Physical Instability and Functional Deterioration of High-Protein Dairy Powders: Mechanisms of Caking, Agglomeration, and Rehydration Loss

The rapid expansion of high-protein dairy-based powders (HPDPs), including milk protein concentrates and isolates (MPC/MPI), whey protein concentrates and isolates (WPC/WPI), and micellar casein concentrates and isolates (MCC/MCI), has intensified the need to understand instability phenomena that emerge during processing and storage. These products are governed by protein-rich amorphous matrices, in which molecular mobility, interfacial composition, and mineral interactions dictate both physical stability and functional performance. Importantly, these physical instabilities are directly coupled with functional deterioration, particularly in terms of impaired wetting, dispersion, and dissolution during rehydration. This review presents an integrated mechanistic framework linking these instability phenomena across processing, storage, and reconstitution, thereby consolidating concepts that remain fragmented across the current literature on high-protein dairy matrices. Key controlling factors include glass transition temperature (Tg), water activity-induced plasticization, protein–protein and protein–mineral interactions, and surface compositional heterogeneity established during spray drying. These factors govern the progression from surface stickiness through uncontrolled agglomeration to caking, forming a consolidation continuum. In contrast to lactose-driven matrices, caking and agglomeration in HPDPs arise primarily from protein-mediated restructuring and inter-particle bonding, with lactose crystallization acting only as a secondary mechanism in mixed-composition grades. The review further distinguishes engineered agglomeration from storage-induced consolidation and evaluates advances in molecular mobility characterization and Tg-based stability mapping. Significant gaps remain in linking localized surface evolution, mineral redistribution, and inter-particle bridge chemistry under realistic environmental conditions. The review concludes by proposing a mobility-centered “stability-by-design” framework that integrates composition, processing, particle architecture, and storage conditions to guide the development of future HPDPs with improved physical stability and functional recovery.