How small-scale tests can help scale new technologies

Analysing factory samples using advanced microscopy and benchmarking data in small lab-scale dairy production processes means the researchers can replicate the large-scale conditions in a controlled and high throughput environment. With opportunities to troubleshoot processes or assess the effect of new ingredients before they reach the factory floor, this has allowed industry partners to work more efficiently, be more sustainable and reduce costs. The laboratory has developed small scale processes with potential application to a range of products, from cream cheese to processed cheese or Mozzarella.

By being part of a cross functional team working through industry issues or problem solving opportunities, we have been able to translate science into commercial benefits for the Australian Dairy Industry.Shane Cooney, Industry Advisory Committee member

Working with whole pallets of cheese, 1,000 to 1,000,000 times larger than some sample studies done in academic literature, the work done with the Dairy Innovation Hub has highlighted how tools and product innovation can benefit from multidiscipline expertise across academic researchers and networks of industry partners.

New methods for predicting and tracking freezing and thawing of dairy products have minimized waste and improved product quality, yielding a substantial return on investment. Three publications were also published describing this research.

To help the industry partners reduce the risk of innovative projects, the Hub worked to create and establish technology ready for industry adoption. Ensuring the research was relevant, the Hub connected with industry partners over established pre-competitive and competitive research themes to identify the relevant needs and adaptation to an industrial scale that would enable a return on investment.

The research program also seeks to reduce the risk and costs with scaling up new technologies. Small-scale testing capabilities enable rapid iterations and adjustments, which are crucial for meeting the fast-paced demands of industry. This adaptability means the Lab can quickly address and solve production challenges. By integrating academic research with practical industry needs, the Gras Laboratory stands as a model for how small-scale testing can drive large-scale success.

A great example is the cream cheese production process at the Gras laboratory, which has been effectively used to provide insights into structure development in the production process. Three publications showcase capabilities in this area.

By utilising partnerships and the connections between academic researchers and industry networks, we can make the most of the expertise and specialist knowledge available to improve processes at every level.

The foundational work of the Dairy Innovation Hubs now has potential for adaptation and further innovation through the Centre of Excellence in Plants for Space. The tools, processes and understanding resulting from the Hub’s work at the Gras Laboratory, for example, are now being used to contribute to finding novel ways to provide nutritious food and medicine from plants for the next generation of space explorers.

Hub researchers from across the program spent a significant amount of time working at manufacturing sites of member companies, working both at pilot or at large scale.

“One of the highlights was the novel product development work we performed together with industry, looking at the link between pilot scale processing and sensory properties of yoghurt," says Professor Greg Martin.

This included research improving the processing of high protein yoghurts with novel application of hydrolysed milk, which featured in the International Dairy Federation (IDF) Dairy Sustainability Outlook on ‘Minimising waste in dairy processing’.

The University also has pilot scale equipment and processes used across the program, which are available for future application with the dairy manufacturing industry.

Pilot-scale studies allowed us to obtain technical information more relevant to commercial operation. This helped us size the plant in our process design and acquire the technical and economic parameters required for the techno-economic feasibility studies. Dr George Chen, Senior Lecturer, Chemical Engineering, University of Melbourne