1. Receiving and Storage: Milk is received from dairy farms and stored in large refrigerated tanks to maintain its freshness until it's ready to be processed.
2. Standardization: Milk may be standardized to achieve a consistent fat content in the final product. This involves removing or adding cream as necessary.
3. Pasteurization: Milk is heated to a high temperature for a short period to kill any harmful bacteria and increase shelf life. Commonly, this is done using ultra-high temperature (UHT) pasteurization or HTST (high-temperature short-time) methods.
4. Cooling: After pasteurization, the milk is rapidly cooled to prevent the growth of any remaining bacteria and to prepare it for the next step.
5. Culturing: Yogurt cultures, which contain specific strains of lactic acid bacteria such as Lactobacillus bulgaricus and Streptococcus thermophilus, are added to the milk. These bacteria ferment lactose (milk sugar) and produce lactic acid, which causes the milk proteins to coagulate and thicken, resulting in yogurt.
6. Incubation: The milk is then incubated at a controlled temperature (usually around 41-45°C or 106-113°F) for several hours to allow the bacteria to multiply and ferment the milk.
7. Flavoring and Mixing: Once the yogurt has set, flavors, fruits, or sweeteners can be added if desired. This step varies depending on the type of yogurt being produced.
8. Filling and Packing: The yogurt is filled into containers and sealed. It may also be stirred at this point to create a smooth consistency for stirred yogurts.
9. Cooling and Aging: The filled containers are cooled to slow down the fermentation process and aged to develop flavor and texture.
10. Quality Control: Throughout the process, quality control checks are performed to ensure that the yogurt meets safety and quality standards.
11. Storage and Distribution: Once the yogurt has been properly cooled and aged, it is stored under refrigeration until it's shipped to stores and retailers.
The equipment used in a yogurt processing plant includes milk tanks, homogenizers, pasteurizers, cooling systems, culture addition systems, mixers, filling machines, packaging machinery, and refrigerated storage facilities. Additionally, there are strict hygiene and sanitation protocols to follow to ensure food safety.
Yogurt processing flow chart
A flow chart for the yogurt processing can be visualized with the following steps, each represented as a node or box connected by arrows showing the sequence of operations:
Milk Reception
• Milk is received at the processing facility.
• Storage & Cooling
• Milk is cooled to around 4°C to inhibit bacterial growth and stored in refrigerated tanks.
• Standardization
• Milk is standardized to ensure a consistent fat content.
• Homogenization
• Milk undergoes homogenization to break down fat globules and prevent separation.
• Pasteurization
• Milk is heated to a high temperature to eliminate pathogens and spoilage microorganisms.
• Cooling Down
• Milk is rapidly cooled to a temperature suitable for culture inoculation.
• Inoculation with Starter Culture
• Specific lactic acid bacteria cultures are added to the milk.
• Incubation
• The milk-culture mixture is incubated at a controlled temperature to allow the fermentation process to occur.
• Cooling After Incubation
• Once the yogurt has set, it is cooled to halt the fermentation process.
• Flavoring (Optional)
• Flavorings, sweeteners, or fruit are added to the yogurt.
• Mixing (if applicable)
• Ingredients are mixed thoroughly if needed.
• Packaging
• Yogurt is filled into containers and sealed.
• Quality Control
• Final products are inspected for quality assurance.
• Chilling & Storage
• Packaged yogurt is chilled and stored in cold rooms.
• Distribution
• Yogurt is shipped to retailers and distributors.
Each step in the flow chart is critical for producing safe, high-quality yogurt products. Depending on the specific yogurt type and the company's processes, additional steps might be included, such as thickening for Greek yogurt or the addition of probiotics for functional yogurts.
Yogurt processing machine
Yogurt processing machines are specialized equipment used in the dairy industry for converting milk into yogurt through various stages such as pasteurization, homogenization, culturing, and cooling. These machines can range from simple, manual units to complex, fully automated systems capable of handling large volumes of milk.
Here are the main components and types of machines involved in the yogurt processing line:
Milk Reception and Storage Tanks:
• These tanks receive the raw milk and store it at a low temperature to maintain freshness and prevent bacterial growth.
• Pasteurizers:
• Pasteurizers heat the milk to a specific temperature to kill harmful bacteria while preserving the nutritional value and flavor of the milk.
• Homogenizers:
• Homogenizers are used to break down the fat globules in the milk to create a more uniform texture and prevent cream from rising to the top.
• Coolers:
• After pasteurization, coolers rapidly decrease the temperature of the milk to prepare it for the addition of yogurt cultures.
• Culture Addition Systems:
• These systems add the required bacteria (cultures) to the cooled milk to start the fermentation process.
• Incubators:
• Incubators maintain the milk at a controlled temperature (around 42°C) to facilitate the fermentation process, turning milk into yogurt.
• Cooling and Stabilization Equipment:
• Once the yogurt is set, cooling equipment brings it down to a lower temperature to halt fermentation and stabilize the product.
• Mixing and Flavoring Stations:
• If flavors or additives are to be included, these stations incorporate them into the yogurt base.
• Filling and Packaging Machines:
• Filling machines portion the yogurt into individual containers, which are then sealed and packaged for distribution.
• Conveyors and Automated Handling Systems:
• Conveyors move containers between the different processing stations and help automate the production line.
• Quality Control and Inspection Equipment:
• This includes devices for checking the consistency, pH, and other quality parameters of the yogurt.
• Cleaning and Sanitizing Systems:
• Critical for maintaining hygiene, these systems clean and sanitize the equipment after each production cycle.
• Control Panels and Software:
• Modern processing lines use control panels and software to monitor and adjust the production process for efficiency and quality control.
When choosing yogurt processing machines, it's important to consider factors such as production capacity, the type of yogurt being produced (e.g., plain, Greek, flavored), space constraints, budget, and the level of automation desired. We offer turnkey solutions that include design, installation, and after-sales service.
Shanghai Beyond Machinery Co., Ltd.
Beyond Machinery specializes in the design and manufacturing of yogurt processing plant machinery.Please contact us now, and ourprofessional technical engineers will customize the equipment plan for yogurt processing plant machinery and provide a quotation.Please contact us now to obtain the latest equipment plan and quotation.
