A Definitive Guide to Yoghurt Production

Yoghurt is a product made from fermented milk with the characteristics of bifidobacteria. Many factors influence the bifidobacteria concentration in the human digestive system, Yoghurt being one of them. In this blog, we will walk through the different types of yoghurts and the processing technologies used to understand the current trend in the global yoghurt market.

History of Yoghurt Production

The term ‘Yoghurt’ is derived from the Ottoman Turkish word ‘yoğurt’ which translates to be curdled or coagulated; to thicken. Yoghurt is seen as having footprints dating back to ancient times and being an important part of the daily diet. Yoghurt’s industrialization first occurred in 1919 by Isaac Carasso in Barcelona, Spain. He started his small business in Spain and later expanded it in the United States under the name Dannon. In 1933, Radlická Mlékárna Dairy patented another type of yoghurt: Yoghurt with added fruit jam.

Benefits of Yoghurt Processing

A mix of Lactobacillus delbrueckii subsp. bulgaricus and Streptococcus thermophilus bacteria is considered to serve various health benefits, not just today but from ancient times. This microflora of yoghurt improves gut health, which in turn helps in better digestion. Other than this, benefits yoghurt has:

Different types of yoghurt provide different types of health benefits to us, with a few improving your gut health and a few preventing any severe infections.

Difference Between Yoghurt and Curd

Yoghurt and curd are both popular fermented dairy products, but they differ significantly in their origins, production processes, and bacterial cultures used. The basic difference between the both is their method of production. Preparation of yoghurt requires adding live strains of two bacteria Lactobacillus bulgaricus and Streptococcus thermophilus whereas, curd can be made at home simply by curdling the milk. Yoghurt requires the milk to be pasteurized at 90°C with a holding time of 5-10 minutes and curd is usually warmed to a lower temperature of 30-40°C.

While both yoghurt and curd are fermented milk products, they are distinct in several key ways. Yoghurt is typically made with specific bacterial cultures and a controlled fermentation process, resulting in a consistent, tangy product. Curd, on the other hand, is often made with natural or less standardized bacterial cultures and a simpler fermentation process, leading to a milder, more variable product. Both have unique places in culinary traditions around the world.

Different Types of Manufacturing Yoghurt

Yoghurt being a fermented milk product, the type of milk used to produce yoghurt characterises what type of yoghurt is being made. There are different types of yoghurt available on the market, like:

These different types of yoghurt making process require different incubation methods and temperatures depending on their viscosity.

Yoghurt production is a relatively simple process as compared to other dairy products. The main ingredient used in the preparation of yoghurt is milk, and the type of yoghurt depends on the type of milk used. For full-fat yoghurt, whole milk is used, whereas for low-fat yoghurt, low-fat milk is used, and for zero-fat or no-fat yoghurt, skimmed milk is used.

Basic Yoghurt Process Technology

The basic process to manufacture yoghurt is to add milk powder or milk concentration, pasteurisation, cooling, and inoculation with starter bacteria. This is the basic process of preparing yoghurt, also known as dahi.

The yoghurt process starts with first handling and storing the milk received from the dairy. Then the milk further proceeds for standardisation, as in yoghurt the fat percentage differs from 0.5% to 3.5%, whereas the SNF (solids not fat) values present are much higher, i.e., around 8.5% to 9%. These SNF values are different for different types of yoghurt. While standardizing the milk, milk powder or milk concentration is being added; both of these are common practices, but in India, adding dry powder to solidify is a common practice. After standardization, milk goes in for cooling and then pasteurization at 90 °C for 5 to 10 minutes. Yoghurt milk is pasteurized at a higher temperature for protein denaturalization. Along with this, homogenization and deaeration also take place to achieve a smooth texture for the yoghurt. Now, after the milk gets pasteurized, it's stored in a pasteurized milk storage tank at 4 °C. Further, as per requirement, the milk is transferred to a heating tank, and the milk gets heated from 4°C to 45°C. After heating, the milk is further sent for inoculation.

*Image representation of the process

This is the basic yoghurt processing method used. Post-inoculation, the process changes for different types of yoghurts.

Processing Technology Used for Different Types of Yoghurt Production

Yoghurt production involves several key processing technologies that vary depending on the yoghurt that is being produced.

Types of yoghurt and their processing technologies:

Each type of yoghurt requires specific adjustments and technologies to achieve its unique texture, flavour, and consistency. The choice of technology depends on the desired final product and production scale.

*Image representation of the process

Neologic Engineers provides equipment that adds dry powder to milk without adding unnecessary air. We also supply a sophisticated system for milk concentration by way of RO.

Quality Control and Challenges in Handling Viscous Yoghurt

In the yoghurt market, quality and texture are of utmost importance and product viscosity is its correlated parameter. Yoghurt is usually consumed in a semi-solid state but with changing trends, consumers demand less viscous yoghurt. Adding texture to the yoghurt is an intricate task as it affects the viscosity of the yoghurt. Producers of processed yoghurt need to ensure that their yoghurt processing lines are of high quality enabling continuous monitoring of yoghurt’s texture and viscosity.

Yoghurt manufacturers often face challenges with the ever-changing nature of yoghurt consumption. Consistency in yoghurt production is the first challenge. Every producer wants the same level of quality in their product. To ensure consistent end product qualities, within and between batches, it is imperative to handle all of the yoghurt in a line in the same manner.

A few producers even face the challenge of plant inflexibility. Now yoghurt processing lines require the capability to produce different kinds of yoghurts, ranging from high viscous to low viscous along with different fat levels and lactose-free variants.

There are quality assurance parameters of the yoghurt set that check the characteristics of yoghurt including appearance, texture and taste. Certain factors affect these characteristics resulting in low-quality produce.

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Factors affecting the quality of yoghurt

Any deviation from the set quality assurance parameters causes a defect in the final product. Various factors that affect the quality of yoghurt are:

Growth Potential of The India Yoghurt Market

With its natural high-protein content, microbial properties, and low-fat content, Yoghurt has gained substantial popularity among health-conscious consumers. With a consistent growth rate, the India Yoghurt Market is expected to grow annually by 8.97% (CAGR 2024-2029).

Increasing population, rising incomes, and improving standards of living are resulting in the expected average consumption per person going up to 12.4 kg in 2024. The revenue of the India Yoghurt Market in 2024 is expected to be US$32.83bn. In the case of the Retail Yoghurt market, players like GCMMF, Mother Dairy, Nestle India and Parag Milk Foods have held more than 50% of the market.

With the rapidly rising demand for yoghurt, several brands have introduced flavoured yoghurt, low-fat and no-fat yoghurt, and frozen yoghurt – a healthy alternative to ice creams. This healthy and tasty gut-friendly option is undergoing many innovations in 2024, like:

In conclusion, yoghurt, with its rich history and diverse manufacturing processes, has established itself as a vital component of diets worldwide. From set to stirred, and from frozen to plant-based varieties, each type offers unique health benefits, primarily due to its probiotic content. The evolution of yoghurt processing technologies has enhanced its quality, consistency, and nutritional value, catering to changing consumer preferences. In markets like India, the demand for yoghurt is growing rapidly, driven by health-conscious consumers and innovative product offerings. As yoghurt continues to evolve, it remains a nutritious and versatile option in the global dairy industry.