Method For Producing A High Protein Food

Abstract

A high protein food may be produced via an extrusion process whereby acid casein is mixed with whey protein, alkali and water. Upon exiting the extruder, the mixture may be cut, dried, and/or tempered, milled and screened before being further processed or packaged. The final product may be configured as a crisp high protein food or a powdered high protein food. The protein content of the end product may be approximately 90-95% on a dry weight basis.

What is claimed is: 
     
         1 . A high protein food comprising a protein content from 15% to 35% by weight whey protein, and from 65% to 85% by weight casein, wherein said high protein food does not include a protein source other than said casein and said whey protein, wherein a bulk density of the high protein food is from 20 g/L to 400 g/L. 
     
     
         2 . The high protein food according to  claim 1  wherein said high protein food is further defined as having a moisture content from about 1% to about 14% by weight. 
     
     
         3 . A method for producing a high protein food, said method comprising the steps of:
 a. creating a mixture of a specific amount of acid casein, a specific amount of whey protein, and a specific amount of an alkali;   b. introducing said mixture into an extruder;   c. adding a specific amount of water to said extruder to create a second mixture;   d. forcing said second mixture through a specific die engaged with said extruder to create a plurality of cut pieces;   e. allowing said second mixture to expand in an environment with approximately ambient pressure and temperature; and,   f. removing moisture from said plurality of cut pieces such that the moisture content of said plurality of cut pieces is from 0.5% (one-half percent) to 12% (twelve percent) by weight, and wherein a protein content of said plurality of cut pieces is 50% (fifty percent) or greater by weight.   
     
     
         4 . The method according to  claim 1  wherein said mixture has a moisture content from 3% (three percent) to 13% (thirteen percent) by weight. 
     
     
         5 . The method according to  claim 2  wherein said second mixture has a moisture content from 3% (three percent) to 30% (thirty percent) by weight. 
     
     
         6 . The method according to  claim 3  wherein said extruder is further defined as being a twin, co-rotating screw extruder. 
     
     
         7 . The method according to  claim 4  further comprising the step of removing heat energy from said second mixture. 
     
     
         8 . The method according to  claim 5  wherein said protein content is further defined as comprising from 15% (fifteen percent) to 35% (thirty-five percent) by weight whey protein and from 65% (sixty-five percent) to 85% (eighty-five percent) by weight casein. 
     
     
         9 . The method according to  claim 6  wherein said plurality of cut pieces is further defined as having a bulk density from about 20 g/L to about 400 g/L. 
     
     
         10 . The method according to  claim 6  wherein said method further comprises the step of milling said plurality of cut pieces into a powder. 
     
     
         11 . The method according to  claim 8  wherein said powder is further defined as having a bulk density from about 0.2 g/ml to about 0.9 g/ml. 
     
     
         12 . The method according to  claim 6  wherein said method is further defined such that a residence time of said mixture within said extruder is greater than 4 seconds. 
     
     
         13 . A high protein food produced by a process of extruding a mixture of acid casein, whey protein, an alkali, and water through an extruder at about 150 to 300 RPM and at a temperature of about 5 degrees Celsius to about 120 degrees Celsius to produce said high protein food, wherein a residence time of said high protein food in said extruder is between 4 and 90 seconds, wherein said high protein food contains at least 90% protein by weight, and wherein a protein content of said high protein food is from 15% (fifteen percent) to 35% (thirty-five percent) by weight whey protein and from 65% (sixty-five percent) to 85% (eighty-five percent) by weight casein. 
     
     
         14 . The high protein food according to  claim 13  wherein said high protein food is further defined as a crisp high protein food having a bulk density from about 20 g/L to about 400 g/L. 
     
     
         15 . The high protein food according to  claim 13  wherein said high protein food is further defined as having a moisture content from about 1% (one percent) to about 14% (14 percent) by weight. 
     
     
         16 . The high protein food according to  claim 13  wherein said high protein food is further defined as a powdered high protein food having a bulk density from about 0.2 g/ml to about 0.9 g/ml. 
     
     
         17 . The high protein food according to  claim 16  wherein said high protein food is further defined as having a moisture content from about 1% (one percent) to about 14% (14 percent) by weight. 
     
     
         18 . The high protein food according to  claim 15  wherein said residence time of said high protein food in said extruder is further defined as between 5 and 25 seconds. 
     
     
         19 . The method according to  claim 11  wherein said high protein food is further defined as having a bulk density of the high protein food is from 20 g/L to 400 g/L.