Curd Processing: From Traditional Methods to Industrial-Scale Production

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Curd Processing: From Traditional Methods to Industrial-Scale Production

Introduction: What is Curd (Dahi)?

Curd, or dahi, is a semi-solid fermented dairy product made by inoculating milk with lactic acid bacteria (LAB). These cultures ferment lactose into lactic acid, giving curd its:

Tart flavor
Improved digestibility
Therapeutic benefits

The Indian curd market is booming, expected to grow from ₹1365.5 billion (2022) to ₹3175 billion (2028) at a CAGR of 15.1%. This surge is fueled by:

Rising demand for packed curd
Health-conscious consumers
Busy lifestyles requiring convenient food options

Nutritional Highlights of Whole Milk Curd

According to FSSAI (2011), dahi from whole milk is:

Rich in calcium, potassium, phosphorus, and magnesium
A source of vitamin D, supporting bone health
A natural probiotic, aiding gut health and digestion

Industrial Curd Processing: Step-by-Step

While traditional dahi is still widely prepared at home, modern dairy plants follow a structured, hygienic, and scalable process.

1. Milk Filtration & Clarification

Removes extraneous matter and microbial load
Performed at 30–40°C using clarifiers and bactofuge machines

2. Milk Standardization

Adjusts fat and SNF content
Ensures uniform texture, protein content, and nutrient retention

3. Homogenization

Conducted at 60°C, 175 kg/cm²
Improves texture and reduces cream separation
Enhances incubation consistency

4. Pasteurization

90–95°C for 10–20 minutes
Destroys pathogens and air-borne contaminants
Releases nutrients essential for fermentation microbes

5. Inoculation & Incubation

Milk cooled to 37°C
LAB culture added (1–1.5%)
Incubated at 37–42°C for 8–10 hrs
Target pH: 4.4–4.5

6. Packaging

Primary packaging types:
Plastic pouches
Cups/jars
Earthen pots
Materials used: LDPE, LLDPE, EVOH, MLLDPE, PVC

Packaging may occur before or after incubation, depending on the product type (e.g., set curd vs stirred yogurt).

7. Cooling & Storage

Rapid chilling to 4–7°C
Halts fermentation
Maintains texture, shelf life, and microbial stability

Curd Cultures and Their Role

⚠️ Possible Defects in Curd

Whey separation (syneresis)
Bitter or sour off-flavors
Slimy or grainy texture
Gas formation / bloating in sealed cups

These issues are typically caused by:

Poor temperature control
Inadequate pasteurization
Unbalanced culture ratios
Contaminated equipment

A food consultant helps set up SOPs, QC tests, and culture validation to prevent defects and product recalls.

Packaging Innovations in the Curd Industry

Portion control cups for on-the-go use
Multi-compartment packs for flavored/stirred curds
Use of eco-friendly materials and UV sterilized packaging lines

Conclusion: Modern Curd Processing Marries Tradition and Technology

From age-old fermentation to CIP-automated dairy plants, curd remains a staple with massive commercial potential. Modern curd processing ensures:

Safe, standardized production
High market appeal with clean packaging
Growth opportunities in health-based, probiotic, and regional variants

A professional food manufacturing consultant helps:

Design curd plants with flow-optimized layouts
Source appropriate equipment and packaging
Implement FSSAI, ISO, and HACCP-compliant processing systems

PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering CURD 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 4 5 x Introduction Raw material Processing Methods Possible defects in curd 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 fermented product prepared using fermentation technique used to preserve milk constituent for longer duration. • It is defined as semi-solid product obtained from pasteurized cultured milk using harmless LAB (Lactic acid bacteria) or other bacterial culture. • The fermentation: - Gives acidic taste to milk, - its sensory characteristic Improve making it more palatable/digestible and - Provides some therapeutic advantages not originally present in milk. - breakdown lactose into lactic acids and some flavouring compound such as diacetyl. 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 Status of Dahi in Indian Market • The market analysis report shows that market size of curd reaches to Rs. 1365.5 billion in 2022. • It is expected to grow curd market to Rs. 3175.0 billion by 2028 with growth rate of 15.1%. • Currently, Maharashtra have highest market share followed by Uttar Pradesh and Andhra Pradesh & Telangana. • Health-conscious consumers favoring healthier options drive innovation, like low-fat, high-protein variants, in the sector. • Furthermore, due to busy lifestyle the demand of packed curd has risen leading to further growth in the market . 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 Curd (Whole Milk Curd) • As per FSSAI regulation 2011, dahi prepared from whole milk must have nutritional composition as mentioned below: # Parameter Values (%) 1. Water 2. Carbohydrates 3. Sugar (Lactose) 4. Protein 5. Fat 6. Ash* 7. Acidity (lactic acid) 85-88 4.6-5.2 4.6-5.2 3.2-3.4 5-8 0.7-0.75 0.5-1.1 - Rich in calcium*, good source of potassium, phosphorus and magnesium. - Dahi is also a good source of vitamin D, leading bone strengthening in coordination with calcium and phosphorus. 5 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 2. Raw Material 1. Milk of good quality 2. Bacterial cultures* * Lactic acid bacteria such as lactobacillus strains like Lactococcus lactis etc: Produces lactic acid from lactose resulting increase in acidity, * Streptococcus diacetyl lactis: Produces diacetyl (buttery flavour) * Streptococcus Cremoris: Produces lactic acid from glucose as in misti dahi. * Leuconostoc citrovorum or Leuconostoc Dextranicum: Produces dextran and levan (exopolysaccharides) from sucrose contributing to specific aroma. 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 3. Processing Methods • Curd or dahi processing is done from ancient times by fermentation of milk using natural microflora. • Hence, it can be produced using any of traditional or modern industrial method. 1. Conventional/ Traditional Method: and - To make dahi, milk is boiled for 5-10 ambient cooled min temperature, of small buttermilk or curd incorporated, and leavened overnight to solidify. at portion 2. Industrial method - This method is inspired by tradition method. Hence, processing of dahi done at industrial level includes similar method but in systematic way. 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 3.1 Process Flow Diagram Receiving of Raw milk Preheating (30- 40°C) Filteration/ Clarification/ Bactofugation Standardization @11-13%SNF, 0-5%Fat Concentration* & Mixing* Deaeration @70°C & Cooling to 40°C Pasteurization @90-95°C/ 10- 20 min Homogenization @70°C/20-25 Mpa Inoculation @2% Incubation @42-46oC/ 4-20 hours Packaging (Filling) Cooling/ Cold storage @4-7°C *Optional step: performed as per the type of the yogurt required. Build World-Class Food Factories Build World-Class Food Factories Transportation/ delivery 8 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3.1(a). Filteration/ Clarification • After preheating at 30-40oC of selected milk majorly suitably buffalo milk, clarification is done. - To remove any extraneous esp. contaminants matter/ vegetative microbes. • Done using Clarifier & Bactofuge machine. - It separates microbes based on density difference (bacteria is heavier than milk). 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 3.1(b). Standardization • Milk is standardized using industrial standardization machine with - Standardized fat content: fat-free or full fat, - SNF content: a minimum 2% increase. • Effect of standardization on dahi quality - Enhances body texture and custard consistency, - Boosting protein, - Boost calcium, and other minerals content, and - Reducing spoiling during storage 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 3.1(c). Homogenization • After standardization, milk is again heated to milk transferred to 60oC and homogenizer - To melt milk fat and - To increase homogenizer efficiency. • Milk is homogenized using single stage homogenization with 175kg/cm2 pressure. • Homogenization results: - Reduction in cream layer formation during incubation, and - Improve texture of dahi 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 3.1(d). Pasteurization • After that it is pasteurized at higher temperature @ 90-95°C/ 10-20 min than usual to destroy maximum microorganism and kill pathogenic microbes. • Benefits: - Denatures and coagulates milk albumin and globulins - Destroy microbial contaminants - Removes incorporated air - Releases peptones and sulfhydryl groups (Nutrients for fermentative microbe) 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 3.1(e). Inoculation & Incubation • The pasteurized milk cooled @37oC is taken into mixing & coagulating vats where inoculum addition and mixing performed. • Specific dahi culture added at the rate of 1 to 1.5%. • For incubation, either cultured milk stored in it for 8 to 10 hours (until pH reaches 4.4-4.5) or supplied to packed and then stored at incubating room/ chamber @37-42oC temperature. 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 3.1(f). Packaging (Filling) • The packages (SKUs) used for packaging of curd are: 1. Plastic bag/pouches 2. Plastic cup, jar 3. Plastic pots 4. Earthen pot etc., • Packaging material used are LDPE, LLDPE, EVOH, MLLDPE, PVC and other resin compounds for 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 14 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3.1(g). Cooling/ Cold Storing • After packing, curd rapidly cooled around 4-7°C - - to stop the fermentation process, to preserve the curd freshness and flavor and, - To ensures the curd’s desired texture and consistency by preventing excessive fermentation or whey separation. • Furthermore, cold storage done at a controlled temperature to ensure curd safety until its expiry date. 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 4. Possible Defects in Curd # 1 Hard & lumpy e Watery r u t x e T & y d o B Whey off Defects Cause Corrective Measure Low solids, poor milk quality, insufficient heat treatment Proper Standardization Over ripening Controlled ripening Low solids, Higher acidity Ropiness Faulty fermentation Bitter & cheesy Peptonising proteolytic organisms Cooked Flavour Overheating Low acid and diacetyl production Proper Standardization and limited fermentation Controlled fermentation Controlled fermentative growth Uniform & accurate heating Controlled fermentation, acids addition Lipolytic organisms Proper pasteurization Yeast and molds growth Controlled fermentation, & good hygiene practices. 2 r u o v a l F Flat Rancid Fruity & alcoholic Malty defect Growth of S. lactis var. multigenes Controlled fermentation 16 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 5. References • Curd Market in India: Industry Trends, Share, Size, Growth, Opportunity and Forecast 2023-2028 (giiresearch.com) • DT-4: Lesson 23. DAHI PREPARATION METHODS, QUALITY OF DAHI, PACKAGING, SHELF LIFE AND DEFECTS (iasri.res.in) • India Curd Market Report 2021: Industry Trends, Share, Size, Growth, Opportunity and Forecast 2015-2026 - ResearchAndMarkets.com | Business Wire 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 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

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