92-Fabricando Made in Spain - Yogures

How is Yogurt Made?

Historical Context of Yogurt

• The bacteria Lactobacillus bulgaricus and Streptococcus thermophilus, essential for yogurt production, were known as early as 7000 BC. Nomadic tribes transported fresh milk in goat skin bags, where heat and contact with the skin facilitated bacterial growth.

Ingredients and Initial Processing

• The basic ingredients for yogurt include fresh milk, cream, and starter culture. On average, each Spaniard consumes about six yogurts per month.

• Yogurt is a popular food item due to its taste and health benefits; however, its production involves more than just milk.

Milk Preparation

• Fresh milk from cows varies in fat content; thus, the process involves removing excess fat to ensure uniformity across all yogurt products.

• Each batch of incoming milk undergoes antibiotic testing before entering the factory. Milk without antibiotics is crucial for fermentation.

Pasteurization Process

• After passing antibiotic tests, the milk is pasteurized to eliminate harmful bacteria. This step may involve using skimmed milk depending on the product requirements.

• The pasteurized mixture combines skimmed milk, cream, and powdered milk to achieve a homogeneous blend before cooling it down.

Fermentation Stage

• Approximately 20,000 liters of mixed milk are processed at once through a pasteurizer that heats it up to 95 degrees Celsius.

• A sample from the pasteurized batch is taken for microbiological analysis before introducing the fermenting agents.

Role of Bacteria in Yogurt Production

• The two key bacteria involved in fermentation are Lactobacillus bulgaricus and Streptococcus thermophilus. They convert lactose into lactic acid during fermentation.

• Lactic acid causes the milk to coagulate and gives yogurt its characteristic tangy flavor while aiding digestion and protecting against harmful bacteria.

Storage of Bacterial Cultures

• The bacterial cultures are stored at -80 degrees Celsius to preserve their properties until needed for production.

Final Steps in Yogurt Making

• A small amount of concentrated bacterial culture is added to large batches of prepared milk to initiate fermentation effectively.

How Yogurt is Made

The Packaging Process

• The yogurt packaging process begins with a plastic roll, which is heated and molded to form the yogurt containers. Approximately 200 million yogurts can be produced for a city like Vitoria.

• After forming the container, it is filled with milk. The natural yogurt requires fermentation overnight, allowing bacteria to work effectively.

• A sterilized lid is placed on top to ensure food safety. The volume of milk used is monitored, and expiration dates are printed on the containers.

Flavoring and Distribution

• Natural aromas and colorants are added to the yogurt mixture before sealing. Care is taken not to overfill the containers.

• Yogurts are arranged in trays for distribution, with each tray holding 24 units. They are organized into groups of eight for easier handling.

Palletization and Temperature Control

• Once packaged, yogurts are moved onto pallets containing 216 trays each, totaling 3,456 yogurts per pallet.

• To maintain consistent temperature across all packages during transport, they spend about 20 minutes in a stabilization area.

Fermentation Process

• After stabilization, yogurts enter a heating room at 40 degrees Celsius for 150 minutes where fermentation occurs; this transforms milk into yogurt through bacterial action.

• Post-fermentation checks ensure that the product meets quality standards before cooling down to halt further fermentation.

Final Cooling and Storage

• Yogurts are cooled rapidly after fermentation to prevent changes in texture or flavor. They must remain at controlled temperatures during storage.

• An automated system manages approximately 3,000 pallets of yogurt in cold storage for up to 48 hours before distribution.

Ingredients and Quality Control

• Key ingredients for making yogurt include fresh milk, cream, and powdered milk. Fresh milk undergoes antibiotic testing upon arrival before pasteurization.