Yoghurt is produced from fermented milk. The fermentation aim is to acidify and gelify the milk.

In the European Union, the name « yoghurt » can only be attributed to products where fermentation was made with specific lactic yeasts : Lactobacillus bulgaricus and Streptococcus thermophilus.

Throughout the world the name is less restrictive and a wide variety of fermented milk is produced :

• Acid fermented milk : yoghurt, laban (Originally from Lebanon)

• Concentrated fermented milk (or rayeb) : labneh (origin : middle east)

• Acid milk with low alcohol : Kefir (origin: Caucasus), koumiss (mare-milk origin: Central Asia)

• Low-acid fermented milk (buttermilk), possibly thickened.

� APPLICATIONS :• White mass transfer for set stirred and drinking yoghurt.

FOOD

*PRODUITS LAITIERS FRAIS / DAIRY

SET, STIRRED & DRINKING YOGHURT - PLF*

The manufacturing process is divided into 3 main steps :

• Milk reception• Skimming• Pasteurization

� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

Collect

Skimming

REC

EPTI

ON

SKIM

MIN

GPA

STEU

RIZ

ATIO

N

Analysis Raw whole milk1st heating treatment cooling

Full-cream milk

4 up to 6 °C39 up to 42 °F

4 °C39 °F

42°C - 107 °F Seeding

Maturation5 up to 7h

Immediatefilling

Whipping

Cream

Cream dosing

Skimmed milk Cream overage sold to other factories

Standardized milk

Primary recipe

Lactic ferments

Packaging machine

STANDARDIZATION

HOMOGENIZATION

SET YOGHURT STIRRED YOGHURT DRINKING YOGHURT

Cold room 4 °C - 39 °F Cold room 4 °C - 39 °F

Steamingchamber 42°C - 107 °F

Dostam or Dosymix™

Hycare™

Hycare™ Hycare™

Hycare™

Hycare™

Hycare™

Hycare™

Mixing

Hycare™

Packaging machine Packaging machine

Hycare™

NAT

UR

AL

Rec

ipe

1 ACTIVITY AND MANUFACTURING

PROCESS

• Reception : refrigerated raw milk from dairy cooperatives.• Skimming : separation of milk fat through centrifugal force and the density difference between skimmed milk and cream.• Standardization: the standardization consists in adjusting the milk fat content by adding cream to get the desired content of fat.

• Homogenization : the fat in the milk is broken up into smaller more consistently dispersed particles. Homogenization has the benefits of giving a uniform product which will not separate.• Pasteurization : eliminates unwanted micro-organisms to humans. It is done through contact with hot plates. The milk is heated to 72°C ( 162°F) for 15 seconds.• Seeding: Adding yeasts in the standardized milk to 42/45 °C (107/113°F).• Fermentation : - For set yoghurt, incubation is directly made in the package. After filling the yoghurt packages and after palletizing, the pallets are placed in an incubation chamber, 42°C (107°F) for 4 hours. - For stirred and drinking yoghurts, the incubation is made in a tank for between 5 to 7 hours before mixing and packaging.

Buffertank

Brassage

42°C - 107 °F Seeding

Flavour

Fruit

Dosyfruit™

Dostam

Dosymix™

Dostam or Dosymix™

Additive Station

Additive Station

Just in time mixingIn line injection

(Bottom flavor injection possible with MDS*)*Multi Dosing Synchrone (Bottom fruit injection possible with Dosyfill)

In line mixing before buffer tank

Flavour

Maturation5 up to 7h Whipping

FLAVOURED SET YOGHURT FRUIT STIRRED YOGHURT FLAVOURED DRINKING YOGHURT

Hycare™ Hycare™

Hycare™

Hycare™ Hycare™

Cold room 4 °C - 39 °F

Cold room 4 °C - 39 °FCold room 4 °C - 39 °F

Mixing

Packagingmachine

Packagingmachine

Packaging machine

Buffertank

Steamingchamber 42°C - 107 °F

Faire des yaourts avec pourcentage à l'intérieur en gardant codes couleurs

78 up to 96%

2%0 up to 7%

0 up to 10%0 up to 1%

2%

Set yoghurt

85%

5%7%3%

Natural stirred yoghurt

65 up to 80%

3%0 up to 7%

5 up to 15%

0 up to 7%3%

Fruit stirred yoghurt

FLA

VOR

ED O

R F

RU

IT R

ecip

e

Skimmed milk

Fruit

Milk powder

Cream

Sugar

Flavour

Ferment

1 ACTIVITY AND MANUFACTURING

PROCESS

� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

� FOR TRANFER APPLICATIONS OF CREAM, FERMENTS AND STIRRED YOGHURT :

• A gentle mechanical process such as Moineau™ technology (non-pulsating constant flow) that respects product fragility. When shearing occurs on white mass, manufacturers are forced to enrich the recipe with proteins (additional costs).

• Reduce backslip to less than 10% to reduce shearing :

- Backslip is constant (L / h), the pump speed can be increased to increase the total flow and reduce (in%) the slip flow rate being careful not to exceed 250 rpm.- Equipment complying with food hygiene standards.

� WHITE MASS :• Viscosity :

- Cream : > 500 cPs- Stirred yoghurt : 1500 cPs- Drinking yoghurt : 500 cPs- Labneh: 4 000 up to 5 000 cPs- Kefir: 50 up to 150 cPs

• Particles size : - Natural yoghurt : 0 mm- Fruit stirred yoghurt : 6 up to 15 mm

• Discharge pressure : between 5 to 18 bars• Suction pressure : flooded (below tank)• Temperature : 4°C - 39°F (European regulation)

� LACTIC FERMENTS :Lactic yeasts are of microbial strains and should be used in perfect hygienic environment.

� PROCESSING RESTRICTIONS :• Shearing risk of the structure of cream or white mass • Lean manufacturing process : use of machinery 7/7 and 24/24H. This is due to the continuous arrival of truckloads of raw milk from dairy cooperatives. • Duration and storage temperature : the white mass must be maintained at a temperature between 4 and 6°C (39/43°F) from production to sale to the consumer to avoid a restart of fermentation.• Food security, bacteriologically sensitive product.

Filling : Fruit stirred yoghurt

Fruit station : Dosys™ pump

Moineau™ Technology

2 TECHNICAL DATA & PROCESSING RESTRICTIONS

3 EQUIPMENT RECOMMENDATIONS

� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

� FOR ADDITIVES INJECTION (flavour, colours) :The motto « do not lose a drop » will be fully respected by the precision of Dosys™ dosing system (accuracy +/- 0.5%).

� FOR MIXING IN DAIRIES INDUSTRIES :It is strongly recommended an In Line Process rather than a solution in batch allowing :

• finalization (or specialization) at the very end of production process (aroma or fruits changes)• production of small batches.

PCM Mixers technologies allow :• Continuous injection of base and additive (proportional dosing) with PCM Moineau™ technology pumps.• Continuous injection of base and additive in pulsed mode. (In Line injection) with Dosys™ technology pump.• Injection of base and additive in pulsed mode. (Just in Time) with Dosys™ technology pump synchronized to a conditioning nozzle (Dosyfill).

� FOR FILLING POTS OR BOTTLES :The Dosys™ filling technology (Dosyfill) offers maximum versatility and high volumetric metering accuracy of +/- 0.5% of heterogeneous or complex products.

� HYCARE™ SERIE : the reference in Dairies industriesThanks to Moineau™ technology, the HyCare™ pump preserves the dairies products texture and integrity. Moreover, its design offers the guarantee of hygiene and unbeatable food safety.

• Cleaning In Place designed : CIP connection• Duraflex flexible titanium shaft made in a one-piece design to guarantee the absence of retention area. • Design optimized : the body shape and the tangential inlet increase the cleaning efficiency• Hygienic mechanical seal

Additive station duo

3 EQUIPMENT RECOMMENDATIONS

4 PRODUCTRECOMMENDATION

� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

4 PRODUCTRECOMMENDATION

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www.pcm.eu

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� DOSYMIX™ & DOSTAM MIXERSThe dynamic mixer Dosymix™ is preferred for mixing heterogeneous or homogeneous, viscous, shear-sensitive, ingredients and white mass (with or without pieces).The static mixer Dostam will be chosen for mixtures of homogeneous liquid without pieces (lactic ferments, flavors…).

� DOSYFRUIT™ : fully automatic multi-ingredient stationThis system allows fruit piece dosing (up to 48 mm). It guarantees accuracy of dosing (+/- 0.5%) from 1 to 6 different fruit containers or bags in box. The dosing is directly synchronized by the packaging and packing machine or according to the main ingredient flow. In addition, this station is completely cleanable and sterilizable in place (sterile air, steam sterilization feet containers, injection point).

� DOSYFILL : filling system This system allows gradual starts and stops snapshots to ensure the settings ready to drop (Metering accuracy +/- 0.5%).For optimum performance, Dosys™ nozzles are directly synchronized by the filling machine and packaging (Dosyfill).

2 main advantages :• Metering accuracy +/- 0.5%).• Preserve the ingredients even if they are made of semi-solids of large size (up to 48 mm).

2 DM4000 : In Line configuration

Dosyfruit™ : 2 flavours

� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

Remove caustic traces

10 min.

20 min.10 min.0 min.

5 min.

25 min.

3. CAUSTIC(NaOH)

1.5 %

70°to 80° max

5 min.

STOP 10 min.

10 min. 10 min. 10 min.

Remove particles

35 min.

2. RINSING(H2O)

15° to 25°

10 min.

STOP 15’’ s.

4. RINSING(H2O)

15° to 25°

STOP 15’’ s.

10 min.

45 min. 55 min.

6. RINSING(H2O)

15° to 25°

STOP 15’’ s.

10 min.

8. RINSING(H2O)

15° to 25°

10 min.

Remove acids tracesRemove organic materials

5 min.

40 min.

5 min.

5. ACID(HNO3)

60° to 65° max

STOP

5 min.

1.2 %

5 min.

7.a SANITATION(H2O)

90° to 95° max

STOP 15 min.

5 min.

7.b STERILIZATION

140° max

STOP X min.

Remove minerals residues

OU

120 rpm

150 rpm

150 rpm

120 rpm

120 rpm

120 rpm

150 rpm

� CIP* GUIDE FOR PCM MOINEAU™ PUMPS*Cleaning In Place

Please consult the CIP guide

For more information, please find your nearest contact :

www.pcm.eu