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Production Process of Stirred Yoghurt

The production process of stirred yoghurt is almost similar to that of the normal yoghurt but some differences are there. Process initiates from the collection and storage of raw milk in milk collection centers and stored milk is then transported to the processing factories in conditioned transporting vehicles and after transportation, the milk is stored in silos prior to the further processing. This steps are common to the all milk products and for the yoghurt production, the milk in silos is then transported to the pre-heating section and then to the cream separating device. The milk from the cream separator is then standardized to obtain desired fat content in the yoghurt and directed to a process called Fortification where the milk is being added with sugar, skimmed milk powder and other ingredients including colorants, flavorings, and accepted chemicals and preservatives. Fortified milk is then subjected to the super-pasteurization treatment where 80-95 0C of temperature condition is applied for about 8-9 minutes and then cooled to a temperature (about 420C) at which the desired culture microorganisms grow followed by culture addition and incubation. Then the specific step at which stirring and cooling is done and the stirred milk mixture is then pumped while stirring to the packaging area where flash cooling and cold storage is done and final product is obtained as stirred yoghurt.
Raw Milk Collection Transporting & Storage (4 0C) Pre-heating

Super Pasteurization
(80-90
0C)

Sugar & SMP addition

Cream Separation

Cooling & culture addition (42 0C)

Incubation
(42 0C for 3hrs)

Cooling and stirring

Flash Cooling

Packaging

Stirring & Pumping

Cold Storage (5 0C)

Stirred Yoghurt
Transporting and selling

Consumer

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Hazard Analysis of the Production Process

Step 1. Raw milk Collection Hazard(s) Undesirable microorganisms Metal contaminants Chemical residues Type Biological Physical Chemical Reason(s) Improper storing Improper temperature Mishandling Diseased cows Contaminated containers and personnel Improper storing Improper temperature Mishandling Contaminated containers and personnel Damaged and unclean transporting devices Contaminated sugar and other ingredients Impure skimmed milk power(SMP) Unaccepted ingredients Prevention Use of clean equipment Proper thermal application(4 0C) Use of healthy cows and personnel Tests for quality Use of clean equipment Proper thermal application (4 0C) while transporting Disinfection of equipment after use Regular quality checking

2. Transporting and Storage

Undesirable microorganisms Metal contaminants

Biological Physical

3. Sugar and SMP addition

Undesirable Biological microorganisms Undesirable chemicals Chemical

Use of pure sugar Use of clean SMP Super Pasteurization Use of accepted ingredients Use of disinfected equipment Regular cleaning Use of accepted cultures Proper testing for cultures Use of clean devices Proper thermal treatments(42 0C) Use of sterilized packaging materials Use of airtight machines and conditions Flash cooling and cold storage Application of proper storage conditions(4 0C) Handling with care Prevention of physical damages

4. Culture Addition

Undesirable microorganisms Other physical matter Chemical toxins and substances

Biological Physical Chemical

5. Packaging and storage

Undesirable Biological Microorganisms Metal and other Physical residues Undesirable Chemicals Chemical

Use of impure cultures Use of unclean equipment Use of non-tested Cultures Addition of unaccepted chemicals Use of unclean packaging materials Use of unclean devices Improper testing Improper storing conditions Mishandling

6. Transportation and selling

Undesirable microorganisms Damages to the packages and contamination

Biological Physical and chemical

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