Innovation Idaho

Sunday

Sunday, September 13, 2015 • A1 www.magicvalley.com • $3.00

• September 13, 2015

STEPHEN REISS, TIMES-NEWS PHOTOS

Research and development intern Katie Smoot tests the solubility of rehydrated milk protein at the Idaho Milk Products Technical Center on Aug. 6 in Jerome.

Innovation See more of the Times-News’ best work at Magicvalley.com/ bigstory.

CHOBANI

Idaho

Latest Flavor Innovation: Pumpkin Harvest Crisp MYCHEL MATTHEWS mmatthews@magicvalley.com

TWIN FALLS • Chobani’s research and development room doesn’t look like a laboratory.

A rustic wood table sits in the center of the small room, surrounded by shelves full of fresh, natural ingredients: nuts, seeds, fruit, spices.

Company officials say they’ve perfected the process of making Greek yogurt. Now they innovate with flavors.

Kai Sacher, vice president of research and development, called it “sensory innovation — not technical innovation.”

No need for microscopes here, agreed Babu Chinnasamy, research and design scientist.

Chobani founder and CEO Hamdi Ulukaya insists on creating the right ambiance in the room where new flavors of Greek yogurt are designed at the largest Greek yogurt plant

Inside Whey Protein was once waste, see what its used for now on A7 Jerome plant is world’s largest dedicated to milk protein A8

in the world.

“Hamdi wants us to stand in the shoes of the consumer,” Chinnasamy said.

The room has an inviting, homey feeling, similar to a country kitchen. Dozens of glass jars hold colorful, tactile ingredients with tastes and smells that bring back memories.

More Photos If You Do One Thing: Grandparents Day events will be held from 2-4 p.m. to kick off National Assisted Living Week at Syringa Place, 1880 Harrison St. N., Twin Falls. Free.

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To describe the process, the two scientists revealed Chobani’s newest innovation: Pumpkin Harvest Crisp, a seasonal product inspired by fresh pumpkin pie at Thanksgiving time.

“We took that inspiration and asked ourselves, ‘How can we make that in yogurt?’”

Chinnasamy said.

They started with their core product, a popular blended Greek yogurt called Pumpkin Spice, and elevated it to pumpkin pie by playing around with textures and flavors.

Chobani research and development scientist Babu Chinnasamy, left, and Kai Sacher, vice president of R&D, show the ingredients they use to flavor yogurt Aug. 10 at Chobani’s research laboratory in Twin Falls.

3 Dairy Processors Make Magic Valley a Research Hot Spot MYCHEL MATTHEWS mmatthews@magicvalley.com

I

magine a world without innovation. You probably can’t.

Genius surrounds us. As long as man has been around, he’s been thinking of ways to make life easier and more productive.

But is every idea an innovation? Far from it.

Merriam-Webster defines innovation as 1) a new idea, device or method, and 2) the act or process of introducing new ideas, devices or methods.

But in business, innovation is more narrowly defined.

It’s the act of translating an idea into a service or product for which customers will pay. In addition, it must satisfy a specific need or solve a problem — and be replicable at a reasonable cost.

Innovation happens in two ways.

The first is the continual evolution of an idea, where incremental changes are made over time.

Take cow’s milk, for example. It’s a simple process to squeeze milk from a cow’s teat into a pail, then pour it into a glass to be served.

But milk from a single cow doesn’t go far. Without innovation, every consumer who wants milk, butter, cheese, yogurt or ice cream would need a cow or two in their backyard.

The dairy industry, over several generations, incrementally advanced milk production to the point that it’s one of the largest economic drivers in Idaho. The state’s 514 dairies now milk 561,577 cows twice a day, every day.

The second form, called revolutionary innovations, are often game changers. They’re risky because they create new markets.

Take whey, for example.

Whey was a waste product of cheese manufacturing.

For centuries, cheese makers tossed the whey drained from curds. As cheese production grew, disposal of the whey became a problem.

Then someone realized whey contained a significant amount of protein and began feeding it to livestock.

In the late 20th century, food manufacturers started to use albumin-based protein to make nutritious, highprotein drinks. Food scientists at a Magic Valley cheeseprocessing plant then had an idea: Isolate protein from whey and sell it to other food manufacturers.

The innovation created a new worldwide market for whey protein and prompted other companies to follow suit. Some now take milk straight from the cow to protein, bypassing cheese production altogether.

Today we take a look at successful innovations by three Magic Valley dairy processors — innovations that made rural southern Idaho a center of the industry’s advances.

Please see CHOBANI, A7

See more of photographer Stephen Reiss’ images from inside dairy processing plants and testing labs on Magicvalley.com.

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Sunday, September 13, 2015 • A7

GLANBIA

Once a Waste Product, Company’s Whey Yields Proteins, Lactose MYCHEL MATTHEWS mmatthews@magicvalley.com‌

‌ WIN FALLS • Glanbia T Foods not only carved out a place at the top but created a global market for what was once a waste product of its cheese manufacturing process.‌ You can purchase Glanbia’s products all over the world, but you won’t find its brand on the grocer’s shelf.

The “B2B” — or businessto-business — company creates nutritional ingredients that other companies need to make their own products.

“Glanbia is a solutions company,” said Eric Bastian, vice president of research and development. Its innovation is in creating “solutions for our customers.”

About 70 percent of Glanbia’s business is custom created for specific customer needs. The giant milk processor produces two things: cheese and whey protein. But protein means different things to different buyers.

It all started in the late 1990s, when Irish cheese makers Avonmore and Waterford combined, then bought Ward’s Cheese in Richfield. The company became Glanbia, meaning “pure food” in Gaelic.

With operations based in the heart of Idaho’s dairy land, Glanbia quickly became one of the world’s largest producers of cheese.

But with an enormous amount of product came an enormous amount of waste.

While the company produced massive amounts of cheese, it produced even more whey — a sweet, milky fluid the company’s cheese factories had no need for and often struggled to dispose of.

Whey is what’s left after cheese curds form from milk. The company shipped out the whey as livestock feed or dumped it in the desert.

To solve the disposal problem, the company think tank came up with Glanbia’s largest innovation to date: Turn a waste product into a valuable protein supplement.

Before then, “there may have been a few pioneers in the 1970s when people started fractionating whey into protein and carbohydrates,” said former CEO Jeff Williams. But Glanbia was one of the first to recognize its potential.

By separating the components of whey, Glanbia formed two nutritional products.

The proteins were first “isolated” by membrane filters at the Richfield plant, then dried into a powder to be added to milk replacers and bottle-fed to calves. The first whey byproducts were about 34 percent protein.

The company also filtered lactose from the whey to be used in confections and infant formula — still the largest demand for its lactose.

As filtration technology improved, Glanbia in 1993 brought its whey-based protein to 90 percent.

“It was right in the wheelhouse of what people were looking for — high protein and low fat,” Williams said.

Protein Science‌

Protein was first a staple of sports nutrition. Remember the scene in the 1976 “Rocky” movie in which Sylvester Stallone chugs raw eggs?

Before whey protein, egg albumin was the most common source of supplemental protein. It was extracted from egg whites, dried and made into a powder.

Please see GLANBIA, A8

STEPHEN REISS, TIMES-NEWS‌PHOTOS

Master cheese maker Nijaz Herik separates curds and whey Aug. 4 at the Glanbia Cheese Innovations Center in Twin Falls.

Cheese scientist Richard Geslison, right, and maintenance operator Robert Johnston photograph sliced cheese Aug. 4 at the Glanbia Cheese Innovations Center in Twin Falls.

Whey protein and other products July 29 at the Glanbia research and development facility in Twin Falls.

With the success of its whey protein stream, Glanbia has expanded its research and development centers in Twin Falls. The company built a new cheese innovations center downtown and a whey research and development center on Falls Avenue.

ABOVE: Lab technician Zack Lloyd works July 29 in Glanbia’s research and development facility in Twin Falls.

LEFT: Application scientist Niels Palmer monitors a whey dryer July 29 at Glanbia’s research and development facility in Twin Falls.

A8 • Sunday, September 13, 2015

IDAHO MILK PRODUCTS

Jerome Plant Is World’s Largest Dedicated to

The Idaho Milk Products processing facility in Jerome on July 29.

Milk Protein MYCHEL MATTHEWS mmatthews@magicvalley.com‌

J‌ EROME • A local manufacturer of milk protein rose quickly to the top.‌ Just six years old, the Idaho Milk Products plant is now the largest dedicated milk protein plant in the world.

Its owners, a handful of Magic Valley dairy families, knew the volatility in milk pricing and built the plant to smooth out the market’s curves by turning their milk into more valuable products.

Keeping their scope n a r r o w, t h e y t u r n a short-lived commodity into three less-perishable specialty products.

Fast, Fast, Fast‌ IMP’s innovation didn’t have to start at the beginning; it built on what others already learned. With the best science and state-ofthe-art technology, IMP built its facility in 2008 just east of Jerome and started operation in February 2009.

The IMP plant sits among about a dozen large Magic Valley dairies operated by IMP owners. The farthest is a mere 45-minute drive from the plant.

The dairies produce a constant stream of milk from 45,000 head of cows — 3.2 million pounds of milk a day.

The milk is collected, filtered and chilled at the dairies, shipped to the plant by a dedicated fleet of trucks, processed, packaged and sent out the door in 24 hours.

That would be nearly impossible anywhere else, said Kent Giddings, CEO and general manager. A similar plant in another area would need to collect raw milk from some 250 smaller dairies to get that kind of volume, which would add miles of transportation, higher costs and precious hours.

In addition, using milk from so few dairies guarantees conformity in IMP’s products. In the

STEPHEN REISS, TIMES-NEWS‌PHOTOS

Research and development scientist Khilendra Bhanduriya tests lactose levels in a sample at the Idaho Milk Products Technical Center on Aug. 6 in Jerome. milk-processing world, Giddings said, “variability is not your friend.”

Recipe for Volume‌ As raw milk is brought into the plant, it’s separated into cream and skim milk.

Ninety million pounds of fresh cream is pasteurized and shipped out of the plant each year.

Skim milk is then pasteurized and filtered. In the filtering process, milk permeate (water, lactose and minerals) flows through tiny holes in a membrane that retains the larger protein molecules.

Milk protein is then dried, packaged and shipped out of the plant. Forty million pounds of protein are produced each year and sold to

manufacturers of food products, including Greek yogurt and weight management, sports nutrition and adult nutrition products.

What is left of the skim milk is filtered through a reverse osmosis system to separate water from the milk permeate.

The milk permeate is crystallized, dried, packaged and shipped as milk permeate powder (MPP). Fifty-five million pounds of MPP are produced each year to be used to manufacture lactose.

The remaining pure water — 312,000 gallons each day — is recycled and used to clean the plant.

Innovation in and out of the Plant‌ IMP’s facility was built “to operate with as little

waste and as little impact on the environment as possible,” Giddings said.

Since 2010, the company has worked to lower “cradle-to-gate” carbon footprint baselines at the dairies and processing plant. Carbon emissions at the dairy farms are half of the U.S. average. At the plant, emissions are below industry standards.

Dairy owners adopted a national dairy program called Farmers Assuring Responsible Management (FARM), verifying a high level of animal care and quality assurance. The program establishes a standard for on-farm animal care and a third-party verification system assuring that guidelines are followed.

The dairies also embraced t h e u se o f a n a e ro b i c

digesters to separate manure solids and liquids into reusable forms and produce gas that is converted to electricity.

IMP’s highly specialized work can’t afford high employee turnover, said Jessica Henry, marketing manager. So the company offers benefit packages including safety and wellness programs, college tuition reimbursement for employees and scholarships for employees’ children.

Coming Next‌

People have an insatiable desire, and need, to eat more protein, Giddings said.

As folks age, they often develop sarcopenia, the degenerative loss of skeletal muscle mass. That opens the door to a specialty

market for concentrated forms of protein.

The company took a major step last year when it built its off-campus technology center in Jerome, Henry said.

The lab is working on protein formulas that can be consumed in a paste made especially for baby boomers, and a drinkable 50 milligram shot for sports enthusiasts.

Its scientists work to create the most bioavailable forms of proteins — specific combinations of essential amino acids that have not “unfolded” or denatured.

An essential amino acid is one that the body itself does not produce.

And they keep this in view: How will the protein function in the customer’s paste or liquid?

IMP’s facility was built “to operate with as little waste and as little impact on the environment as possible.”

Kent Giddings, Idaho Milk Products’ CEO and general manager

Glanbia Continued from A7

Glanbia purchased the sports nutrition company Optimum Nutrition in 2008 and jumped into the protein drink market.

“We had the whey source and we owned the company,” Williams said.

“And the whole sector just exploded.”

Now, Glanbia processes about a third of the milk produced in Idaho.

With the success of its whey protein stream, Glanbia has expanded its research and development centers in Twin Falls. The company built a new cheese innovations center downtown and a whey research and development center on Falls Avenue.

“This is science,” Bastian said. It is measuring

how proteins break down over time, testing how moisture and heat affect protein, measuring pH and monitoring bacteria levels.

All influence how a protein breaks down into peptides, and that’s what “fits into taste buds.”

Dominated by Customization‌ Glanbia’s Twin Falls centers are where the three streams in both its cheese and whey protein lines flow. Chemical labs adjoin miniature production lines and testing kitchens where small batches of product are analyzed and evaluated.

The first stream of Glanbia’s innovation is customer-driven.

“We may have a customer who wants a certain flavor or certain functionality or ingredient,” said David Perry, director of

cheese research and development.

Glanbia doesn’t make blue cheese, but it developed a product that looks and tastes like blue cheese, Perry said.

Glanbia doesn’t make sliced cheese, but it makes cheese that will be sliced and packaged by its buyer.

That cheese has to be sliced on a miniature version of the customer’s slicer to the customer’s specs in Glanbia’s research lab. Each slice must weigh the same, look the same, feel the same and taste the same. It must slice without crumbling and roll without breaking.

Similar, but more diverse, innovation goes into producing protein products.

Some customers want only a protein powder; others want a protein liquid.

Some want a clear liquid; Please see GLANBIA, A9

Chobani Continued from A1

Reporter Mychel Matthews, a lifelong vegetarian, reintroduced yogurt and powdered dairy protein into her diet after hearing local food scientists talk about the health benefits. She never could give up cheese, and she’s not trying anymore.

“We feed the company with innovative ideas,” said Sacher, who eats a pound of yogurt over the course of a workday.

“We wanted the warm flavors of Pumpkin Spice yogurt,” he said. “But we wanted a texture more like custard.”

Sitting at the table in the tasting room, Sacher and Chinnasamy sampled the yogurt with single ingredients, then with combinations of ingredients.

“The flavor of the yogurt and the crunch all must fit together,” said Sacher, who works in a 5,000-square-foot minifactory inside the 1 million-square-foot plant.

Hamdi uses a music analogy to describe C h o b a n i ’s y o g u r t ,

Chinnasamy said. “The beat of the music is in the ingredients.”

Chobani scientists want to surprise their customers. Sometimes they surprise themselves.

“There are no pumpkin seeds in pumpkin pie,” Sacher said. “But it’s a sensory fit.”

The result: a pumpkin spice yogurt with a custard-like texture, roasted pecans and maple-glazed pumpkin seeds, set for release in early September.

Putting the product in a “flip” container separates the yogurt from added ingredients, keeping them crunchy until the consumer is ready to experience Chobani’s pumpkin pie.

“We keep it simple,” Chinnasamy said. “We use natural ingredients and a lot of thought. That’s our chemistry.”

Sunday, September 13, 2015 • A9

STEPHEN REISS, TIMES-NEWS‌

Governor C.L. “Butch” Otter speaks at the Southern Idaho Economic Development Organization’s annual summit at CSI’s Herrett Center on Thursday in Twin Falls.

Otter Talks Fire Budget, Refugees and Trump NATHAN BROWN nbrown@magicvalley.com‌

STEPHEN REISS, TIMES-NEWS‌PHOTOS

Cheese scientist Richard Geslison slices cheese Aug. 4 at the Glanbia Cheese Innovations Center in Twin Falls.

Glanbia Continued from A8

others want a milky liquid.

If the customer’s end product is a protein bar, Glanbia can’t sell it just any protein powder.

“We have to mimic the processes that our customers use to produce their product using small versions of their equipment,” Bastian said.

A recent request came in for a protein that mimics the marshmallow in a Milky Way bar, but without the sugar. That’s a real challenge, he said.

The second stream of Glanbia’s innovation is what Bastian calls the “market gap” research — finding markets Glanbia’s customers have yet to discover. For instance, Glanbia introduced BarFlex in 2003 as a whey protein isolate that wouldn’t harden a soft

Lab technician Mike Young works an agglomerator July 29 in Glanbia’s research and development facility in Twin Falls. bar during its shelf life, and it took the product to several customers in the bar market.

The third stream, “blue sky” innovation, makes up about 10 percent of Glanbia’s research and

development.

“It’s asking, ‘How are we going to be making cheese in 10 years?’” Bastian said.

Flyboarding Lets You Fly like Iron Man ERIN MADISON Great Falls Tribune‌

‌ REAT FALLS, MONT. • G Craig Smith had seen videos of flyboarding and thought it looked like fun.‌ However, when he had the chance to try it himself, it was way more fun than he ever expected.

“It was amazing,” said Smith, a 21-year-old student at Montana Tech in Butte. “It was just an awesome experience.”

Flyboarding looks like something out of “The Jetsons.” It involves standing on a board, hooked up to a jet ski. Water shoots out of the board making the flyboarder hover above the water.

“I can’t describe it,” Smith said. It wasn’t like anything he had experienced before.

Flyboard of Montana in Whitefish describes flyboarding as “a jet-propelled license to fun.” The board is similar to a wake board, but is hooked by a hose to a jet ski.

Smith was with his friend Lorissa Renfro on their way back from a hike in Glacier National Park, when he talked Renfro into trying the sport at Whitefish Lake.

“It was kind of one of those spur-of-the-moment things I was really glad I did,” Renfro said.

ASSOCIATED PRESS‌

Flyboard of Montana in Whitefish says it has flown 4,000 people.

Flyboarding was totally different from water skiing or wake boarding, she said.

“I just kind of felt like Iron Man,” Renfro said. “It was just a bizarre feeling hovering above the water.”

Justin Heyne opened Flyboard of Montana in Whitefish three years ago.

A friend of his traveled to Costa Rica, tried flyboarding and brought back a DVD. “I had not seen anything like it before,” Heyne said.

“It looked really fun.”

After talking to his friend, Heyne decided to open a flyboarding business in Whitefish. It’s turned out to be a success.

“We’ve flown 4,000plus people,” Heyne said.

People don’t need any

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experience to try flyboarding, and it’s much easier than it looks.

“Most people fly in five minutes,” Heyne said.

Before hitting the water, they watch a short safety and instructional video.

Then, someone from Flyboard of Montana gives them some pointers out on the lake.

“We’re with them the whole time,” Heyne said.

“It looks a little scary and

intimidating,” Smith said.

“It’s really not. It’s easy to pick up.”

It took Renfro five or 10 minutes to get the feel for it.

“I was surprised by how quickly you could pick it up,” she said.

Before long, Renfro and Smith were pulling tricks like 360s and dolphin dives.

“It looks very intimidating, but it’s easy,” Heyne said. “Everybody gets it.”

And most people end up learning to do a trick or two.

The Flyboard was invented by French jet ski champion Frank Zapata in 2011. By 2012, the first ever Flyboard World Championship was held in Doha, Qatar, with 50 professional flyboarders competing from 20 countries.

This year’s world cup will be held in Dubai in December, and Heyne plans to attend.

Flyboarding as a sport is still new and little known but is growing.

“It’s getting really popular and more mainstream,” he said.

‌A ll the wildfires in Idaho are under control, but the state’s fire bill is much, much higher than usual, and maybe the highest it’s ever been, Gov. C.L. “Butch” Otter said Thursday.

Speaking at the Southern Idaho Economic Development Organization’s yearly summit at the College of Southern Idaho’s Herrett Center in Twin Falls, Otter said that state crews stood down on all the major fires in Idaho.

The bad news was that the state’s firefighting bill so far this season is for $70 million, which, Otter said, is at least two-anda-half times higher than it has ever been in his time as governor or even as lieutenant governor before that.

Otter noted that state revenues have been higher than expected — Idaho closed the 2014-2015 budget year with a $108 million surplus in the general fund — but added that he has also received plenty of requests on how to spend this.

“We’re going to have some heavy lifting to do,” he said.

In a brief interview with the Times-News before he spoke, Otter said that most of what he knows about the current debate over the refugee program in Twin Falls is what he’s seen in the media, but he certainly didn’t sound like he would support ending the program. Otter noted that the refugee program has been around for while (more than 30 years in Twin Falls), and that it only seems to have become controversial because of the background (i.e., Syrian) of some of the refugees

Read more blogs by Times-News reporters at Magicvalley.com/blogs.

coming this year.

“I think we can protect the local community and at the same time do the humanitarian thing,” Otter said.

He also wouldn’t tip his hand further as to whom he supports for president, other than to repeat that he wants the party’s nominee to be one of the former or current GOP governors in the race. He said that states with Republican governors have lower unemployment and cited statistics saying they have cut taxes since 2011, while states with Democratic governors have raised them. Otter said he expects to announce who he supports after the Lincoln Day dinner circuit in February 2016. (Idaho’s GOP primary will be on March 8.)

Real estate mogul and reality TV star Donald Trump, who was never a governor, has been leading the GOP polls – including in Idaho – by a wide margin. Otter said Trump is “bringing a new dynamic, if you will, to the presidential race” and was successful in the private sector, but added that getting things done when you run a business doesn’t work the same as when you’re in government. In the private sector, Otter said, you can make a decision at a lunch meeting and have it implemented by 1 p.m.

“It’s a little different when you’re in the political realm and have to deal with 535 members of Congress or 105 members of the state Legislature,” Otter said.

Weldon and Caroline Weigle, your family wishes you both very Happy 80th Birthdays!

We are so proud to be your kids and so grateful to have you as our parents and grandparents.

Love, Brett, Scott, Anne and families.

CELEBRATIONS ANNIVERSARIES The Bristols Kent and Dorothea Bristol, and Dan and Beth Bristol invite you to an Open House honoring their parents Bruce and Mary Lynne Bristol, longtime Albion residents, for their 50th wedding anniversary. It will be held on Sunday, September 20, their birth dates, from 3-5 p.m. in the Albion Church of Christ at 110 W North Street in Albion.

Bruce Bristol and Mary Lynne Amende were married September 5, 1965 in the auditorium at Magic Valley Christian College in Albion. After four years in the Navy and two years in Pocatello where Bruce earned his licenses to be an aircraft mechanic, the Bristols moved to Albion where Bruce farmed with his father-inlaw, Keith Amende. After the farm was sold Bruce became a fulltime Cassia County Sheriff's

The Prines

Deputy. Upon retirement as deputy, Bruce became Chief of Police for Albion. Mary Lynne worked for the Cassia School District as Public Information Officer for almost 30 years.

Your presence is the only gift they request.

Floyd and Arlene Prine of Twin Falls, ID will be celebrating their 50th wedding anniversary.

Friends and relatives are invited to send cards to help them celebrate this joyous milestone.

Floyd Prine, from Pawnee City, NE and Arlene Lackey, from Seneca, KS, were married on September 18, 1965 in Seneca, KS. They moved from Nebraska and have enjoyed living in the Twin Falls area for over 40 years.

Floyd worked at Longview Fibre until he retired in 2009. Arlene retired in 2010 but still continues

to work in the lunch program for Morningside School. During their retirement, they have enjoyed square dancing with the Buttons and Bows, gold prospecting, and camping.

Along this journey they have been blessed with 4 children, 10 grandchildren, and 2 great grandchildren. We love you Dad and Mom!! We are so lucky to be on this inspiring journey with you.