Trouble shooting in
Yoghurt production
Today it is only natural that high quality products are launched. Thus, each single deviation from the standards is controlled in detail. If low quality
products are released for sale, manufacturers do not only loose their customers but also their reputation.
Faults during yoghurt production concern many items like e.g. structure, aroma or bacteriological deviations.
To determine possible sources for undesired faults we assembled the enclosed table to provide a first overview. But in case of any questions do
not hesitate to contact us - your Application-team will give detailed advice!
Fault Reason Prevention / Measures
2/12
Fault Reason Prevention / Measures
Whey separation Infection of the milk Control delivered milk and culture for gas formers.
Examine milk for aerobic spore formers (B. cereus)
Do not apply too old milk (48 h)
Control the age of the cultures or the best before imprint of the yoghurt.
High homogenisation temperature Homogenisation temperature must not exceed 68 °C (not below 55 °C)
Vibrations during incubation or transport Avoid vibrations after filling, especially during transport
Insufficient ripening and acidification before stirring of yoghurt gallert Detailed control of the pH value
Over acidification by insufficient or slow cooling Determine the most profitable time for start of cooling
Strong stirring of yoghurt gallert Stirring of gallert with lowest possible blade load
Fruit supplement with low pH value or separation of the fruits by Careful mixing with fruit supplements/quality control of yoghurt glasses
undesired tanning agents for their cleaniness (CIP control)
Poor cleaning of yoghurt glasses Application of adequate cleaning agent and control of yoghurt glasses
Inadequate glass cleaning agent for set yoghurt (surface) for their cleaniness (CIP control)
Soft yoghurt structure Increase dry matter or optimise heat treatment
Stirred yoghurt: deep acidity level
Set yoghurt: high acidity level
Whey separation Aqueous yoghurt milk. Control aqueousness of yoghurt (decrease of freezing point).
Mechanical influence during ripening or cooling and storage. Avoid strong vibrations.
Over acidity due to delayed and too slow cooling. Timely and fast cooling of whole yoghurt mass.
Poor ripening. Permanent control of SH value or pH value.
Strong stirring at addition of fruit supplements. Careful stirring at addition of fruit supplements
3/12
Fault Reason Prevention / Measures
Soft consistency. Increase dry matter, heating temperature or heating time.
Vibrations during transport. Instruct forwarders to avoid vibrations due to their negative influence on
yoghurt quality.
Wrong or too long storage in markets Lower shelf life.
Avoid that the yoghurt comes off from the bottleneck.
Apply suitable glass cleanser
See as well item “thin” Constant cooling chain.
Cream separation Low homogenisation pressure. Control homogenisator manometer.
Homogenisation pressure should be > 150 bar (150 - 250 bar).
Longer incubation in the tank before filling into cups.
Light and frothy Incorporation of air due to too strong stirring of the milk after addition Avoid strong stirring as well as pumping after addition of culture (avoid
of culture incorporation of air).
Infection of the milk or culture by gas-forming bacteria like coliforms Permanent microbiological control of the milk and the equipment
or yeasts
Poor cleaning and disinfection of whole equipment Stepwise microbiological control of equipment
Increased disifection and cleaning of the whole equipment
Inadequate heating of the milk Raise heating temperature
Leak shaft seals of pumps Replace pump seals (regular control)
Frothy surface due to unsuitable filing device Careful filling of set yoghurt
Thin Aqueous yoghurt milk Control acqueousness of yoghurt (decrease freezing point)
Milk with inhibitors Examine intial milk for inhibitors
Inadequate cultures Apply consistency-improving cultures (e.g. V-range)
Too low dry matter Apply suitable coagulants
Insufficient homogenisation pressure Control homogenisation pressure (manometer)
Low heating temperature, short heating Increase heating temperature and prolong heating
Too high temperatures Decrease temperatures
Too low temperature at filling, too fast cooling Increase heating temperature
pH is too high during stirring Permanent control of SH or pH
Insufficient ripening
Too storng stirring at addition of fruit supplements Careful stirring at addition of food supplements
Pumps with high gravity Apply gentle pumps; stirring device with less revolutions
Toos trong stirring Avoid strong vibrations until sale
4/12
Fault Reason Prevention / Measures
Mechanical influence during ripening or cooling and storage Instruct forwarders to avoid vibrations due to their negative influence on
Strong vibrations during transport yoghurt quality.
Wrong or too long storage in markets Adapt date
See as well item “soft/smeary” Constant cooling chain until sale
5/12
Fault Reason Prevention / Measures
Soft, smeary Contamination by residues of cleaning agents (soapy water) Control cleaning of equipment (control CIP device)
Careful rinsing of the whole equipment with suitable water
Yoghurt milk with too low dry matter Increase dry matter of the yoghurt
Low addition of bulk starter Increase inoculation amount
Stringy cultures from bulk starter Propagate culture again
Too low incubation temperature Control incubation temperatures
Too early cooling (at too high pH) Control SH and cool in time
Infection by alkali-formers, protein-decomposer Control acidification and fermentation equipment for raw milk
Temperature in incubation chamber is not constant Possibly select more convenient culture
See as well item “thin” and “soapy” See as well item “thin” and “soapy”
Stringy, slimy Too long pre-stapling of the milk at deep temperatures Apply adequate, fresh milk
Influence of feeding Control the milk delivered for slime-forming bacteria
Contamination of the milk by slime-forming bacteria Acid cleaning of the whole equipment
Disinfection of the whole equipment and aggregates
Degeneration in the bulk starter Permanent control of bulk starter production
Too low incubation temperature increase incubation temperature
Too much St. filant Reduce content of St. filant
Curdy/mealy Too high dry matter Decrease dry matter (possibly apply more adequate mp)
Vibrations during incubation (set yoghurt) Avoid vibrations during and after incubation
Irregular temperature during incubation Control temperature during incubation
Clumpy/gritty Milk of cows with udder diseases or secretion disorders Exact control of SH value
Milk of cows which were milked continuously for a long period Apply fresh milk
High dry matter Possibly decrease milk dry matter
Long heating time = protein grains Control heating and possibly limit heating time
Over acidification and thus cheesy coagulum Apply adequate, not over acidified culture
Vibrations during incubation or cooling Avoid vibrations during incubation and cooling
Yoghurt gallert was stirred at high temperature Control the temperature during cooling of the gallert (the sensors as
well)
Filling into cups at unsuitable pH Filling of set yoghurt at pH < 5.7
Drop in temperature during filling (set) Avoid drop in temperature during filling
Possibly change cultures
6/12
Fault Reason Prevention / Measures
Over acidified Too long ripening and acidification at inadequate temperatures Keep acidification times and control them by permanent measuring of
SH or pH
Delayed or too slow cooling (surplus of lactobacilli) Application of culture with low post acidification
Cultures with strong post acidification
Storage of the yoghurt at too high temperatures Adequate cooling (control temperature sensors)
Interrupted cooling chain Keep cooling chain
Post acidification Delayed and slow cooling Improve intensity of cooling, control pH values
Timely cooling
Cultures with strong post acidification Apply cultures with less post acidification
Control storage temperature (sensors as well)
See as well item “over acidified” See as well item “over acidified”
Acidification Processing of inhibitor-containing milk Do not apply inhibitor-containing milk (inhibitor test)
disorders
Phage attack of culture and yoghurt milk after heating Do prepare the cultures in dry rooms only (contamination of ambiental
air)
Insufficient activity of the culture (phage attack) Apply phage alternative and improve cleaning of process equipment
Inadequate incubation temperatures Control temperature sensors and temperature control system
Careful cleaning and disinfection of the whole equipment
Mouldy Infection of the milk or the yoghurt culture by the air, equipment or Check for recontaminants
inadequate water
Residues of rinse water in pumps and pipes
Humid production rooms Dry production rooms and stores
Ceilings and walls, equipment and pipes are infected with moulds Disinfection of the whole equipment with adequate cleaning agents
Microbiological step-wise control of the equipment
Mould infection of the production rooms (ambient air) Laminar flow of filtrated air
Infected filling devices, tops, cups and glasses Bacteriological control of the packaging material
Infected fruit supplements Examine fruit supplements for yeasts and moulds (control specifications
Product age Avoid that shelf life is exceeded during storage in plant or market
Daily organoleptic control of those goods, which are to be despatched
Use protective cultures
See as well item “yeasty” See as well item “yeasty”
Soapy Residues of cleaning agents Adequate rinsing of the whole equipment
Inadequate cleaning agents Application of suitable and recommended cleaning agents
Insufficient rinsing of the yoghurt glasses
Old or degenerated cultures from bulk starter Apply fresh bulk starter cultures.
7/12
Fault Reason Prevention / Measures
Tallowy Sun light Prevent from exposure to light
See as well item “oily/tallowy” and “metallic” See as well item “oily/tallowy” and “metallic”
Unclean Unclean raw milk Application of clean, fresh milk (max. 48 h old)
Too much milk proteins Possibly reduce content of whey protein powder
Application of old milk powder with unclean flavour Control supplements for off-flavour
Unclean culture milk Avoid overheating of culture milk (possibly only long-term
pasteurisation)
Culture with restricted activity Do only apply fresh bulk starter or direct set
Foreign germs Control cleaning and disinfection
Permanent microbiological control
Storage of packaging material in inadequate stores Store packaging material (cups, bottles, tops) as well as milk powder,
sugar and other ingredients in dry and well-aerated rooms
No aroma Wrong cultures Change culture
Weak or old bulk starter Cultivation of new bulk starter
Dominant development of streptococci Elevate incubation temperature, control pH, change medium
Inoculum is too high Reduce inoculum
Short ripening and acidification times Prolongation of ripening and acidification times (better pH control)
Low incubation temperature Elevate incubation temperature (control temperature sensors)
Too few supplements (aroma or fruit supplements) Increase of supplement quantity
Contamination of equipment and bottles Control culture preparation and propagate new cultures
Bitter Poor war milk quality Do not process old milk (max. 48 h)
Bitter agents from feed (potatoes, leguminosas etc) Exclude feed milk
Presence of protein decomposing germs Examine raw milk for protein decomposing germs (old milk)
Old bulk starter, contaminated bulk starter Propagate new bulk starter, incrased microbiological control of the bulk
starter
Late or slow cooling (over acidification) Better supervision of acidification course
Too warm storage Control all temperature sensors in cooling and storage rooms
Long storage of yoghurt Lay down best before date.
Scorched Overheating of initial milk or culture milk Careful heating of initial milk and culture milk
Too long heating Control heating time of culture milk
Strong pre-coagulation of the milk Concentration in the vacuum
Addition of inadequate milk powder or condensed milk Do not add scorched milk powder or scorched condensed milk
Sensory control of initial milk and culture milk before propagation
See as well item “cooked flavour” See as well item “cooked flavour”
8/12
Fault Reason Prevention / Measures
Putrid Unclean raw milk Apply adequate, fresh milk (< 48 h)
Influence of feeding Test the smell of the initial milk
Poor hygiene in production plant (equipment, vats, filling devices, Control cleaning and disinfection
bottles etc.)
Residues in vats etc. Permanent microbiological control (step-wise control)
Inadequate water Permanent control of the water
Contamination with spore formers Permanent microbiological control (step-wise control)
Feed flavour, Unclean raw milk Apply adequate milk (increase control of delivered goods)
unclean
Inadequate heating of the milk Heat milk at 90 – 95 °C, 1 – 5 min
Wrong or inadequate aeration Possibly vacuum degassing
Contaminated bulk starter, old bulk starter Apply new bulk starter
Low acidification Increase propagation temperatures; increase inoculum
Cheesy Infection of the milk with protein-decomposing germs like Processing of adequate, fresh milk
Pseudomonas fluorescens
Contamination of water Control the water
Infection of bulk starter Permanent microbiological control of yoghurt culture and bulk starter
Old culture Control best before dates and storage temperatures
Inadequate heating of the milk Increase heating temperature and prolong heating
Infection via packaging material Microbiological control of yoghurt glasses, cups and lids
Interrupted cooling chain Keep cooling chain
Avoid that best before dates are exceeded (plant and market)
Cooked flavour Overheating of initial milk or culture milk Careful heating of initial milk and culture milk
Long heating Control heating time
Strong pre-coagulation of the milk Concentration in the vacuum
Addition of inadequate milk powder or condensed milk Do not add milk powder or scorched condensed milk
9/12
Fault Reason Prevention / Measures
Fermented flavour Strong infection of the raw milk by influence of feeding or low hygiene Choose adequate, fresh milk and examine it for gas formers and
standards at milking fermentation germs
Increased disinfection of the whole equipment
Control yoghurt glasses and lids
Contamination of the milk or the culture after heating with gas Heat the milk at 90 – 95 °C, 1 – 5 min
formers and fermentation germs like Bacterium coli aerogenese, milk
sugar yeasts, Betabacteria
Inadequate heating of the milk
Contaminated supplements (sugar, fruit additives) Control supplements delivered
Poor cleaning of the whole equipment incl. packaging material Increased disinfection of the whole equipment
Inadequate rinsing water Control the water
Malty Infection with malt flavour forming germs Processing of adequate, fresh milk (max. 48 h)
Inadequate raw milk with bad fermentation properties Examine the milk for its fermentation properties
Long heating of culture milk at high temperatures Do not heat the culture milk at too high temperatures (avoid brown
colouring)
Infection of yoghurt culture Examine the culture for infections
Inadequate temperatures Keep the prescribed ripening and acidification temperatures during the
whole process
Degenerations of the acidity formers in the culture Propagate fresh cultures ; microbiological and microscopic control of the
culture as well as the final yoghurt
Different treatments of the yoghurt culture or the yoghurt during the
cooling as well as during ripening and acidification process
Metallic Transfer of heavy metal (iron, cupper etc.) to the milk or the yoghurt Increase control of the milk delivered
(oxidated, tallowy) Processing of emery raw milk or milk concentrates Control all vats and the equipment that are applied in production
process
Incorporation of air by defect pumps/pipes. Exchange emery pumps, cocks etc.
Application of vats, pumps and pipes, which are not protected Control pumps, cocks etc.
against light
Inadequate cleaning agents and disinfectants Do not apply inadequate cleaning agents
Milk or yoghurt was not protected against light (tallowy) Packaging material has to protect the milk or yoghurt against light.
10/12
Fault Reason Prevention / Measures
Musty Inadequate raw milk Increase control of delivered milk (control of smell)
Inadequate, not ventilated filling and production rooms Ventilation of production rooms
Overdosification of whey protein concentrates Possible reduction f whey protein concentrates
Inadequate water for the rinsing of the equipment or poor cleaning of Permanent control and supervision of the water and the whole
equipment and vats and yoghurt glasses production plant incl. yoghurt glasses and lids
Residues of rinse water or milk in equipment Microbiological step-wise control of the whole equipment
Application of packaging material and raw materials, which are not Control shelf life of the raw materials applied
stored correctly Raw materials and packaging material have to be stored under dry
conditions
Oily/tallowy This type of fault may occur once in connection with a “metallic”
flavour
Negative influence of light, especially direct sun light or addition of Protect yoghurt against direct sun light during the whole production
vitamins process until delivery to the consumer
Protection against light by packaging material
Adequate raw milk
Oxidation Old milk Do exclusively apply fresh milk, max. 48 h after milking (test the smell)
Raw milk with off-flavour (lipasis) Test the taste of the initial milk and the raw materials applied
Leaky valves and screwed connections of pipes Control valves and connections regularly and exchange them, if
necessary
Infection of heated yoghurt or culture milk (mixture of raw and past. Careful cleaning and disinfection of equipment
milk)
Deep homogenisation temperature Control homogenisation temperature (> 60 °C)
Rancid milk powder Test milk powder and other raw materials sensorically
Flat Weak culture (culture does not form enough yoghurt flavour) Apply cultures with more aroma
Low inoculum Elevate inoculum
Short incubation time Prolonged incubation by suitable cultures; possibly increase
temperature
Low incubation temperatures Do not cool the yoghurt too early
Dominant growth of streptococci Permanent control of bulk starter
Yeasts and moulds See item “yeasty” and “mouldy” See item “yeasty” and “mouldy”
on the surface
11/12
Fault Reason Prevention / Measures
Yeasty Contaminated equipment (vats, pipes, filling devices, bottles etc) Permanent disinfection and microbiological step-wise control of the
equipment and the water
Inadequate water for cleaning of equipment Microbi8ological control of the water
Infection of the culture with yeasts, especially Kahm- and Torula- Permanent microbiological and microscopic control of the culture
yeasts
Possible infection of the yoghurt in the mixing vat Daily organoleptic evaluation of the culture and final products
Control ceilings and walls as well as the floor in the production plant and
the filling rooms
Avoid condense water ceilings
Infection of fruit supplements Control fruit supplements for yeasts/moulds (specifications)
Infection of the ambient air by contaminated air Rinse vats and filling devices with sterile air or nitrogen
Old yoghurt Control best before dates
Apply protective cultures
12/12
