FOOD

SET, STIRRED
& DRINKING
YOGHURT - PLF*

*PRODUITS LAITIERS FRAIS / DAIRY

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.
� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

1 ACTIVITY AND

RECEPTION
MANUFACTURING
PROCESS Full-cream milk
1st heating
Collect Analysis Raw whole milk treatment cooling

Cream
The manufacturing process Skimming

is divided into 3 main steps :

• Milk reception
Skimmed milk

SKIMMING
Cream overage sold
• Skimming to other factories
• Pasteurization

Cream dosing

Hycare™ 4 up to 6 °C
39 up to 42 °F

Standardized milk
STANDARDIZATION Hycare™
HOMOGENIZATION

Primary recipe

Hycare™

Hycare™
4 °C
39 °F

Lactic ferments
Dostam or Dosymix™

42°C - 107 °F Seeding

Hycare™ Hycare™ PASTEURIZATION

Packaging machine
Hycare™
NATURAL Recipe

Immediate
Maturation
filling
5 up to 7h
Whipping
Mixing
Steaming Hycare™
chamber 42°C - 107 °F
Hycare™

Packaging
machine Packaging machine

Cold room 4 °C - 39 °F Cold room

4 °C - 39 °F

SET YOGHURT STIRRED YOGHURT DRINKING YOGHURT

� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

• Reception : refrigerated raw milk from dairy cooperatives.

1 ACTIVITY AND • Skimming : separation of milk fat through centrifugal force and the density
MANUFACTURING difference between skimmed milk and cream.
PROCESS • 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.
42°C - 107 °F
Seeding

Hycare™ Hycare™
Additive
Station
Flavour

Hycare™
Dostam
FLAVORED OR FRUIT Recipe

Maturation
5 up to 7h
Packaging machine
Whipping Additive
Station
Fruit Hycare™ Mixing
Brassage Hycare™ Flavour
Dosyfruit™
Buffer
tank

Steaming Dostam or
chamber 42°C - 107 °F Dosymix™
Dosymix™ Buffer
tank
Packaging Packaging
machine machine

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

FLAVOURED SET YOGHURT FRUIT STIRRED YOGHURT FLAVOURED DRINKING YOGHURT

In line injection In line mixing before buffer tank
Just in time mixing
(Bottom flavor injection possible with MDS*)
*Multi Dosing Synchrone (Bottom fruit injection possible with Dosyfill)

Ferment Milk powder

2% 3% 3%
0 up to 1% 7% 0 up to 7%
0 up to 10% 5% 0 up to 7% Flavour Fruit
0 up to 7%
3%
2%
Sugar Skimmed milk
5 up to 15%
85%
Cream
65 up to 80%
78 up to 96%

Set yoghurt Natural stirred yoghurt Fruit stirred yoghurt

� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

� WHITE MASS :
2 TECHNICAL DATA • Viscosity :
& PROCESSING - Cream : > 500 cPs
- Stirred yoghurt : 1500 cPs
RESTRICTIONS - 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) Filling : Fruit stirred yoghurt

� 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.

Fruit station : Dosys™ pump

� FOR TRANFER APPLICATIONS OF CREAM,

3 EQUIPMENT FERMENTS AND STIRRED YOGHURT :
RECOMMENDATIONS
• 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
Moineau™ Technology
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.
� SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

� FOR ADDITIVES INJECTION (flavour, colours) :

3 EQUIPMENT The motto « do not lose a drop » will be fully respected by the
RECOMMENDATIONS 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. Additive station duo
• 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 industries

4 PRODUCT Thanks to Moineau™ technology, the HyCare™ pump preserves the dairies products
RECOMMENDATION 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
 � SET, STIRRED & DRINKING YOGHURT - PLF / DAIRY

4 PRODUCT � DOSYMIX™ & DOSTAM MIXERS

The dynamic mixer Dosymix™ is preferred for mixing
RECOMMENDATION 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…).

2 DM4000 : In Line configuration

� DOSYFRUIT™ : fully automatic multi-ingredient station
This 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%). Dosyfruit™ : 2 flavours
• Preserve the ingredients even if they are made of semi-
solids of large size (up to 48 mm).

� CIP* GUIDE FOR PCM MOINEAU™ PUMPS 7.a SANIT

*Cleaning In Place (H2O)

2. RINSING 3. CAUSTIC 4. RINSING 5. ACID 6. RINSING 90° to

(H2O) (NaOH) (H2O) (HNO3) (H2O)
1.5 % 1.2 %
STOP
15° to 25° 70°to 80° max 15° to 25° 60° to 65° max 15° to 25°
A - 04/2015

150
rpm
120
rpm 10 min. STOP 10 min. 120
rpm 10 min. STOP 5 min. 120
rpm 10 min.
2014

STOP 15’’ s. 150

5 min. STOP 15’’ s. 150
5 min. STOP 15’’ s.
Index

rpm rpm

7.b STERI
Indice A - Avril

Remove particles Remove organic materials Remove caustic traces Remove minerals residues Remove acids traces
140
10 min. 10 min. 5 min. 10 min. 5 min. 5 min. 10 min.
STOP
0 min. 10 min. 20 min. 25 min. 35 min. 40 min. 45 min. 55 min.

Please consult the CIP guide

Pour plus d'informations, contactez notre agence la plus proche :
For more information, please find your nearest contact :
www.pcm.eu
www.pcm.eu