes Build and nurture our capability . . Dairy industry actions should be directed to long term profitability The most important collective step is to develop and pursue a strategy for innovation, investment and growth
  34. 34. Thank You 34

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