Real-time product release and process control challenges in the dairy milk powder industry

•Real-time product release and process control challenges in the dairy industry.•The dairy milk powder industry has unique characteristics.•Unique features of dairy industry need to be considered before PAT implementation.•An explicit focus on process control for real-time release testing is needed.

Real-time release testing in the dairy milk powder industry may potentially be achieved by implementing process analytical technology. Research advances have focused on the application of spectroscopic sensors and multivariate data analysis, while neglecting suitable process control strategies and decision-making tools to control critical quality attributes. Due to the unique characteristics of this industry, real-time release, and process control challenges need to be considered before achieving the goal of real-time product release. For example, complex quality attributes can be inferred using proxy measurement; the dependence of advanced analytical sensors can be minimised by using standard pressure/flow/temperature sensors; and investment is required in additional resources and skills for advanced analytical sensors, multivariate models, and control strategy development.