FACULTY AGROPROCESSING

DEPARTMENT OF DAIRY PROCESSING TECHNOLOGY

COURSE TITLE: TRADITIONAL AND NEW TECHNOLOGY

YOGURT PROCESS

NAME…………………………………………….IDNO

DARAJE ABDETA…………………………….1164/13

BY: DARAJE ABDETA

. ADVISOR: ___________________

ADDIS ABABA

DEC 2023

TABLE CONTENT
Table of Content…………………………………………………..I

Acknowledgment…………………………………………………………..II

Abstract………………………………………………………………………..I.II
Abbreviation……………………………………………………..…..V

1Introduction…………………………………………………………….……....1

1.1.Objective………………………………………………………………….…..2
1.2Generalobjective…...............................................................................................2

1.3 Specific objective:……………………………………………… …………..….2

3.LiteratureReview…………………………………………………………………….3

3.1.1ReviewOn Manufacturing Of GoodQualityYoghurtAnd Assessing…………….3

3.2 Symbiotic Growth of Yoghurt Starter Bacteria…………………….……...4

3.3 Role of Starters in Yogurt Production……………………………………..5
3.4 lactic acid production…………………………………………………..………..…6

3.4 lactic acid production…………………………………………………….…

3.5 Traditional method of yogurt making……………………………………………….8

3.6 Industrial method of yogurt making…………………………………………..7

3.7 Varieties in yogurt presentation…………………………………………………...8

4 factor that alter the quality of yogurt………………………………………9

4.1 General Yogurt Processing Steps…………………………………………...12

4.2 Set Yogurt Manufacturing Processes …………………………………………13

4.3 Packaging Materials for Yogurt…………………………………………………...15

5 conclusion ………………………………………………………………………………22

6.Recommendations…………………………………………………………………23

7 References …………………………………………………………………………24

I
Acknowledgment

I thank God who protected and kept me alive to complete this work according to his plan and
will. I would like to express my deepest gratitude to my advisor,Dr. Ganesh Kumar, for his
suggestions, advice and encouragement throughout the work. I would also like to thank all staff
members of Agro processing Department for their support.

II

Abstract
Yogurt is one of the oldest fermented dairy products worldwide. It is commonly made by
fermenting domesticated bovine's milk using a 1:1 ratio of lactic acid producing bacteria,
Lactobacillus bulgaricus and/or acidophilus and Streptococcus thermophilus under a controlled
temperature and environmental conditions. For improving the marketability quality of yogurt, an
ideal yogurt should have better flavor and texture as well as being manufactured in a reducing
cost through better application of transit. A number of studies have focused on the effect of the
starter culture, fermentation process, probiotics, prebiotics and transportation, in the overall
quality, flavor, sensory, and texture of the yogurt. This review generally stresses upon the
different difficulties and advantages being faced while manufacturing yogurt, health benefits of
yogurt, innovations in transportation technology, how the presence of prebiotics are impacting
the dairy industry, and the yogurt as a whole.

III
 Abbreviations

LB - Lactobacilus

ST -striptococcus

HTST- High tempreture short time

SNF -Sold not fat

PH -Power of hydrogen

V
1 Introduction

Yogurt is a semisolid fermented product made from a standardized milk mix by the activity of a
symbiotic blend of Streptococcus salavarius subsp. thermophilus and Lactobacillus delbruechii
subsp. bulgaricus cultures. For the sake of brevity, we shall term the yogurt culture organisms as
ST and LB. Milk of various mammals is used for making yogurt in various parts of the world.
However, most of the industrialized production of yogurt uses cow's milk. It is common to boost
the solids-not-fat fraction of the milk to about 12% with added nonfat dry milk or condensed
skim milk. The increased protein content in the mix results in a custard like consistency
following the fermentation period (Hui, 1992). The typical composition and nutrient profile of
yogurt are shown in Table below. In general, yogurt contains more protein, calcium, and other
nutrients than milk, reflecting extra solids-notfat content.

Yogurt is a food produced by bacterial fermentation of milk.[2] The bacteria used to make yogurt
are known as yogurt cultures. Fermentation of sugars in the milk by these bacteria produces
lactic acid, which acts on milk protein to give yogurt its texture and characteristic tart flavor.[2]
Cow's milk is the milk most commonly used to make yogurt. Milk from water buffalo, goats,
ewes, mares, camels, and yaks are also used to produce yogurt. The milk used may be
homogenized or not. It may be pasteurized or raw. Each type of milk produces substantially
different results.

Yogurt is produced using a culture of Lactobacillusdelbrueckii subsp. bulgaricus and

Streptococcus thermophilus bacteria. In addition, other lactobacilli and bifidobacteria are
sometimes added during or after culturing yogurt. Some countries require yogurt to contain a
specific amount of colony-forming units (CFU) of bacteria; in China, for example, the
requirement for the number of lactobacillus bacteria is at least 1 million CFU per milliliter.

To produce yogurt, milk is first heated, usually to about 85 °C (185 °F), to denature the milk
proteins so that they do not form curds. After heating, the milk is allowed to cool to about 45 °C
(113 °F).[4] The bacterial culture is mixed in, and a warm temperature of 30–45 °C (86–113 °F)
is maintained for 4 to 12 hours to allow fermentation to occur, with the higher temperatures
working faster but risking a lumpy texture or whey separation.
2 objectives

2.1 General Objective of the review work

To modify traditional yoghurt prococessing by new tchnology

2.2 The specific objective of this review work is

to give insight knowledge about the production of yogurt;

To discuss the main ingredients, main unit operation and equipment‟s used in yogurt production.

The microbial and chemical defects of yogurt and prevention mechanisms will also cover in this
review work.

Moreover quality and safety of yogurt: before process, during process and after process will
touch and described in this review work
3 LITERATURE REVIEW

3.1 Review On Manufacturing Of Good Quality Yoghurt And Assessing Its Ingredient

Yogurt is the food produced by culturing one or more of the optional dairy ingredients with a
characterizing bacterial culture that contains the lactic acid-producing bacteria, Lactobacillus
bulgaricus and Streptococcus thermophilus. One or more of the other optional ingredients
described below may also be added. All ingredients used are safe and suitable. Yogurt, before the
addition of bulky flavors, contains not less than 3.25% milkfat and not less than 8.25%
milksolids- not-fat, and has a titratable acidity of not less than 0.9%, expressed as lactic acid
(Hui, 1992).Yogurt is a fermented milk product that contains the characteristic bacterial cultures
Lactobacillus bulgaricus and Streptococcus thermophilus.

All yogurt must contain at least 8.25% solids not fat. Full fat yogurt must contain not less than
3.25% milk fat, lowfat yogurt not more than 2% milk fat, and nonfat yogurt less than 0.5% milk.
The full legal definitions for yogurt, lowfat yogurt and nonfat yogurt are specified in the
Standards of Identity listed in the U.S. Code of Federal Regulations (CFR), in sections 21 CFR
131.200, 21 CFR 131.203, and 21 CFR 131.206, respectively.The two styles of yogurt
commonly found in the grocery store are set type yogurt and swiss style yogurt. Set type yogurt
is when the yogurt is packaged with the fruit on the bottom of the cup and the yogurt on top.
Swiss style yogurt is when the fruit is blended into the yogurt prior to packaging.(Hui, 1992)

For thousands of years yoghurt has been produced throughout the Middle East. Although no
records are available regarding the origin, yoghurt is most likely evolved from the nomadic
people living in the Middle East part of the world. The production of milk in the Middle East
was seasonal, being restricted to a few months of the year. The main reason for this limited
availability of milk was the lack of intensive animal production. Farming was in the hands of
nomadic people who moved from one area to another. Hence they were in wilderness away from
cities where they could sell their animal produce. Another factor was the climate in the Middle
East. At as high as 40°C, milk sours immediately under primitive conditions. The animals were
hand-milked, no cooling of milk was possible, and contamination was unavoidable. Under these
conditions transportation and keeping of milk for a long time was not possible. However, the
nomadic people devised a fermentation process, which as a result led them to keep milk for long
times. It was heating the milk over an open fire (Tamime and Robinson, 1985).

Heating milk resulted in;

- Concentration of milk
- Modification of casein in milk
- Selection of thermophilic lactic acid bacteria resistant to high temperatures
- Destruction of pathogenic microorganisms
- Fermentation at slightly higher temperatures during cooling, and enrichment of thermophilic
lactic acid bacteria.

Soured milk with thermophilic lactic acid bacteria became the preservation method of milk, and
other communities learnt of this technique. As a result the product “yoghurt”, coming from the
Turkish name “Yogurt”, has been widely accepted (Tamime and Robinson, 1985). Specific
bacteria cultures, known as starters, are used for manufacturing of fermented milk products.
Yoghurt is made from milk by the protocooperative action of well known starters,
namely Lactobacillus delbrueckii spp. bulgaricus and Streptococcus thermophilus. They lead to
coagulation of milk by lactic acid fermentation and other products give the characteristic
properties, such as acidity, aroma, and consistency. Traditional method, using part of a previous
batch to inoculate a new batch, have been used for centuries. Such cultures lead to variable
performance, however industrial production needs consistency. The method of choice is the use
of bacterial strains with known physiological, biochemical and genotypic characters.

3.2 Symbiotic Growth of Yoghurt Starter Bacteria

Milk fermentation for yoghurt is done by the addition of thermophilic lactic acid bacteria for
thousands of years. This is about the associative growth of microorganisms in growth medium.
Symbiotic growth of thermophilic lactic starter microorganisms is based on their metabolic
compatibility. It was demonstrated by Robinson at 2002; inoculation of mixed cultures results in
the production of lactic acid >10 g/L in 4 hours while 2 g/L and 4g/L lactic acid was obtained by
the fermentation of isolated pure cultures of Lactobacillus bulgaricus and Streptococcus
thermophilus. Protocooperative growth of Lactobacillus bulgaricus and Streptococcus
thermophilus considerably gives better results due to cell densities, the specific growth rates,
lactic acid production ratesStreptococcus thermophilus grows more rapidly than Lactobacillus
bulgaricus initially and begins to produce lactic acid. Lactic acid production results in a decrease
in the pH of the medium. While Streptococcus thermophilus grows, it releases CO2 from the
breakdown of urea and formic acid. Streptococcus thermophilus depletes the oxygen in the
medium and this causes the oxidation-reduction potential more favorable for the growth
of Lactobacillus bulgaricus.

The increased acidity, CO2, formic acid and depletion of O2 stimulates the growth of bacilli
which is more acid tolerant than Streptococcus thermophilus. Besides having a stimulatory effect
on bacilli, the growth of Streptococcus thermophilus depends on the growth of Lactobacillus
bulgaricus. Lactobacillus bulgaricus has higher proteolytic activity than Streptococcus
thermophilus. The proteolytic enzymes of Lactobacillus bulgaricus degrade casein with the
liberation of low molecular weight peptides and amino acids which have stimulatory effect on
the growth of Streptococcus thermophilus (Rajagopal and Sandine, 1990).

Both two microorganisms can grow at a temperature of 42-43ºC, and the optimum temperature
for symbiotic growth is 42ºC. Since the optimum growth temperature for Streptococcus
thermophilus is 37ºC and 45ºC for Lactobacillus bulgaricus, increasing the temperature above
from 42ºC, the growth of lactobacilli will be favored while the temperatures below 42ºC results
in increased growth of streptococci. Either case is resulted in a deviation in the ratio of cocci to
bacilli, for the optimum yoghurt the ratio should be 1:1 (Shah, 2003).

3.3 Role of Starters in Yoghurt Production

The usage of carefully selected strains as starter cultures or co-cultures in fermentation process
can help to achieve in situ expression of the desired property and to maintain a product with
good quality characteristics such as aroma, taste, flavour. Starter culture inoculation into the milk
to during the production of yoghurt leads to production of lactic acid, aroma compounds,
exopolysaccharides and inhibitor compounds which give specific characteristics to the end
product.
 3.4 LACTIC ACID PRODUCTION

Lactic acid can be produced by homofermentative and heterofermentative ways in D (-) and L
(+) forms. Since L (+) lactic acid is produced during the early fermentation, D (-) type is began
to be produced after about second hour of fermentation and increase continuously. Typical
yoghurt flavour is caused by lactic acid which imparts an acidic and refreshing taste (Chaves et
al., 2002). Lactic acid has an effect on regulation of hydrolysis of casein and adsorption of some
amino acids, peptides, lactose and minerals (Akın, 2006).

3.5 PRODUCTION OF YOGHURT

RAW MATERIALS

In yoghurt preparation the following essential materials are use in processing the product: milk
or concentrated skimmed or partly concentrated skimmed milk or milk product and the starter
culture Lactobacillus bulgaricus and Streptococcus thermophilus. In. the absence of pure culture
one to two spoonful of commercially purchased yoghurt can be used for the inoculation. Also,
there are optional ingredients like milk powder, skimmed milk powder, flavour, colours, sugar,
wheat, edible casein, preservatives, stabilizers (gelatin, locust bean gum, pectin, starch) etc.

3.4 LACTIC ACID PRODUCTION

They include refrigerator or cooler, boiler or heater, thermometer.

YOGHURT PREPRATION PROTOCOL

- Homogenized whole or low fat milk

- Addition of skim milk powder
- Heat treatment at 80-90̊C for 30 min
- Cooled to 40-45̊C
- Culture added (2%) at 40-45̊C
- Packaging
- Incubation at 42°C
- Storage at 4̊C
3.5 Traditional method of yoghurt making

The milk is evaporated to 1/3 to 1/4 water content so that it attains the required concentration.
Alternatively, 4-5% non-fat dried milk (NFDM) can be added to the whole milk. It is heated to
82-93°C for 30 minutes. Then it is cooled to 42-43°C and inoculated with 2-3% starter culture
(Lactobacillus bulgaricus and Streptococcus thermophilus).Then the milk is incubated at 42-
43°C for 3 hours or until a titrable acidity of 0.75% lactic acid or coagulation occurs. The
product is chilled to 5°C. Further acidity of 0.9% lactic acid may develop while the product is
being chilled. The product can be stored satisfactorily for 1-2 weeks at 5°C.

3.6 Industrial method of yoghurt making

The desired quantity of milk is weighed and heated to 80-90°C for 15-20 minutes. Then it is
cooled to 45-48°C.Two to three percent of yoghurt culture is added to the milk and mixed well.
The milk is kept in clean and sterilized containers for setting. The milk in the container is
incubated at 45°C until the coagulation is firmer. The product is removed from the incubator and
kept at 5°C until distributed to the consumers. The equipment are cleaned and kept ready for the
next batch of operation.
3.7 Varieties in yoghurt presentation

Yoghurt has been described as a notoriously balanced food, containing almost the nutrients
present in milk but in a more assimilable form. The can be produced from whole or skimmed
milk (Ojokoh, 2006). There are large ranges of flavors enhancer available commercially that can
be used in the production of yoghurt and yoghurt is typically categorized as follows:

SET YOGHURT: This type of yoghurt is incubated and cooled in the final package and is
characterized by a firm Jelly-like texture.
2. STIRRED YOGHURT: This type of yoghurt is incubated in a tank and the final coagulum is
"broken" by stirring prior to cooling and packaging. The texture of stirred yoghurt will be less
firm than a yoghurt not stirred which is somewhat like a very thick cream. There is some slight
reformation of the coagulum after the yoghurt has been packed, however this is slight and cannot
be relied upon.
3. DRINKING YOGHURT: This type of yoghurt is very similar to stirred yoghurt, having the
coagulum "broken" prior to cooling. In drinking yoghurt, the agitation used to "break" the
coagulum is severe. Little care is applied if any reformation of the coagulum will reoccur after
packing.
4. FROZEN YOGHURT: This is inoculated and incubated in the same manner as stirred
yoghurt. However, cooling is achieved by pumping through a whipper/chiller/freezer in a fashion
similar to the cream. The texture of the finished product is mainly influenced by the
whipper/freezer and the size and distribution of the ice crystals produced.
5. CONCENTRATED YOGHURT: This type is inoculated and fermented in the same way as
stirred yoghurt, following the "breaking" of the coagulum. The yoghurt is concentrated by
boiling off some of the water. This is often done under vacuum to reduce the yoghurt often lead
to protein being totally denatured and producing rough and gritty texture. This is called strained
yoghurt due to the fact that the liquid that is released from the coagulum upon heating used to be
"strained" off in a manner similar to making of soft cheese.
6. FLAVOURED YOGHURT: Yoghurt with various flavours and aromas has become very
popular. The following are usually added at or just prior to filling into pots. Common additions
are fruits or berries, usually as a pure or as whole fruit in syrup. These additives often have" as
much as 50% sugar in them. However, with the trend towards healthy eating gained momentum
many manufacturers offer a low sugar and low fat version of their products. Low or no sugar
yoghurts are often sweetened with saccharin or more commonly aspartame. The use of a "fruit
sugar" in the form of concentrated apple juice is sometimes found as a way of avoiding'
"additional sugar" on the ingredients declaration. This tends to be a market ploy and has no real
added benefits.

4 FACTOR THAT ALTER THE QUALITY OF YOGHURT

MILK QUALITY: The milk used for yoghurt manufacture should be of the highest bacterial
quality available. It should also have an absence of any material that will impede or prevent the
growth of the starter microorganism, (anti-biotics, preservative, disinfectants, and
bacteriophages).
2. BACTERIOPHAGES: Bacteriophages are a group of virus that attacks the yoghurt starter
organisms, a whole range of defects can be attributed to the action of this bacteriophage.
Bacteriophage normally referred to just as "phage" are the most likely cause of long or never-
ending incubations. Large manufacturers that have laboratory facilities to check incoming milk
will often eliminate the possibilities of other starter inhibiting substances but "Phages" are
usually found in the drains and floor gullies of a dairy producing any cultured product, poor
hygiene and lack of general housekeeping increase the risk.
3. STARTER CULTURE: The starter culture is the term generally applied to organisms used to
ferment a cultured product (Cheese, Yoghurt, and Kefir). The micro organisms selected for this
purpose need to produce the desired effect in the product. For normal commercial yoghurt the
starter must be capable of fermenting lactose and producing lactic acid, little if any carbon
dioxide is required and the flavour and aroma must be clean and fresh. Traditionally when a
suitable starter organism had been found on a large quantity would be grown in a suitable
nutrient medium and small quantities would be used to inoculate each new batch of yoghurt. This
technique with a main batch of starter culture is often referred to as using "bulk starter". The use
of a bulk starter is becoming increasingly uncommon amongst commercial producers, mainly
because of the risk of "Phage" attack on the bulk starter, and the subsequent lost time while a
new batch of starter organisms are prepared. A technique often referred to as Direct Vat
Inoculation (DVI) is becoming the industry norm. DVI involves inoculating the yoghurt mix
directly with a very large number of freeze dried starter organisms. The advantage of relative
immunity to “Phage” attack for outweighs the slightly longer incubation time required with this
technique.
4. FAT PERCENTAGE: The percentage of fat in the final yoghurt has a significant effect on
the "mouth feel", the normal range of fat content is from 0.5% to about 3.5%, however levels as
low as 0% and as high as 10% are found in some specialty products.

The main (starter) cultures in yogurt are Lactobacillus bulgaricus and Streptococcus
thermophilus. The function of the starter cultures is to ferment lactose (milk sugar) to produce
lactic acid. The increase in lactic acid decreases pH and causes the milk to clot, or form the soft
gel that is characteristic of yogurt. The fermentation of lactose also produces the flavor
compounds that are characteristic of yogurt. Lactobacillus bulgaricus and Streptococcus
thermophilus are the only 2 cultures required by law (CFR) to be present in yogurt.Other
bacterial cultures, such as Lactobacillus acidophilus, Lactobacillus subsp. casei, and Bifido-
bacteria may be added to yogurt as probiotic cultures. Probiotic cultures benefit human health by
improving lactolactose digestion, gastrointestinal function, and stimulating the immune system.
4.1 General Yogurt Processing Steps

• Adjust Milk Composition & Blend Ingredients

• Pasteurize Milk

• Homogenize

• Cool Milk

• Inoculate with Starter Cultures

• Hold

• Cool

• Add Flavors & Fruit

• Package

Starter Culture

The starter is a critical ingredient in yogurt manufacture. The rate of acid production by yogurt
culture should be synchronized with plant production schedules. Using frozen culture
concentrates, incubation periods of 5 hr at 45°C, 11 h at 32°C, or 14 to 16 h at 29 to 300C are
required for yogurt acid development. Using bulk starters at 4% inoculum level, the period is 2.5
to 3.0 h at 45°C, 8 to 10 h at 32°C, or 14 to 16 h at 20 to 30°C.

The production of flavor by yogurt cultures is a function of time as well as the sugar content of
yogurt mix. Acetaldehyde production in yogurt takes place predominantly in the first 1 to 2 h of
incubation. Eventually, 23 to 55 ppm of acetaldehyde is found in yogurt. The acetaldehyde level
declines in later stages of incubation. Yogurt flavor is typically ascribed to the formation of lactic
acid, acetaldehyde, acetic acid, and diacetyl. The milk coagulum during yogurt production results
from the drop in pH due to the activity of the yogurt culture.

The streptococci are responsible for lowering the pH of a yogurt mix to 5.0 to 5.5 and the
lactobacilli are primarily responsible for further lowering of the pH to 3.8 to 4.4 Attempts have
been made to improve the viscosity and to prevent synerisis of yogurt by including a slime-