Manufacturing Yogurt and Fermented Milks

Dr Ramesh C. Chandan , President, Global Technologies Inc, Coon Rapids, Minnesota. Dr Chandan is a consultant in dairy science and technology and has worked for more than 40 years in various food companies including Unilever, Land O'Lakes and General Mills, with special expertise in the manufacture of dairy products. He has served on the faculty of Michigan State University and has taught dairy technology courses for seven years. He has authored/edited six books on the subject of dairy food science. Dr Arun Kilara , Nutri+Food Business Consulting, Chapel Hill, North Carolina. Dr Kilara has long established expertise in teaching and research in dairy food science at Penn State University and is very well known for his contribution in the area of dairy ingredients. He has edited two books on dairy food science.

List of contributors xi Preface to the second edition xiii Preface to the first edition xv PART I BASIC BACKGROUND 1 1 History and consumption trends 3 Ramesh C. Chandan 1.1 Overview of the world dairy industry 3 1.2 Milk production in the USA 3 1.3 Production of dairy foods in the USA 4 1.4 Fermented/cultured dairy products 7 1.5 Occurrence and consumption of fermented milks in various regions 8 1.6 Major commercial fermented milks 11 1.7 Scandinavian fermented milks 15 1.8 Russian and Eastern European fermented milks 16 1.9 Middle Eastern fermented milks 16 1.10 South Asian fermented milks 17 2 Milk composition, physical and processing characteristics 21 Guillaume Brisson and Harjinder Singh 2.1 Introduction 21 2.2 Milk composition 21 2.3 Milk components and processing characteristics 23 2.4 Physicochemical properties of milk 37 3 Regulatory requirements for milk production, transportation and processing 49 Cary P. Frye 3.1 Introduction 49 3.2 From farm to factory 49 3.3 History of milk safety 50 3.4 United States Public Health Grade "A" Milk Safety Program 50 3.5 Inspection of milk safety 51 3.6 Farm requirements 52 3.7 Milk transportation 53 3.8 Processing plant 54 3.9 Hazard Analysis and Critical Control Point System 58 3.10 Standards and regulations 60 3.11 Milk pricing--US Federal Milk Marketing Orders 65 4 Regulations for product standards and labeling 71 Cary P. Frye 4.1 US Code of Federal Regulations 71 4.2 US product standards of identity 71 4.3 Fermented milk and milk products 72 4.4 Stayed provisions 77 4.5 Frozen yogurt 79 4.6 Food additives and packaging 79 4.7 Labeling 80 4.8 Codex Standards and definitions for fermented-milk products 89 5 Principles of dairy processing 95 Arun Kilara 5.1 Introduction 95 5.2 From farm to factory 95 5.3 Storage of raw milk 96 5.4 Overview of processing equipment in a dairy plant 99 5.5 Centrifugal operations 105 5.6 Thermal-processing systems 107 5.7 Homogenization 110 5.8 Membrane technology 111 5.9 Conclusion 113 6 Starter cultures for yogurt and fermented milks 115 Ebenezer R. Vedamuthu 6.1 Introduction 115 6.2 Starter functions 118 6.3 Factors affecting starter performance 120 6.4 Microorganisms used in starters for cultured dairy products 127 6.5 Genus Lactococcus 130 6.6 Comments on Cit + Lactococcus lactis ssp. lactis 136 6.7 Genus Leuconostoc 136 6.8 Genus Streptococcus 138 6.9 Genus Lactobacillus 140 6.10 Genus Bifidobacterium 142 6.11 Starter-culture production 142 6.12 Miscellaneous starters 146 6.13 Literature 146 7 Fermented dairy packaging materials 149 Aaron L. Brody 7.1 Introduction 149 7.2 Fundamentals of packaging 150 7.3 Packaging materials 151 7.4 Interactions between product and packaging 160 7.5 The package in product distribution 162 7.6 Graphic design and assessment 163 7.7 Economics of packaging 164 7.8 Regulation 165 7.9 Packaging and the environment 166 7.10 Packaging for yogurt and fermented dairy products 168 7.11 Future trends 174 8 Milk and milk-based ingredients 177 Isabelle Sodini and Phillip S. Tong 8.1 Introduction 177 8.2 Composition and specifications 177 8.3 Performances in yogurt formulation 178 8.4 Conclusion 189 PART II MANUFACTURE OF YOGURT 193 9 Yogurt: fruit preparations and fl avoring materials 195 Kevin O'Rell and Ramesh C. Chandan 9.1 Introduction 195 9.2 Fruit as a raw material for yogurt preparations 196 9.3 Processing of fruit for use in yogurt fruit preparations 197 9.4 Formulation of fruit preparations 200 9.5 Processing yogurt fruit preparations 209 9.6 Packaging of fruit preparations 213 9.7 Acknowledgment 215 10 Ingredients for yogurt manufacture 217 Ramesh C. Chandan and Kevin O'Rell 10.1 Introduction 217 10.2 Dairy ingredients and their origin 217 10.3 Sweeteners 224 10.4 Stabilizers 233 11 Principles of yogurt processing 239 Ramesh C. Chandan and Kevin O'Rell 11.1 Introduction 239 11.2 Mix preparation 239 11.3 Heat treatment 239 11.4 Homogenization 241 11.5 Yogurt starter 242 11.6 Changes in milk constituents during yogurt production 256 12 Manufacture of various types of yogurt 263 Kevin O'Rell and Ramesh C. Chandan 12.1 Introduction 263 12.2 General manufacturing procedures applicable to all categories 263 12.3 Yogurt types, styles, subcategories and definitions 268 12.4 Market statistics on the yogurt trade 269 12.5 Manufacturing process for major yogurt categories 272 12.6 General manufacturing procedures for major types of yogurt 278 12.7 Post-culturing heat treatment 294 13 Greek-style yogurt and related products 297 Arun Kilara and Ramesh C. Chandan 13.1 Introduction 297 13.2 Greek-style yogurt 299 13.3 Chakka and shrikhand 305 13.4 Quarg and fromage frais 309 13.5 Mishti doi/dahi 315 14 Plant cleaning and sanitization 319 Dennis Bogart 14.1 Introduction 319 14.2 Cleaning 320 14.3 Sanitization 326 14.4 Phage control 328 14.5 A final thought 330 15 Yogurt plant: quality assurance 331 Kevin O'Rell and Ramesh C. Chandan 15.1 Introduction 331 15.2 Regulatory obligations 331 15.3 Quality-control programs 341 15.4 National Yogurt Association criteria for live- and active-culture yogurts 346 15.5 Specification program 348 16 Sensory analysis of yogurt 353 Yonca Karagul-Yuceer and MaryAnne Drake 16.1 Introduction 353 16.2 Sensory-analysis techniques 353 16.3 Sensory analysis of yogurt 359 16.4 Conclusions 364 PART III MANUFACTURE OF FERMENTED MILKS 369 17 Cultured buttermilk 371 Charles H. White 17.1 Introduction 371 17.2 Milk supply 373 17.3 Processing of milk 374 17.4 Buttermilk starter culture 374 17.5 Breaking, cooling, bottling and distribution 376 18 Cultured/sour cream 381 Bill Born 18.1 Early history 381 18.2 Present standards 383 18.3 Sour-cream products 388 19 Other fermented and culture-containing milks 393 Ebenezer R. Vedamuthu 19.1 Introduction 393 19.2 Dahi 395 19.3 Kefir 399 19.4 Koumiss 402 19.5 Acidophilus milk and sweet acidophilus milk 403 19.6 Probiotic milks 406 19.7 Bulgarian milk 407 19.8 Skyr 407 19.9 Viili 408 19.10 Kurut 409 PART IV HEALTH BENEFITS 411 20 Functional foods and disease prevention 413 Ramesh C. Chandan and Nagendra P. Shah 20.1 Introduction 413 20.2 Functional foods 414 20.3 Bioactive dairy ingredients 415 20.4 Milk fat 421 20.5 Probiotics 422 20.6 Fortification 429 20.7 Physiologically active ingredients 429 21 Health benefits of yogurt and fermented milks 433 Nagendra P. Shah 21.1 Introduction 433 21.2 Yogurt and other fermented milks 435 21.3 Health benefits of fermented milks 438 22 Probiotics and fermented milks 451 Nagendra P. Shah 22.1 Introduction 451 22.2 Taxonomy of lactic-acid bacteria 451 22.3 Probiotic bacteria 452 22.4 Selection criteria for probiotics 453 22.5 Health benefits of Lactobacillus acidophilus and bifidobacteria 459 22.6 Conclusion 465 References and further reading 466 Index 469