At FFCE, we provide complete food consulting solutions to support your production of high-quality plant-based dairy products to fit the growing market for healthy and environmentally friendly products. Soybeans and other plant-based derivatives of dairy items like milk, yogurt, cheese, cream, etc are consumed by specially sensitized consumers including the health-conscious and the allergic. It is worth stating that in our company we offer total support from the time of idea generation up to the marketing of the product. 

Our New Product Development services help you formulate plant-based dairy products ranging from beverages, and cultured products to non-dairy cheese, to suit a diverse consumer market. This can also involve designing new products that are not at all present within the market.  To assist you in the correct formulation and production of products with similar texture, taste, and nutritional value as their dairy counterparts, we provide Technological Support for processes such as emulsification, fermentation, and fortification. In our Process Improvement services, the blending, homogenization, and pasteurization processes are accorded special attention. 

We also offer Regulatory Compliance & Documentation to make certain your plant-based dairy products are secure for intake and correctly labeled according to the rules and regulations of any given country. Including those related to allergen control and nutritional claims Though. The Services we offer include Audits & Training to ensure high standards in all your production facilities and guarantee that all batches of plant-based dairy products meet all quality standards you set. We also be able to help you get third-party manufacturing collaborations for the growth of your business. 

What are Plant-Based Dairy Alternatives?

Soy-based dairy products are foods made from plant components like nuts, seeds, grains, and legumes. These are scientifically designed in that they duplicate in taste and texture real dairy foods and also supply the nutrients. The most frequently used samples include almond milk and oat milk, soy yogurt, and cashew cheese. Such products are usually packed with vitamins and minerals thus making them good for those who are struggling with their lactose levels, those who do not take any animal products, and those who are in the process of finding healthier meals..

Establishing a plant-based dairy product production facility requires numerous essential steps to fulfil. One has to start with obtaining plant materials including grinding almonds, soaking oats, or fermenting soybeans to produce a base for the product. This base is then taken and further passed through an emulsification and homogenization stage to have the right texture. For the case of products such as yogurt and cheese, therefore, the process of fermentation is important for product flavor and nutritional value.

Examples of key equipment include emulsifiers for blending cultured products, homogenizers that work to produce a smooth texture and fermentation vats for cultured products. Pasteurization units on the other hand are more important in food preservation and the shelf life of the products. Other complicated forms of packaging required in the preservation of plant-based dairy products include aseptic packaging.

Types of Plant-Based Dairy Alternatives

Plant-Based Milk

  • Profile: Copies the flavor and mouth feel of cow’s milk.
  • Ingredients: Possible bases are: almond; soy; oat; coconut; rice; cashew etc.
  • Applications: For instance; consumed in beverages, cooked and baked products, and as a direct replacement for standard dairy milk in cereal and coffee.

Plant-Based Yogurt

  • Profile: Provides mouth feel and acidic taste synonymous with dairy yogurt.
  • Ingredients: Produced soy, coconut, almond or oat, sometimes with probiotic cultures.
  • Applications: Often eaten separately or added to salads, but also used in making shakes and sauces such as salad dressings and dips.

Plant-Based Cheese

  • Profile: Specifically intended to provide similar flavor and texture profile and melting characteristics as traditional cheese.
  • Ingredients: Usually produced from cashews, almonds, soy, or coconuts, in combination with natural additives and fats.
  • Applications: Common to be included in sandwiches, pizzas, and pasta as well as forming a part of a cheese collection.

Plant-Based Butter

  • Profile: Remains an acceptable imitation in terms of taste and Ease of spreading.
  • Ingredients: Usually derived from plant oils including coconut, palm or olive oil, may be stabilized with emulsifiers and flavored.
  • Applications: Appropriate for baking, cooking, spreading and even sautéing.

Plant-based creams and custards 

  • Profile: Provides structural flexibility giving the product a mouthfeel that simulates dairy creams and custards.
  • Ingredients: Available as soy, coconut, cashew or almond-based products with the use of thickeners and emulsifiers.
  • Applications: May be employed in the preparation of foods that require boiling, frying, roasting or even baking, as a condiment or garnish, or in any sweet preparation such as pastries, cakes, etc.

Plant-Based Ice Cream

  • Profile: Produce the smooth body and smoothness of conventional ice cream.
  • Ingredients: Available dairy products like coconut milk, almond milk, soy milk and contain added sugars and flavoring.
  • Applications: Served with nutritional value as a dessert, a snack, or even a sweet, in different flavors or types.

Production Process of Plant-Based Dairy Products

Selection and acquisition of ingredients.

  • Objective: Select better plant-based products that will give the desired flavor and consistency at the same time.
  • Process: Base ingredients are to be selected out of nuts, grains, legumes, seeds and so on. To make key ingredients available locally in an environmentally friendly manner with no GMO and as far as possible free from allergens.

Base Preparation

  • Objective: Define the specifications of the actual surface of the dense pack of the final product and a homogenized substructure for it.
  • Process: A process of steeping, mashing and mixing plant materials to obtain a paste-like consistency of food. The mass is then filtered to eliminate solid and the blend left is a smooth base.

Fortification and Flavoring

  • Objective: Improve the nutritional value of the food and create better palatability of the product.
  • Process: Replacing cookies with milk products with the same or improved nutritional values that contain vitamins and minerals for example calcium, vitamin D and B12. To make it tasty and thick, natural flavors, sweeteners and thickeners may also be used.

Utilization of Proteins (Yogurts and Cheeses)

  • Objective: They also have to define characteristic tastes and consistencies Specific instructions:
  • Process: Adding probiotics and cultures to the base mixture to make the formula ferment which also thickens it up. Peculiar taste attributes that are harnessed through this process include sharp tone and off-flavor profiles which are akin to dairy yogurts and cheese.

Emulsification and homogenization.

  • Objective: They make sure that it is stable and homogeneous product.
  • Process: Combining fats in to the liquids with the help of emulsifiers and homogenization to achieve the right texture. This step is important especially for product such as plant-based milks and creams.

Bacteriological or pasteurization and preservation

  • Objective: Promote product safety and increase its shelf-life.
  • Process: To remove pathogenic microorganisms or to preserve food products heat treatment or other preservation techniques are used. Depending on type, season and processing techniques may also include the use of preservative in order to maintain freshness.

Quality Control and Testing

  • Objective: Maintain food product consistency, safety as well as quality.
  • Process: Sensory analysis, nutritional analysis, and determination of microbial load. Compliance with legal requirements for food safety and information labeling Compliance with legal requirement on food safety compliance with food labeling regulation.

Packaging and Labeling

  • Objective: Safeguard the product and at the same time give relevant information to the consumer.
  • Process: Selecting packaging forms that help maintain the product’s freshness at the stores and increase shelf life. These labels should also contain the nutrient declaration, list of ingredients, allergens, and any directions for use.

Packaging Solutions for Plant-Based Dairy Products

There is a need to package the plant-based dairy alternatives in a package that protects them from being damaged, while retaining their qualities and shelf life. This paper focuses on identifying appropriate packaging materials that protect the product, easy to use and are environmentally friendly.

Cartons and Bottles

  • Objective: Give a recyclable and reusable Product that retains the quality of the product for the consumer.
  • Materials: Pouched aseptic packaging and Tetra Pak cartons are widely used, together with PET or HDPE bottles.
  • Benefits: Such materials shield it from light and oxygen so as to retain the product’s flavor as well as nutrients. Aluminum foils are generally reusable and PET bottles can be recycled using material from recyclable cartons.

Tubs and Cups

  • Objective: It should also be available in single-serve or a multiple serves’ packaging for easier use.
  • Materials: This type is normally made of plastics whereby their uses are in preserving yogurts, spread, and other types of cheese.
  • Benefits: As they come in individual serving packs with resealable lids it is easy to store as well as use them. Currently, most manufacturers are wetting their bets in developing biodegradable or recycle materials to replace plastic.

Sustainable Packaging Systems

  • Objective: Reduce environmental impact and target the customer who cares about the environment.
  • Materials: There are choices including biodegradable plastics, plant materials or fully recycled packaging.
  • Benefits: Saves the carbon footprint and the environment by cutting costs on packaging. Reflects customer preferences of green and ecofriendly products.

Labeling and Branding

  • Objective: In this case, giving key data about the product offered as well as drawing in customers.
  • Materials and Design Considerations: All content on labels should include the ingredient list and their quantities, amount of nutrients, allergens and related information, and non-GMO and vegan logos. It is the creativity and attractive logos and designs that markets set to make a difference for products in the same line.