Frontline Food Consultants and Engineers right food consultancy services to produce the best quality yogurt in terms of taste, texture, and nutritional value. Unlike making yogurt it involves some considerations such as the quality of milk, the fermentation process, and the standard final product to be consumed. Nonetheless, FFCE also assists in the evaluation of sensory characteristics, and formulation of recipes. We give complete means and ways to make your products reach the market. 

Our Technological Support services for these yogurt manufacturing include all the key steps like pasteurization, cooling, packaging solutions and even regulatory compliances on food safety. The pasteurization of milk and controlled fermentation are key activities in the making of yoghurt that has an appropriate consistency as well as doses of viable probiotics. Process optimization we work on to help with the various steps for production. To ensure that the yogurt tastes best. 

We also provide Regulatory Compliance & Documentation solutions to enable you to achieve the right food safety regulation worldwide, especially in other areas such as bacterial culture management and shelf-life stability. Audits & Training help guarantee that your production facility is clean and operating efficiently by producing a product that meets market quality and standards. We also offer third-party manufacturing services for your next big production line. 

What is Yogurt Processing?

Yogurt manufacture entails converting milk into a thicker, sour entity by allowing controlled bacterial fermentation. The first step involves pasteurization of the milk, which kills most of the bacteria that may be present making the milk safe to be consumed. After pasteurization, the milk is cooled and then cultured a process by which the milk is inoculated with live-friendly bacteria which then work on the lactose in the milk turning it to lactic acid, which gives yogurt its taste and furry texture.

In yogurt production, factors such as specific temperature control during fermentation to obtain the think and taste right are among the important processes to be controlled. The yogurt is next cooled, to retard the fermentation, and then prepared for packing. Proper packaging is important because the food needs to be fresh and first of all, clean from other bacteria’s. With features such as single-serve cups for those who prefer a cup at a time, and large containers to suit large markets.

Types of Yogurt

Yogurt is produced in different types with individual properties and uses as explained below.

  1. Plain Yogurt
  • Profile:
  • That is produced from milk and bacterial cultures with no added flavors and sweeteners.
  • It is also commonly eaten raw or it can act as a base ingredient for numerous dishes.
  • Benefits:
  • Nutritional Value: Calcium richest high source of protein and friendly bacteria probiotics. Aids in digestion and is also beneficial to the bones.
  • Applications:
  • Culinary Uses: Consumed raw as a snack, cooking ingredient or as a thickening agent for sauces, dressings and smoothies.
  1. Flavored Yogurt
  • Profile:
  • Any yogurt that is flavored, sweetened and may contain fruit chunks or other supplementary ingredients.
  • Standard fills are vanilla, strawberry, blueberry or mixed berries.
  • Benefits:
  • Variety and Appeal: More chances are given to the consumer in terms of tastes and this goes well with the consumers.
  • Nutritional Value: Similar to plain yogurt, is nutritious since the vitamin and mineral additives depend on the chosen flavor.
  • Applications:
  • Culinary Uses: Often taken with drinks, baked in products, added in certain dishes and even used in confectionaries.
  1. Frozen Yogurt
  • Profile:
  • A dessert is similar to ice cream that is made from yogurt and may be sweetened and or flavored.
  • An interesting one because it offers an ice cream-like product with less fat content.
  • Benefits:
  • Lower Fat Content: Less fat than a usual ice cream and therefore can be considered better for those who want to eat less fat, but still want to eat an ice cream.
  • Probiotics: Preserves the advantageous bacteria that are essential for the functioning of the human digestion system.
  • Applications:
  • Culinary Uses: Consumed as ice cream and included in milkshakes and topped on fruits, or granola.

Production Process of Yogurt

  1. Purchasing and choosing of raw materials

Objective: Selecting good quality of milk and bacterial cultures will give your yogurt a better taste and texture. Process: The procurement of fresh milk from well-established dairy producers and picking the right bacteria strains for the fermentations.

  1. Pasteurization

Objective: Reduce the amount of bad bacteria and enhance the quality of the milk. Process: Cooking milk at a desirable temperature (85-90 o C) for a certain duration to eliminate/pathogens but retain nutrients.

  1. Homogenization

Objective: To guarantee a consistent texture and avoid the formation of the cream layer. Process: Using high pressures to push milk through several processes to get break up fat globules for additional creaminess.

  1. Cooling and Inoculation

Objective: Boil dairy products, that will be used for milk fermentation. 

Process: Heat the milk to a temperature that the bacterial cultures will thrive in (42-45°C) before inoculating it.

  1. Fermentation

Objective: Culture milk to thicken and obtain the right taste of yogurt. 

Process: He put the milk to churn for some hours till it gets to the required through and acidity level he desired.

  1. Cooling and Storage

Objective: Suspend the fermentation process and maintain the quality of yogurt. 

Process: The second step to produce this yogurt is to cool it at the rate of 4 °C for a short time in order to prevent further bacterial actions while keeping the physical traits and taste intact.

  1. Cup Filling Process for Curd
  • Objective: Subdivide yogurt in packs that allow the consumer to have a single serving from the pack. 
  • Process:
  • Filling: The yogurt is then either poured or packed in sterilized cups by means of automated filling machines. The cups are filled both accurately and in as hygienic a manner as possible in order to preserve the overall quality of the food served.
  • Sealing: To ensure the quality and aseptic nature of the product every cup comes with a tamper-evident lid.
  • Cooling and Storage: The cups with nutrient loss are filled and sealed and then stored in a cold place to increase their shelf life.

Packing Material for Yogurt 

There are various importance that packaging has in the need to maintain the freshness, taste and texture of yogurt. Key packaging materials and considerations include:

  1. Cups and Containers
  • Materials:
  • Plastic Cups: Sometimes used for individual portions for various conditions. Sanitary for it’s generally made from polypropylene (PP) or polystyrene (PS) and has good barrier properties as well as convenience.
  • Glass Jars: Also used for premium or artisanal yogurt. Glass is safe and does not contaminate the yogurt or affect it taste and quality in any way.
  1. Lids and Seals
  • Materials:
  • Aluminum Foil: Specially used in sealing yogurt cups to protect it for a longer time and have a tightly sealed pack.
  • Plastic Lids: It is tamper-evident and is often used with plastic cups in order to avoid making them too difficult to handle.