What is the process of yogurt production?

Yogurt Production Line: From Fresh Milk to Delicious Yogurt, Quality Assurance Through Comprehensive Process Control

Driven by healthy eating trends, the global yogurt market continues to grow at an annual rate exceeding 8%, and consumer demands for taste, flavor, and functionality are becoming increasingly diverse. For dairy companies, an efficient and stable yogurt production line not only ensures production capacity but also serves as the core of product competitiveness. From raw milk to chilled, ambient, or functional yogurt on the shelf, automated production lines utilize standardized processes and precise control to ensure that every cup of yogurt is both safe and delicious.

1. Working Principle: Using Technology to Lock in the Active Properties of Milk

The core of the yogurt production line is the synergistic effect of pasteurization and bacterial fermentation, transforming fresh milk into a fermented dairy product rich in probiotics. Its key technical logic is reflected in two major systems:

Pasteurization System: Utilizing a low-temperature pasteurization process of 72-85°C for 15-30 seconds, coupled with heat exchange through a plate heat exchanger, this system eliminates pathogenic bacteria (such as Listeria) in the raw milk while maximizing the activity of whey proteins—the foundation for the smooth taste of yogurt. Compared to high-temperature sterilization, this technology reduces nutrient loss by 30%, allowing the finished product to retain the milk's original aroma.

Intelligent Fermentation System: The fermentation tank features a built-in PID temperature control module (accuracy ±0.5°C) and a low-speed agitator (5-10 rpm). After inoculation with lactic acid bacteria (such as Lactobacillus bulgaricus and Streptococcus thermophilus), the system maintains a stable temperature at the optimal fermentation range of 42-43°C, while also ensuring uniform distribution of the bacterial population through agitation. A sensor monitors acidity (pH) in real time. When the target pH value of 4.0-4.5 is reached, a cooling process is automatically initiated (to below 10°C), terminating fermentation. This ensures consistent acidity and consistency across each batch of yogurt.

II. Standardized Process: Full-Chain Control from Fresh Milk to Finished Product

A complete yogurt production line involves six core steps, each reflecting the ultimate pursuit of quality:

Raw Material Inspection and Pretreatment: After online testing, the fresh milk enters a double filter to remove impurities. It then passes through a homogenizer (at a pressure of 20-25 MPa) to break down fat globules to 1-2 μm, preventing stratification in the finished product.

Pasteurization: As mentioned above, after low-temperature pasteurization, the milk is rapidly cooled to 45°C to prepare for bacterial inoculation.

Fermentation and Maturation: The culture is injected according to the recipe, and the fermentation tank is used for 4-6 hours to grow the bacteria. For flavored yogurt, jam, cereals, and other ingredients can be added during this stage. The agitator speed is increased to 15 rpm to ensure uniform mixing.

Filling and Sealing: Equipment is selected based on product type—cup yogurt uses an aseptic filling line (accuracy ±1g), while bagged products utilize a pillow-type packaging machine. The sealing temperature is controlled at 180-200°C to ensure a tight seal.

Refrigerated Curing: Low-temperature yogurt requires refrigeration in a cold storage at 0-4°C for 12-24 hours to further stabilize the protein network and develop a smooth texture.

Quality Inspection and Packaging: Metal detectors and weight sorters are used to remove defective products, followed by boxing and coding. Full traceability is ensured throughout the entire process.

III.four core advantages enhance both production efficiency and quality.

1. Fully automated control reduces labor costs by 60%. Traditional workshop-style production requires 8-10 people to operate, while the automated production line only requires 2-3 people for monitoring. PLC control controls the entire process, from raw material input to finished product delivery. After introducing the production line, one dairy company increased its daily production capacity from 5 tons to 30 tons, reducing labor costs by 62%.

2. Precise parameter control, quality fluctuation ≤ 2%. From sterilization temperature, fermentation time, to filling volume, parameters for each step can be preset and recorded in real time. Compared to the ±10% quality fluctuation of manual production, the production line can control acidity and viscosity variations to within 2%, ensuring a consistent taste for every purchase.

3. Flexible adaptation to multiple categories, rapid market response. By replacing filling molds and adjusting recipe parameters, the company can produce over 10 product categories, including low-temperature plain yogurt, ambient fruit yogurt, and high-protein Greek yogurt. When switching between products, equipment cleaning and disinfection takes only 30 minutes, meeting the flexible production needs of small batches and multiple varieties.

4. Full-chain safety and compliance, easily passing certification

All food-contact components are made of 316 stainless steel and equipped with a CIP cleaning-in-place system (acid-base cleaning + hot water sterilization), meeting standards.

IV. Scenario-Specific Configuration: A Full-Lifecycle Solution from Startup to Scale

Small Dairy Companies: A compact 500L/hour production line, including sterilization, fermentation, and semi-automatic filling modules, is suitable for regional brands with daily production volumes under 10 tons, with a return on investment of approximately one year.

Medium-Sized Enterprises: A standard 2000L/hour line integrates fully automated filling, metal detection, and boxing systems, supporting the online addition of ingredients such as fruit pieces and grains. With an average daily production capacity of 30-50 tons, it meets the needs of regional supermarket chains.

Large Groups: Custom lines with a capacity of 5000L/hour or more can be integrated with upstream farm cold chain systems and back-end warehousing and logistics, enabling full digital management from fresh milk to the end consumer. With an annual production capacity exceeding 100,000 tons, it is suitable for national brands.

V. Three Reasons to Choose Us

1. 25 Years of Experience Serving Dairy Companies: Weishu machinery have provided production line solutions to numerous companies and are deeply familiar with the process challenges faced by various yogurt categories (e.g., whey removal technology for Greek yogurt and sterilization parameters for ambient yogurt).

2. Outstanding Customization: We can customize by adding probiotic counting modules, low-temperature filling systems, and even developing specialized production lines for plant-based yogurt (e.g., almond yogurt).

Amidst the wave of consumer upgrades, a stable and reliable production line can help your products gain a firm foothold in a competitive market. Inquire now for a customized capacity planning solution.