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PRESENTATIONS

Curd Processing: From Traditional Methods to Industrial-Scale Production

By PMG Engineering · 11 Sep 2023

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: