Understanding the Process of Concentrating Fermented Yoghurt: From 12% to 90% Dry Matter

When it comes to concentrating fermented yoghurt, the goal is to start with a product that contains around 12% dry matter and transform it into a powdered form with 90% dry matter. This process is crucial in order to achieve key requirements such as ensuring the viability of probiotic bacteria at a rate of ≥10⁸ CFU/g, high sphericity, good solubility, and a shelf life of at least 12 months at room temperature.

At Longxin, we have unique features and safeguards in place to ensure the success of this process. Our methods include using low temperature and active protection to avoid heat stress on the materials. By utilizing a "upward air flow and exhaust" mixed flow design, we are able to keep the actual material temperature below 75°C. Additionally, our vacuum freeze-drying machines can be equipped with in-situ pre-freezing plates and integrated cold traps to minimize contamination during handling.

We also incorporate microencapsulation and additive systems to enhance the final product. By adding 2-4% maltodextrin or skim milk powder online, we are able to increase the glass transition temperature and reduce wall sticking. Our spray nozzle pressure ranges from 5-10 MPa, with droplet size D50 adjustable between 10-50 μm, resulting in a final product sphericity of ≥0.85.

Our approach also emphasizes modularization and intelligent control. With quick-change CIP/SIP systems, batch switches can be completed in under 30 minutes. Our AI predictive maintenance system increases Overall Equipment Effectiveness by 15% and reduces downtime due to malfunctions by 40%.

Longxin is committed to environmental sustainability and energy efficiency. We achieve a solvent recycling rate of ≥95% through closed-loop systems and maintain tail gas dust levels below 50 mg/m³. By implementing waste heat recovery modules, the comprehensive energy consumption per ton of dry powder is reduced by 20%.

The implementation process involves the following steps: fermentation of yoghurt, vacuum membrane concentration (40-48% solids), low-temperature drying (spray/freeze/fluidized bed granulation), online cooling, nitrogen filling and packaging, and final product distribution.

For future collaborations, please provide information on the planned processing volume (t/d), target bacterial activity indicators, steam/electricity conditions on-site, and whether organic or GMP certification is required.

We welcome samples for testing and offer free trials along with comprehensive process reports. For inquiries, please contact us at +8613611616575 or email aimee.wang@longxinglobal.com.cn.