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Dairy Products 2 Yoghurt

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Dairy Products 2 Yoghurt Dairy Products 2 Yoghurt A webinar presented by: Dr Andy Bowles Attendee Notes 07/04/2020 Dairy Products 2 Yoghurt 1 This webinar will consider Introduction Typical process Types of yoghurt Technology Common hazards and controls 2 This webinar will consider Introduction Typical process Types of yoghurt Technology Common hazards and controls 3 1 07/04/2020 Introduction Most common fermented milks: Yoghurt Kefir 4 Yoghurt - Codex definitions Yoghurt: Symbiotic cultures of Streptococcus thermophilus and Lactobacillus delbrueckii subsp. bulgaricus. 5 Kefir - Codex definition Starter culture prepared from kefir grains: Lactobacillus kefiri, Leuconostoc spp, Lactococcus spp and Acetobacter spp. Grains contain yeasts: lactose fermenting Kluyveromyces marxianus non-lactose-fermenting Saccharomyces unisporus, Saccharomyces cerevisiae and Saccharomyces exiguus. 6 2 07/04/2020 Factors affecting quality of yoghurt Choice of milk Milk composition Additives Homogenisation Heat treatment Choice of culture Process flow 7 Choice of milk High quality milk Free from: Antibiotics Bacteriophages Residues 8 Milk composition Fat 0 – 10% Typical 3.5% Solids not Fat (SNF) Increased by skim milk powder, whey, lactose 9 3 07/04/2020 Additives Common other ingredients: Sweeteners Stabilisers Flavourings and colours Fruit and other ingredients 10 Homogenisation/heat treatment Effect of homogenisation pressure and heat treatment on viscosity of fermented milk 35 30 25 20 15 Viscosity 10 5 0 0 7.5 15 30 Pressure MPa Past Milk High Heat Milk 11 Choice of culture Commercially available Frozen Freeze dried Influence Taste Mouthfeel Acidity 12 4 07/04/2020 Process flow Product influenced by Nature Order of process. 13 Yoghurt Introduction Typical process Types of yoghurt Technology Common hazards and controls 14 Yoghurt – typical process Milk for yogurt production pasteurised: 85°C for 30 mins 95°C for 10 mins High temperatures used: To allow starter culture to work Coagulation of whey proteins Enhanced viscosity and texture 15 5 07/04/2020 Yoghurt – typical process Milk commonly homogenised to stabilise components. Starter culture added 16 Yoghurt – typical process Starter culture = LB + ST When used together, produce rapid acidity Fermentation ensues producing: Lactic acid Acetic acid Acetaldehyde 17 Yoghurt – typical process Temperature maintained at 43°C for 4-6hrs When titratable acidity + 0.85-0.90% Cooled to 5-22°C, agitated Fruit etc added Packaged 18 6 07/04/2020 Yoghurt Introduction Typical process Types of yoghurt Technology Common hazards and controls 19 Types of yoghurt Main types Stirred yoghurt: incubated in tanks and cooled before packing, Set yoghurt: incubated and cooled in the package. Drinking yoghurt: Coagulum is broken down to a liquid before being packed, Frozen yoghurt: incubated in tanks and frozen like ice cream Greek yoghurt or strained yoghurt: incubated in tanks, concentrated and cooled before packed. 20 Stirred yoghurt Incubation Treated milk + culture 42-43˚C 4 – 5 hours Incubation Cooling 15 - 22˚C Cooling Stops acid development Flavouring Flavouring Heat treated fruit Packing 21 7 07/04/2020 Set yoghurt Incubated in pack Treated milk + culture Rapidly cooled Flavouring Packing Incubation Cool 22 Drinking yoghurt Low viscosity Reduced SNF Milk + culture Stabiliser added pectin Incubation mixing Heat treatment Packing 23 Frozen yoghurt Commonly: Milk/Mix/Culture Mix yoghurt with ice cream mix Incubation Ferment ice cream mix Freezing Packing Hardening 24 8 07/04/2020 Greek yoghurt/strained yoghurt SNF increased Skim milk + culture After fermentation Drain whey Incubation Concentration Mixing Packing 25 Yoghurt Introduction Typical process Types of yoghurt Technology Common hazards and controls 26 (c) ABC Food Safety Ltd 27 9 07/04/2020 (c) ABC Food Safety Ltd 28 (c) ABC Food Safety Ltd 29 30 10 07/04/2020 Yoghurt Introduction Typical process Types of yoghurt Technology Common hazards and controls 31 HACCP Most likely problems Poor management Cooling Incubation Contamination Fruit etc Packaging Packing 32 Summary Introduction Typical process Types of yoghurt Technology Common hazards and controls 33 11 07/04/2020 Dr Andy Bowles [email protected] www.abcfoodlaw.co.uk @abcfoodlaw 01603 319863 34 12 section V- HACCP-based Plans FERMENTED MILK PRODUCTS This family of fermented milk products includes kefir, yoghurt, buttermilk, ymer, filmjölk, rjażenka and others - whose common feature is their acidification by lactic acid bacteria. There are two ways of making fermented milk products: 1. Set type method. Milk is mixed with ingredients (sugar, fruits, flavours, colourings etc.) then inoculated with starter cultures, filled into its final packaging before incubation and, finally, cooling. 2. Stirred type method. Milk is inoculated with starter cultures and incubated in a fermentation vessel. When a required pH has been reached, the coagulum is cooled and mixed with ingredients before filling and packing. Depending on the technology used, the producer should determine the exact sequence of steps appropriate to their product. Process step to Checking/Monitoring Why do we have to be careful? Preventive actions Corrective actions monitor procedure Filling the vat C, M: Contamination of milk by processing Ensure that equipment is always Organoleptic inspection. Repeat cleaning and/or disinfection. equipment and utensils (vats, stirrers, buckets, clean. Never put small pieces of Rinse thoroughly with potable water. scoops etc.) Dirty equipment can cause equipment directly on the floor. Adjust cleaning procedure. If it is a contamination of milk with pathogenic (1) (2) recurrent issue review training of bacteria. Residues of cleaning agents can staff. contaminate milk. Pasteurisation** (3) M: Fermented milk products are very sensitive Provide adequate facilities for Measurement of Re-pasteurise the milk if the required to the development of pathogenic bacteria. pasteurisation. temperature and time. temperature drops below the limit. Some bacteria can survive inadequate Change or improve pasteurisation pasteurisation. equipment. Cooling to M: Possibility of recontamination due to too Ensure quick cooling time using Measurement of Change or improve cooling incubation long cooling time or unsuitable cooling effective cooling equipment. temperature and time. equipment temperature equipment. Addition of starter M: Contamination of milk during inoculation Use only active starters of Visual inspection: check Reject packs of poor quality, cultures (4) due to poor quality of starter bacteria or known origin or those with a appearance and expiry abnormal appearance and smell. inadequate handling by the production staff. certificate of conformity and date. Adjust handling and storage suitable for food-use. Store and procedures, change the supplier. handle hygienically. 75 section V- HACCP-based Plans FERMENTED MILK PRODUCTS Process step to Checking/Monitoring Why do we have to be careful? Preventive actions Corrective actions monitor procedure Addition of* fruit, M, C, P: Possibility of contamination Use only tools cleaned and/or Visual and organoleptic Reject ingredients and packaging of colourings, during additions of ingredients. disinfected after each dosing. Use only inspection. suspect quality, abnormal flavourings etc. (5) ingredients obtained from a reputable appearance and smell. supplier or known source and checked upon delivery and before use. Heat-treat Adjust handling and storage herb mixes or fruit where the source and procedures, change the supplier harvesting conditions are not known. Incubation* M: Acidification if slower than Ensure good technical condition of Visual and organoleptic Reject products with unusual smell expected according to the recipe can process facilities: (incubation vessels inspection and/or taste allow development of harmful or chambers) Maintain appropriate microorganisms. time and temperature, according to Monitoring of Adjust incubation parameters the given technology acidification or pH measurement Generally recommended value: final acidity pH ≤ 4,5 Cooling of the M: Possibility of development of Ensure rapid cooling of the products Measurement of Maintain and/or replace cooling product harmful microorganisms because of temperature and time. equipment long and slow cooling. Packaging M, C, P: Possibility of contamination Clean and/or disinfect filling and Visual inspection. Reject packages if damaged or of by packaging machines, packaging packaging lines after each use. poor quality, material, production staff or the Keep packages in dry and clean place, packing environment e.g. by airborne protected against pests. Carefully clean Maintain packaging equipment in a fungi. reusable packaging. Minimise air good state of repair. circulation; close doors and windows If it is a recurrent issue review and turn off fans if not required. training of staff. * According to a specific technology, these steps may occur in different order. ** This step is strongly recommended but not compulsory See Also: 1) GHP cleaning. 2) GHP Disinfection 3) HACCP-based Plan Milk Collection, Storage and Treatment. 4) GMP Cultures. 5) GMP Additions to the milk and curd 76 .
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