PMG Engineering | Build World-Class Food Factories | Presentation | Yogurt Processing: From Fermentation to Flavorful Innovation

PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Yoghurt Processing Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering CONTENTS 1 2 3 Introduction Raw material Processing 4 Major Process Equipment Required 5 Factor Affecting yogurt quality 6 7 8 x Health benefits of Yogurt Recent Innovations in Yogurt References About PMG Engineering Build World-Class Food Factories 2 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1. Introduction • A dairy product made by controlled fermentation using certain bacterial culture grown in symbiosis condition. • It involves microorganism: 1. Lactobacillus bulgaricus and 2. Streptococcus thermophilus, • Sensory characteristics of yogurt: - smoother texture - more consistent flavor - Tart taste - Custard-like consistency • Yogurt offers a delicious and probiotic-rich food option to consumers other than curd. Build World-Class Food Factories Build World-Class Food Factories 3 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1.1 History of Yogurt • Yogurt, originating from domesticated goat and sheep milk, originated in Mesopotamia from around 5000 B.C., naturally occurring bacteria. forming curds • Yogurt, derived from Turkish "yoğurmak," and referred to have health-promoting properties since 6000 BC in Indian Ayurvedic scripts. • When Spanish yogurt manufacturer Isaac Carasso started blending yogurt with jams, the product became commercially successful. • The first laboratory and factory started at: 1. France: 1932 2. United state: 1941. • It gained popularity in the US in the past 30- 40 years. Build World-Class Food Factories Build World-Class Food Factories 4 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1.2 Nutritional Status of Yogurt (per 100 g) # 1. 2. 3. 4. 5. 6. 7. 8. Parameter Energy Carbohydrates Sugar Protein Fat Cholesterol Calcium Sodium 10. Phosphorus 11. Riboflavin Values 61 Cal 4.7 g 4.7 g 3.5 g 3.3 g 0.01 g 125.9 mg 48.08 mg 99.14 mg 0.14 mg Build World-Class Food Factories Build World-Class Food Factories 5 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1.3 Classification of Yogurt Today, there are more than 700 yogurt found in Indian cuisine. Hence, classified as following depending upon their forms: Firm Stirred Powder Classes of Yogurt Frozen Concen- trated Drinking Build World-Class Food Factories Build World-Class Food Factories 6 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 2. Raw Material 1. Milk (Various type) 2. Additives; Stabilizer*, Emulsifiers**, Sweeteners, & Flavors*** 3. Fruits 4. Bacterial cultures *Role of stabilizer: Prevent syneresis (separation of whey), Increase firmness, and helps to hold the fruit uniformly. Ex: sodium alginates, pectin etc. **Role of emulsifier: Enhance texture, consistency, lecithin and mono- and and diglycerides. stability. Ex: ***Role of sweetener & flavor: Provides variety of product for consumption. Build World-Class Food Factories Build World-Class Food Factories 7 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Processing: Process Flow Diagram Receiving of Raw milk Preheating (30- 40°C) Clarification/ Bactofugation Inoculation @2% Deaeration @70°C & Cooling to 40°C Homogenization @70°C/20-25 Mpa Standardization @9-16%SNF, 1- 10%Fat Pasteurization @70–95°C/ 15sec to 30 min Incubation @42-46oC/ 4- 20 hours Mixing Cooling/Homog enization/ Concentration* Fruiting & Flavouring Transportation / delivery Cooling/ Cold storage @4- 7°C Packaging (Filling) *Optional step: performed as per the type of the yogurt required. 8 Build World-Class Food Factories Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3(a). Standardization • A good quality yogurt requires specific composition of milk constituents. • Done to 1. Standardize fat content, and 2. SNF/protein content, followed by 3. Addition of some additives such as stabilizer, emulsifier, and sweeteners. • Done at temperature of 40 – 55oC machine using standardization comprising of centrifuge/ separator and mixing unit. Build World-Class Food Factories Build World-Class Food Factories 9 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3(b). Pasteurization & Homogenization • Pasteurization involves killing pathogenic microorganism, reduces number of vegetative microorganism and promote controlled fermentation. in • In addition, it denatures whey protein and yogurt texture influencing consistency. • Followed by pasteurization, homogenization fat particle and globules consistently resulting, smoother and creamier texture. disperse breaks down • Condition: 1. Pasteurization: 70 – 95oC/ 15 sec to 30 min. 2. Homogenization: 70°C/20-25 Mpa Build World-Class Food Factories Build World-Class Food Factories 10 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3(c). Inoculation & Incubation • For yogurt preparation, milk is inoculated using two strains of bacteria 1. S. Thermophilus 2. L. delbrueckii subsp. Bulgaricus • pre-formulated inoculum having freezed dried culture (more than 1010 colony- forming units (CFU)/g ) standardize milk making conc. of 106 to 107 CFU/g is used. • The mix is transported to fermentation tank or packaging machine at 2% conc. In fermentation tank, the mixture is incubated at 42-46oC/ 4-20 hours. • This fermentation step, converts lactose to lactic acid and other metabolism producing the characteristic yogurt flavor. • The fermentation assumed to be completed at either at least 0.9% acidity and a pH of about 4.4. Build World-Class Food Factories Build World-Class Food Factories 11 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3(d). Fruiting & Flavouring • Fruiting and flavouring done to enhance the acceptability of the yogurt amongst various consumers. • It helps to capture the market. • Provides large number of product range for the consumers. Build World-Class Food Factories Build World-Class Food Factories 12 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3(e). Packaging (Filling) • The packages (SKUs) used for packaging of yogurt are: 1. Plastic bag 2. Plastic cup 3. Plastic bottle etc., • Packaging material used are LDPE, LLDPE, EVOH, for MLLDPE, and other resin compounds manufacturing of various packages. • Packaging done at two stages, - First after inoculation, - Secondly, after flavouring and fruiting depending upon types of yogurt needs to be manufactured. Build World-Class Food Factories Build World-Class Food Factories 13 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3(f). Cooling/ Cold Storing • After packing, yogurt rapidly cooled around 4-7°C to stop the fermentation process, to preserve the yogurt's freshness and flavor and, - - - To ensures the yogurt's desired texture and consistency by preventing excessive fermentation or whey separation. • Furthermore, cold storage done at a controlled temperature to ensure yogurt safety until its expiry date. Build World-Class Food Factories Build World-Class Food Factories 14 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 4. Quality control in yogurt processing • Quality control programs for yogurt manufacturing involve ensuring product flavor, texture, color, process, and composition. • Flavor defects can be caused by excessive sweetness, tartness, or atypical flavors. • Overcooked or tart flavors can result from poor processing procedures. • Hard-pack frozen yogurt may have i. ii. coarse or icy texture due to storage temperature fluctuations, sandiness due to lactose crystals, iii. soggy or gummy defects due to high milk solids or sugar content, and iv. weak body due to overrun and insufficient total solids. • Proper blending of fruit purees and yogurt mix is essential for uniformity. • Good microbiological quality of all ingredients is also crucial. Build World-Class Food Factories Build World-Class Food Factories 15 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 5. Factors affecting Yoghurt Quality Microbial Contaminants Starter culture Fat content Dry Matter content Stabilisers 1. Microbial Contaminants: Such as Bacteriophages presence occur due to poor hygiene and lack of pest, insect and waste management. 2. Starter culture: The quality of yogurt depends on strain, as it produces specific desired compound in the yogurt. 3. Fat content: The amount of fat present in the yogurt affects mouthfeel. Higher fat% increases creaminess and smoothness. 4. The Dry Matter content: It affect firmness of the product, higher the dry matter content more will be the firmness. 5. Stabilisers: bind with water resulting increase in viscosity of the yoghurt. Build World-Class Food Factories Build World-Class Food Factories 16 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 6. Health Benefits a. Reduce osteoporosis & improve bone health b. Lowers hypertension problems c. Excellent alternative for lactose intolerance d. Protein rich food e. Probiotic strains boost immunity system f. Improves gut health Build World-Class Food Factories Build World-Class Food Factories 17 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 7. Recent Innovations in Yogurt • Recent research is concentrated on creating yogurt products with extended shelf lives, improved nutrition, and new tastes. • Goat milk yogurts and icelandic skyr strained yogurt are two of the newest fads. • Greek yogurts with lots of protein, probiotic yogurts with minimal lactose content, and savory yogurts are also well-liked. • In addition, Studies are also being conducted to enhance the nutritional value and shelf life of yogurts. Build World-Class Food Factories Build World-Class Food Factories 18 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 8. References • (PDF) The Product and the Manufacturing of Yoghurt (researchgate.net) • How Yogurt Is Processed - IFT.org • Yogurt 101: Nutrition Facts and Health Benefits (healthline.com) • Yogurt Nutrition Facts and Health Benefits (verywellfit.com) • Yogurt Production | MilkFacts.info • Yogurt | Yoghurt Manufacturing Production Process (dairyconsultant.co.uk) • How is Yogurt Made Step by Step: Flow Chart, Manufacturing Procedures and Quality Control (biologydiscussion.com) Build World-Class Food Factories Build World-Class Food Factories 19 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Our Clients Build World-Class Food Factories Build World-Class Food Factories # We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients