UNIT 3 PACKAGING, STORAGE COMMON

DEFECTS OF FERMENTED MILKS

Structure
3.0 Objectives
3.1 Introduction
3.2 Packaging
3.3 Protective function of packs and requirements
3.4 Packaging materials
3.5 Storage and keeping quality of fermented milks
3.6 Factors affecting the keeping quality of fermented milks (yoghurt)
3.7 Defects of fermented milks
3.8 Enhancing the shelf life of fermented milk products
3.9 Let Us Sum Up
3.10 Key Words
3.11 Some Useful Books
3.12 Answers to check your Progress Exercises

3.0 OBJECTIVES
After reading unit we should be able to:
• know the significance of packaging of fermented milk products.
• make selection of suitable packaging materials for fermented milks.
• understand the keeping quality of fermented milk products.
• know the common defects of fermented milks.
• prolong the storage life of fermented milk products.

3.1 INTRODUCTION
According to International Dairy Federation (IDF), 1969 fermented milks are defined
as products prepared from milks – whole, partially or fully skimmed, concentrated
milk or milk substituted from partial or fully skimmed dried milk, homogenized or
not, pasteurized or sterilized and fermented by means of specific organisms. Currently,
about 2.3 per cent of the total dairy product market is in the form of cultured dairy
products and their production has been showing a marked increase with the advent
of genetic improvement in the starter culture technology together with the programmes
for the improvement of these products, progress in technology and particularly the
increased understanding of their beneficial efforts in human nutrition and health, these
products have become popular throughout the world.
The advantages of fermented milks over plain milk are as follows:
56 • Easy to manufacture.
• Better keeping quality. Packaging, Storage and
Common Defects of
• Possess different flavour and taste. Fermented Kilks

• Possess different palate and acidity level.

• Better nutritive value
• Better digestibility
• Good for lactose intolerants.
• Good therapeutic benefits.
• Good carrier for probiotics and probiotics.

3.2 PACKAGING
Packaging can be defined as a tool that protects and contains our goods with the
aim of minimizing the environmental impact on them. It forms an integral part of food
production, marketing and distribution. The changing lifestyles, urbanization and
increased consumerism have flooded the market with value added, branded, and
attractively packaged food products. Today, an array of packaging materials and
systems such as aseptic and retort packaging, gas/ vacuum packaging, thermoforming,
bag-in-box and lined carton systems, shrink wrapping and stretch wrapping is
available. Development of high barrier materials, Controlled Atmosphere Packaging
(CAP) or Modified Atmosphere Packaging (MAP) systems, aseptic packaging system
and the like has changed the food marketing system, providing more “fresh food” in
retail stores for a longer duration. Development of suitable packaging systems is
essential for modernization of the traditional dairy products industry, and the organized
sector’s greater participation in it. Already, systems have been developed for assembly
line packaging of ghee, shrikhand, dahi, mishti doi, etc. The hi-tech packaging
technology has also extended the shelf life of paneer and facilitated its marketing in
remote areas.
The choice of an appropriate packaging material is governed by several factors
such as:
• The specific sensitivities of the contents, e.g. moisture, oxygen, etc.
• Factors changing the contents viz. temperature, RH, pH and the reaction
mechanism involved.
• Weight and shape of the container.
• Effect on filling and sealing speeds.
• Contamination of food by constituents of the packaging material.
• Storage conditions – duration of the product needs to be protected.
• Bio-degradability and recycling potential.
• Transportation – distance and transportation conditions.
• Dairy products being highly perishable, utmost care is needed in its preservation
during storage, handling and transportation.

3.3 THE PROTECTIVE FUNCTION OF PACKS AND

REQUIREMENTS
The protective function of packs to the effect of mechanical, physical, chemical and
microbiological factors is presented in the Figure 3.1. 57
Fermented Products MECHANICAL

SHOCK TENSION PRESSURE

Composition Light

Product/ packaging material

PACK WITH
Environmental
PRODUCT Temperature

Atmosphere

Microorganisms
Fig 3.1 Protictive Functions of Pack
i) Chemical protective functions
• Aroma tight
• Odour tight (protection against environments dours which may be easily
taken up).
• Oxygen-tight (prevention of the growth of moulds and of fat oxidation).
• No adverse effect on the product (e.g. no migration of soluble and toxic
substances from the packaging materials).
• Acid resistance of packs and of materials for declaration.
• No corrosion of the AI foil lids occurring as a result of the mutual action
between lactic and fruit acids and aluminium.
ii) The microbiological protective function
• Micro-organisms must not pass through packs.
• Acidification should not be disturbed.
• Smaller openings of packs are better for the prevention of airborne
contamination (e.g. the versus-conical cups are more suitable shape than
the conical ones).
• Prevention of contamination during storage.
• Protection against microbiological effects (environmental effects through
non-tightly closed containers, too large empty space in packs, etc.)
• Single-trip packs and their lids should be germ-free as far as possible.
• Multiple-trip packs should have a light-weight and be designed for cleaning.
iii) The hygienic protective function
The hygienic protection of the upper rim of cups is required with yoghurt/ dahi
58 beverages which are consumed directly from cups.
iv) The mechanical protective function Packaging, Storage and
Common Defects of
• Resistance against shocks. Fermented Kilks

• Water-tight (liquid-tight).
• Resistance against moisture.
• Ability to resist transport and storage.
• The shape stability.
• Suitable shape.
• Head space above the filled product should be as small as possible.
v) The physical protective function
• Effect of light should be reduced e.g. through laminated foils with the light
barrier. Therefore, transparent packs are not recommended. Sunlight
affects the natural yoghurt stronger than the fruit yoghurt.
• In order to prevent airborne contamination by micro-organisms due to
the electrostatic properties of plastic materials (polystyrene) caused by
dust particles, cups should be packaged in tightly closed carton boxes
during storage.
• Antistatic design of the plastic cups is recommended (e.g. by means of
laminated foils).
vi) The environmental protective function
• Possibility to utilize sweepings.
• No damaging effect to the environment during burning of sweepings.
• Development of plastics which are decomposed by microorganisms.
• Possibility of recovery and further utilization of the packaging materials
already used.
vii) The marketing function
Packs should cope with the marketing conception of the packaged product
e.g. shape, graphical illustration, nice printing and informative declaration.
Actually, packs represent a manufacturing firm.

3.4 PACKAGING MATERIALS

Packs can be made of glass, plastic or carton.
i) Glass Packs
Advantages
• No environmental contamination during destruction of glass.
• No adverse effect on the product.
• No odour and taste
• Resistance against moisture
59
• No gas diffusion
Fermented Products Disadvantages
• Higher weight than plastic packs or carton packs, being important for transport.
At present investigations have been done to reduce the weight of glass containers
as much as possible.
• Since glass containers are usually returnable packs, additional room is needed
for storage.
• Additional work for cleaning of returned bottles.
• Glass containers give a bad protection against light-induced flavour changes.
This can be reduced through the corresponding colouring of glass (e.g. brown
bottles).
• Impossible to print (sticking of advertising labels is possible).
• Larger space is required for sweepings.
• No tight closure (but protects efficiently against external contamination).
ii) Plastic Packs
Plastic packs enjoy today a great popularity. They consist of polyvinylchloride (PVC),
polyvinylchloride/ polyvinylidenchloride (PVC/ PVDC), polystyrene (PS), laminated
foils with sarane, or a low pressure polyethylene (LPE).
The PVC and PVDC have a relatively low permeability to water vapour, oxygen,
nitrogen and carbon dioxide. In contrast to this, polystyrene and polyethylene
demonstrate a high permeability to oxygen, nitrogen and carbon dioxide. The oxygen-
tight properties of PVC and PVDC foils make them very suitable materials for
packaging.
a) Pre-Fabricated Cups (Ready-Made Cups)
The pre-fabricated cups are usually used as packs. The main advantage is a
diversification of packaging the product, e.g. shape, printing and other market
requirements.
Another advantage is an equal quality of cups. The ready-made cups are tested
for weight, electrostatic properties, strength, homogeneity, etc. and subsequently
packaged into dust-tight carton boxes. A disadvantage of these cups may be
their liability to airborne contamination by undesirable organisms.
(b) Thermoformed Cups
The thermoformed cups are produced in the dairy by using specially designed
equipment for automatic cup forming, filling, sealing and punching.
It is interesting to make a comparison between the pre-fabricated cups and the
thermoformed cups from the practical point of view. This is shown below.
c) Automatic Plastic Cup Forming, Filling, Sealing and Punching Machines
Advantages are:
• Lower costs of the packaging materials.
• Firm blown and splinter-proof materials.
• Lower labour costs.
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 • Gas-tight and light impermeable packs can be obtained by using complex Packaging, Storage and
Common Defects of
foils. Fermented Kilks

• Multi packs are possible.

• Small store volume for the packaging foils.
• Heat treatment of the plastic foils and AI lids.
• Aseptic packaging is developed.
Disadvantages are:
• Increased liability to interruption in running of a machine.
• Higher requirements for service personnel.
• Higher costs for maintenance and repair.
• Limitations in the shape of cups.
• Greater investment.
• Small pressure load on cups.
• Waste of the packaging foils and lids.
• Higher energy costs.
d) Automatic Plastic Cup Filling and Capping Machine
Advantages are:
• High safety in operation of a machine.
• Low liability to interruption in running of a machine.
• Low costs for maintenance.
• Low energy costs.
• Higher pressure load on cups.
• Changing cups to different size and shape is possible.
• Gas-tight and high impermeable packs can be installed.
• No waste.
• Aseptic packaging is developed.
Disadvantages are:
• Higher material costs
• Larger store volumes required for the stock of cups.
• Certain store volumes required for the stock of cups.
• Certain machines require a separate punching unit.
• Increased labour expenses
iii) Waxed Carton Packs
• Carton packs coated with paraffin have been somewhat displaced by 61
plastic packs. Carton packs have the following advantages:
Fermented Products • Can be very nicely printed.
• They have light-weight
• Not-returnable.
• No problems in the utilization of sweepings.
Disadvantages are:
• Discolouration of the internal part of containers caused by certain fruit
base (e.g. partial blue discolouration with bilberry yoghurt).
• Eventual occurrence of the paper taste.
iv) Combined Materials and Laminated Foils
The favorable price, weight and stability of a paper can be combined with
advantages of other packaging materials in order to obtain a material with new
characteristics. Many packs developed at present have been based on the
combination of papers and cartons with AI foils and plastic foils.
Suitable combinations of different plastic foils may be interesting, too. Such
laminated foils have the following advantages: gas and moisture tight, the
possibility for hot filling of yoghurt after pasteurization, the maintenance of
increased storage life of the product, a high structural strength of pack, special
protection against light, etc.
Check your Progress I
1) Define packaging.
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2) How will you select an appropriate packaging material?
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3) Name the protective function of packs.
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4) Enlist the chemical and microbiological protective functions of packs.
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5) Write down mechanical, physical and environmental protective functions of
packs..
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62 ...................................................................................................................
6) Describe packaging materials used for fermented milk products. Packaging, Storage and
Common Defects of
................................................................................................................... Fermented Kilks

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3.5 STORAGE AND KEEPING QUALITY OF

FERMENTED MILKS
During the storage of fermented milks, various changes may occur such as microbial,
enzymatic and abiotic spoilage. The spoilage of yoghurt is discussed hereunder:
i. Microbiological Spoilage
Microbial spoilage refers to an alteration of the outer appearance of yoghurt caused
by micro-organisms. The culture of yoghurt does not cause this type of spoilage. On
the other hand, contaminants capable to grow at lower temperatures and at a low
pH, form colonies or film on the surface of yoghurt deteriorating its appearance. The
microbial spoilage of yoghurt is presented in table 3.1.
Table 3.1. The microbial spoilage of yoghurt
Microorganisms Type of spoilage
Yeasts Colourless, flat, moist colonies.
Moulds White or blue colonies with the formation of film
and over growth of the whole surface.
Geotrichum candidum White-yellow colonies with the formation of film
(Oidium lactis) on the surface.

ii. Enzymatic Spoilage

Enzymatic spoilage (Table 3.2) is attributed to the activity of enzymes present in
yoghurt. These enzymes derive from both the yoghurt culture and contaminants.
Other enzymes such as milk enzymes or those originating from the microflora of raw
milk, which eventual resist heat treatment of the milk have no practical significance.
Table 3.2 shows that contaminants are the main causative agents for the enzymatic
spoilage of yoghurt. They adversely affect the taste and consistency of the final
product.
Table 3.2. The Enzymatic spoilage of yoghurt
Microorganisms Type of spoilage
Yeasts Yeasty flavour and gas formation with bombage
of the closure eventual whey separation in the set
yoghurt.
Moulds Rancidity due to the high degradation of fat.
Cheesy and bitter taste due to the high protein
degradation.
Geotrichum candidum Rancidity due to the high fat degradation. Cheesy
(Oidium lactis) or bitter taste due to the high protein
Yoghurt bacteria After-acidification depending on the after-
acidification ability of cultures may lead to over-
acidification of yoghurt.

63
Fermented Products iii. Abiotic (Chemical) Spoilage
The spoilage occurs without the activity of microorganisms and enzymes. Table 3.3
shows the abiotic spoilage of yoghurt (changes in protein, fat, lactose, vitamins,
mineral salts and in additions such as fruit base or other flavorings) influenced by the
gaseous oxygen and light.
Table 3.3. The Abiotic spoilage of yoghurt
Constituent of Yoghurt Type of Changes through abiotic spoilage
Milk proteins Ageing of the proteins. Changes in the
hydratation state
Milk fat Oxidation and oxidative flavour affected by the
light and air
Vitamins Progressive losses along with ageing
Balance of mineral salts Changes leading to slight increase of pH value
Colour of flavouring and Tendency to pale
fruit base
Fruit acids Affecting the migration of soluble matters from
the packaging materials.
Appearance, Freshness Surface of the product changed due to slight
drying up.

3.6 FACTORS AFFECTING THE KEEPING

QUALITY OF FERMENTED MILKS
(YOGHURT)
A number of factors can affect the keeping quality of yoghurt. Some of them are
external, others are internal.
i. External Factors
i) Influence of Temperature: Unfavorable changes in the quality of
yoghurt, which may occur during its storage, depend considerably upon
the after-acidification ability of culture, the extent and type of contamination,
the quality of packaging and the storage temperature above 0oC.
ii) Influence of Air: The atmospheric oxygen and a low relative humidity of
air may contribute to some abiotic deterioration of yoghurt (oxidation,
drying up of the surface). However, under practical conditions the effect
of atmospheric oxygen has a secondary role in the spoilage of yoghurt.
Also, the effect of the atmospheric relative humidity on the quality of
properly packaged yoghurt with a storage life of 3-4 weeks practically
has no significance.
iii) Influence of Light: Chemical changes in the milk fat occurring in the
presence of gaseous oxygen and catalyzed by light, lead to the so-called
oxidized flavour. It seems that the unstirred yoghurt is more sensitive to
this defect than the stirred yoghurt.
Under practical conditions the appearance of the oxidized flavour in yoghurt
can be prevented by using the packaging materials with a reduced light
permeability and by storing the product in dark.
iv) Packaging Material :A migration of the soluble substances from the
packaging materials into the product may occur depending on the type of
64 plastic materials, the time of contact with the product and the kind of fruit
 acids present in the product. Therefore, all packaging materials should be Packaging, Storage and
Common Defects of
properly tested before use. Fermented Kilks

v) Period of Storage: The period of yoghurt storage before its consumption

depends on the following factors: a) the interval of storage in a dairy plant
(up to 4-6 days); b) the storage time in distribution channels (upto 7 days);
c) the home storage by the consumer (upto 4-6 days). This means in total
2-3 weeks of storage time after the manufacture of yoghurt. Therefore, a
reasonable effort should be made to produce yoghurt with a storage life
of at least 3 weeks. This can normally be achieved in the careful
manufacture.
ii. Internal Factors
i) After acidification of yoghurt: As mentioned, the metabolic activity of
yoghurt organisms during the manufacture of yoghurt is considerably
reduced by cooling after incubation. However, the final product undergoes
after-acidification during its storage even at 0-5oC, because it is not possible
to completely stop the enzymatic activity of lactic cultures through cooling.
The rate of after-acidification of yoghurt depends upon the after-
acidification ability of cultures, the rate of fermentation in bulk or in retail
containers, cooling, the storage temperature and the initial pH value. The
acid production of the streptococci at a pH of 3.9 to 4.3 and of the
lactobacilli at a pH of 3.5 – 3.8. Therefore, the lactobacilli mainly contribute
to acidification at pH value below 4.0. But at a pH above 4.0 both
lactobacilli and streptococci contribute to after-acidification of yoghurt.
ii) The Consistency and Viscosity of Yoghurt: The consistency of set
yoghurt and the viscosity of stirred yoghurt depend upon a number of
factors. During cooling and storage of yoghurt for 48 hours after the
manufacture, an improvement in its consistency, i.e. viscosity occurs. This
phenomenon may occur due to the hydration of proteins, the structure
solidification of the gel during cooling and eventual thyxotropie of the stirred
yoghurt. However, quickly cooled yoghurt does not have optimum
consistency, because the protein hydration and the structure solidification
take a certain interval of time. Fruit yoghurt containing pectin-rich fruits
shows a strong increase in its consistency during the first 10 days of storage
due to the swelling of pectins.
iii) Flavour in Yoghurt: The flavour in yoghurt may be affected during storage.
Practical observations show that during cooling of yoghurt and at the
beginning of its storage, an improvement of flavour occurs probably due
to the formation of specific aroma compounds, the structure solidification
and the impression of freshness influenced by cooling. However, a
significant after-acidification of yoghurt, which may occur during storage,
can mask the flavour sensation.
Certain strains of the yoghurt culture active in the production of
acetaldehyde, may reduce its flavour during storage. Other carriers of
flavour such as fruit base, fruit concentrate do not impose problems in
their stability during storage for 4-6 weeks. Also, the flavour in yoghurt
may be affected by the migration of soluble matters from the packaging
materials. The bitter taste of yoghurt can appear during storage as a result
of the high proteolytic activity of cultures.
65
Fermented Products iv) Colour in Yoghurt:During the long term storage of fruit yoghurt, the colour
of fruit base may become pale (e.g. strawberry and raspberry yoghurt).
The Cold Store
Cooling of yoghurt is carried out in the cold store which should fulfill the following
requirements:
• To allow the normal transport and stapling
• To avoid any losses of cooling.
• Lighting should be made by using special lamps with a little proportion of UV-
rays.
Transport of Yoghurt and its Retail Distribution
Transport of yoghurt or other fermented milks imposes similar requirements in
maintaining a refrigeration as those of storage. It is difficult to fulfill these requirements
during warm days in the summer when the atmospheric temperature may rise to
40oC (e.g. in countries with a warm climate). It is recommended to maintain a
refrigeration in the transport vehicles in two ways:
• Large scale transport should be carried out in insulated vans with own
refrigeration units.
• Small scale transport can be done in cars with different possibilities for
refrigeration (dry ice, liquid nitrogen, moist air, etc.).
During retail distribution, the quality of yoghurt is influenced mainly by the mechanical
shaking, the storage temperature and time of storage.

3.7 DEFECTS OF FERMENTED MILKS

The sensory defects of fermented milks may be divided into the following groups:
• Defects resulting in changes of appearance,
• Defects of flavour and aroma
• Defects of consistency, body and texture, and viscosity.
The defects of dahi and yoghurt are discussed here:
i. Defects resulting in changes of appearance
The most important defects affecting the appearance of yoghurt are presented here
under:
Natural Yoghurt
Defect Cause of Defect
Settled, whey separation Separation of whey due to over acidification/
mechanical shaking of gel/ low solids content/
admixture of air in stored yoghurt.
Fermented Contamination by yeasts and coliform
organisms
Unclean appearance Mud particles, dirt, etc.
66
Formation of colonies or film on Growth of yeasts or moulds Packaging, Storage and
Common Defects of
the surface Fermented Kilks

Aged, not fresh appearance Formation of film on the surface due to drying
up crystal structures on the surface due to
freezing/ packages smeared over/ packages
damaged/ lacking care during transport
Cream line None or insufficient homogenization
Condensed water inside of lid Great fluctuations in temperatures and air
of package pressure
Additional Defects for Fruit- and Flavoured Yoghurts
Atypical colour Addition of fruit juice for colouring or artificial
fruit colouring
Pale colour Discolouration of fruit colour due to heating/
too pale colour of flavouring and fruit base

Un-homogenous appearance Insufficient stirring/ fault during stirring

ii. Defects of Flavour and Aroma
The most important defects affecting the flavour and aroma of yoghurt are presented
here under:
Natural Yoghurt
Defect Cause of Defect
Feed Feed flavour of raw milk
Bitter Too long storage of yoghurt/ high proteolytic
activity of cultures/ growth of proteolytic
contaminants
Burnt (cooked) Too severe heat treatment of the milk
Unclean sour Cultures contaminated by wild lactic acid
bacteria, coliform organisms, etc.
Yeast, fruit Contamination by yeasts
Stale, empty (no aroma) One-sided growth of the streptococci/ too
short time for fermentation or too low
temperature of incubation/ low aroma
production/ low total solids content of the milk/
too strong slime production.
Mealy, gluey Excessive addition of milk powder/ too high
evaporation
Rancid Fat degradation by contaminants/ eventual
due to insufficient heat treatment of the milk.
Cheesy Contamination by proteolytic organisms (e.g.
moulds)
67
Fermented Products Oxidized flavour Effect of light, Metal catalysator, Oxidized
flavour spontaneously occurring after 1-2
days of cold storage (without the effect of light
and metal traces).
High acid (over-sour) Too high acidification during incubation and
after that
Low acid Too low acidification during incubation/
inhibitory substances present in milk/
bacteriophage attacking the yoghurt culture.
Additional Defects for Fruit- and Flavoured Yoghurts
Artificial flavour The use of too high concentrations of fruit base
and flavours/ artificial flavours.
Too sweet Excessive addition of sugar
Atypical, flat Addition of foreign stuffs affecting flavour/
blunting the fruit acids by neutralization/ sever
heat treatment of the fruit base and flavouring
concentrate/ faults in the manufacture of fruit
concentrate.
iii. Defects of consistency and viscosity
The most important defects affecting the consistency and viscosity of yoghurt are
presented here under:
Defects in the consistency of Set Yoghurt
Defect Cause of Defect
Whey separation, settled High acidification of yoghurt before cooling/
containers too early moved/ insufficient
cooling/ strong acid producing cultures/ low
heating temperature of the milk.
Soupy, soft Low protein content of the milk/ too small
inoculum of culture/ short time of incubation/
mechanical shaking of the gel before the
completed coagulation.
Spitted, cleavage Splitting of a spherical segment of the gel due
to mechanical shaking.
Defects in the Viscosity of Stirred Yoghurt
Sandy Contraction of the gel particles: Severe heating
of the milk/ homogenization of the milk at too
high temperature-pressure combination/ too
much evaporation of the milk/ excessive
addition of milk powder and/ or uneven stirring/
shaking during incubation i.e. too early moving
yoghurt from the production line/ stirring the
gel above 38oC, followed by holding above
38oC.
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Slimy Slime-producing contaminants/ slime Packaging, Storage and
Common Defects of
production by yoghurt culture/ addition of Fermented Kilks
slime-producing strains of yoghurt culture/ too
low temperature of incubation of the yoghurt
culture.
Gummy, gluey, tough The use of unsuitable stabilizers/ high
quantities of added stabilizers/ faulty
incorporation of stabilizers.
Phase separation on containers Admixture of air: strong cooling/ pumps;
(below whey, above gel) stirring
Liquid Too strong stirring the gel/ low solids content
of yoghurt/ insufficiently concentrated flavours
and fruit base, insufficiently cooled/ short time
of cold storage/ culture of low slime
production.
iv. Common Defects in Dahi
Defect Cause of Defect
Green/ yoghurt flavour Acetaldehyde accumulation
Oxidized flavour Copper contamination and/ or exposure to
fluorescent light or sunlight.
Yeasty/ Cheesy Contaminating yeast growth
Rancid High lipolytic activity
Insufficient flavour Poor quality starter, low citrate level in milk

Acidic/ sour Excessive level of starter culture.

Weak body Insufficient heat treatment of the mix, milk
SNF too low.
Grainy texture Acidity too high, skim milk powder not
properly stabilized.
Chalky/ powdery texture Excess amount of skim milk powder, poor
quality of powder.
Wheying off Excessive acidity development
Check your Progress 2
1) Describe different cause of spoilage of fermented milk products
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2) Write down the type of spoilage due to microorganisms, in yoghurt.
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Fermented Products 3) What are enzymatic spoilage of yoghurt?
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4) Discuss the factors affecting the keeping quality of yoghurt.
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5) Write down the common flavour defects and their cause of defects in dahi.
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6) Describe different body and texture defects in dahi.
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3.8 ENHANCING THE SHELF LIFE OF YOGHURT

The storage life of yoghurt refers to maintaining its characteristics unaltered for sufficient
period of time, i.e. until the product is consumed. Certain circumstances require the
manufacture of yoghurt with considerably increased storage life, which in turn involve
the use of corresponding methods.
i. Methods for Enhancing the Shelf Life of Yoghurt
Table 3.4 shows different methods for prolonging the storage life of yoghurt. They
involve aseptic manufacture, biostabilization, preservation by heating, drying, freezing
or addition of chemical agents. Microbiological spoilage is more or less restricted
by using all methods. Enzymatic spoilage is controlled entirely or partially by
pasteurizing the gel, drying, freezing or biostabilization.
A biotic spoilage is not essentially restricted by using any method. However, spoilage
plays a slight role in the storage life of yoghurt within 4-6 weeks, when product is
properly packaged and stored.
Table 3.4. Methods for enhancing the shelf life of yoghurt.
Method Effect Removal of spoilage
Aseptic Prevention of contamination Microbial spoilage
manufacture Prevention of contamination Microbial spoilage
Biostabilization and restriction of enzymatic and restriction of
activity enzymatic activity
(after-acidification)
Gassing of the Preventing the growth of Microbial spoilage
head space in contaminants on the surface (by yeasts and
containers of of yoghurt moulds)
70
yoghurt
 Chemical Addition of chemicals for Microbial spoilage, Packaging, Storage and
Common Defects of
preservation preservation (e.g. sorbic acid, partial abiotic
Fermented Kilks
sorbates) spoilage

Pasteurization of Destruction of contaminants Microbial and

yoghurt such as yeasts and moulds enzymatic spoilage
and the majority of lactic acid
bacteria
Freezing yoghurt Prevention of microbial and Enzymatic and
enzymatic spoilage, as well as microbial spoilage,
slowing down abiotic Inhibition of abiotic
spoilage. spoilage
Drying yoghurt Removal of water Enzymatic and
microbial spoilage
HF/ UHF Yeast and molds are killed Partial microbial and
Multiples Lactic acid bacteria are enzymatic spoilage
frequency method “shocked” (?)

The following possibilities for using long life yoghurt are:

• Countries with a warm climate.
• When distribution of foods is difficult and time-consuming.
• Use in countries with suddenly occurring social-medical attention (hunger)
protein-deficiency, etc.).
• For addition in culinary preparations (sauces).
• For yoghurt beverages which must have a rather long storage life.
ii. Temperature and Time of Storage in Different Methods for Prolonging
Shelf Life of Yoghurt
Table 3.5. Temperature and time of storage in different methods for
increasing the Shelf Life of Yoghurt
Method Temperature of Storage ability
storage at at 15-20oC
refrigeration
1. Aseptic manufacture 0-5oC 4-6 weeks Several days
2. Biostabilization 0-5oC 4-6 weeks Several days
3. Gassing 0-5oC 4-6 weeks1 Several days
4. Chemical -- -- --
preservation
5. Pasteurization of 15-20oC Many weeks Many weeks
yoghurt
6. Freezing yoghurt 25oC Deep frozen 3- --
12 months
7. Drying yoghurt Room temperature Many months Many months
1
With complete hermetical closure and hygienic manufacture many months at 3-
4oC

At room temperature only pasteurized yoghurt can be stored for many weeks and
dried yoghurt for many months.
At refrigeration temperature the aseptic made yoghurt. with or with out gassing with
CO2 of the head space in containers, has the storage life of 4 -6 weeks. Freezing
yoghurt may prolong its storage for 3-12 months.
71
Fermented Products i) Aseptic Manufacture: As mentioned, the storage life of yoghurt is adversely
influenced by contaminants such as yeasts and moulds and by the after-
acidification ability of cultures.
Therefore, aseptic manufacture should be combined by using culture of a mild
after-acidification ability.
Manufacture with Special Aseptic Technique: The following requirements
should be accomplished in the aseptic manufacture of yoghurt:
• The yoghurt culture must be free of contaminants.
• Yoghurt milk should be germ-free or at least vegetative germ-free
• The closed production line must be used.
• The production line must be designed for sterilization and aseptic operation.
• Filling and capping to be carried out by using aseptic or semi-aseptic
machines.
• Containers for yoghurt should be germ free.
ii) Aseptic Acidification: This method consists of inoculating the sterile milk under
aseptic conditions with a special culture, followed by acidification,
homogenization and aseptic packaging. Another possibility consists of inoculating
the sterile milk (UHT sterilized), aseptic packaging (Tetra-pack or Brick-pack)
and acidification in packages. The whole method of aseptic acidification can
be applied in large-scale production of long life yoghurt.
iii) Hygienic Manufacture:This method involves the application of common
hygienic measure in production phase (milk, cultures, inoculation, acidification,
cooling, packaging) without the use of special aseptic equipment. Practical
experiences show that it is possible in this way to obtain a reasonably good
storage life of yoghurt. It is important to exclude as much as possible
contamination by yeasts and moulds, as major causative agents of the spoilage
of fermented milks.
iv) Biostabilization: Biostabilization is a method for prolonging the storage of
yoghurt. It involves a regulation of the bacterial growth (streptococci-lactobacilli
ratio), and the enzymatic activity (low after-acidification, reduction of proteolysis,
inhibition of lipolysis). The above biotechnical measures should be supplemented
with aseptic manufacture.
Biostabilization enables the production of long life yoghurt without heat treatment
of the gel or the addition of chemicals. The main purpose is to prevent the
acidification of the final product and to exclude air borne contamination by
yeast and moulds.
v) Gassing:The filling with intent gas carbon dioxide or nitrogen of the head space
in containers of yoghurt can improve the keeping quality of the finished product
by inhibiting the growth of air borne contaminants such as yeasts and moulds.
The packaging material must be sufficiently impermeable.
However, this procedure shows a much better effect when it is combined with
the hygienic or aseptic manufacture of yoghurt. According to the investigation
CO2 treatment extends the storage life of yoghurt, made with the exclusion of
contamination with moulds and yeasts by about 25 per cent.
72
vi) Chemical Preservation: This method refers to the addition of chemicals into Packaging, Storage and
Common Defects of
foods in order to prevent the microbial spoilage (e.g. addition of sorbic acid or Fermented Kilks
sorbates for inhibiting the growth of moulds). The concentration of sorbic acid
used in making cultured milk products of prolonged storage life usually from
0.025 – 0.15 per cent. Yoghurt beverages of prolonged storage could be
produced too by the addition of 50-100 per cent water to yoghurt after
incubation together with sorbic acid, followed by homogenization, cooling,
incorporation of CO2 and bottling.
However, fermented milks including yoghurt are regarded as natural products which
should not contain any foreign chemicals. Therefore, the above method for
prolonging the storage life of yoghurt is not recommended for the practical
application.
vii) Pasteurization of Yoghurt: Pasteurization of yoghurt after incubation aims to
reduce microbial and enzymatic spoilage. By pasteurizing the yoghurt, organisms
such as yeasts and moulds are destroyed completely together with the majority
of the lactic acid bacteria. Since microorganisms in an acid medium are more
susceptible than in a non acid medium, relatively low temperatures such as 60-
70oC are bactericidal. The additional safety measure is either to fill the product
into retail containers while hot or when pasteurized yoghurt has been cooled
before its filling to use aseptic or semi-aseptic packaging machines. Thus, fresh
product is changed to a preserved product with a storage life of many weeks.
The main problem arises in the reduced consistency of yoghurt and losses of
aroma during heating. The latter is slightly affected in flavored yoghurt.
viii) HF/UHF Multiples Frequency Method: This method refers to fast bioelectric
treatment of the product filled into plastic cups by using high frequency and
ultra high frequency frequent alternate electromagnetic field. Yeasts and moulds
are killed and lactic acid bacteria “shocked” but remain viable. The storage life
of yoghurt is increased to 6 weeks without refrigeration. The process is
applicable to set and stirred yoghurt or similar fermented milk products.
ix) Prolonging the Storage Life of Yoghurt by the Artificial Acidification:
The partial or complete artificial acidification, carried out by the addition of
edible acids to milk. This method can improve the storage life of product through
shortening a time for the growth of contaminants during incubation, as well as
through reducing after-acidification of the final product. Since the above method
involves the manufacture of products which is not natural, it does not correspond
to the desire of consumers.
x) Freezing Yoghurt: This method is only applicable for stirred yoghurt. In set
yoghurt ice crystals damage the gel structure causing whey separation. Freezing
stirred yoghurt is little used in dairy plants, although it was shown experimentally
that storage could be considerably prolonged. Stirred yoghurt may be
successfully frozen in a deep cold store at below – 18oC or at -26oC, provided
that its total solids content is sufficiently high as is the case with fruit yoghurt
(20-25%) and often with natural yoghurt (13-14%). Addition of stabilizers has
a similar effect as high total solids. Rapidly frozen yoghurt may be stored at a
low temperature, e.g. -26oC for 3 to 12 months. The defrosting should be
carried out slowly in the cold store, e.g. at +5oC for 24-36 hours. The freezing
does not affect the microflora but the surface of defrosted yoghurt has a less
fresh appearance.
The following advantages of freezing yoghurt may be quoted:
73
Fermented Products a) The efficient prevention of spoilage; b) simple equipment; c) maintenance of
the biological properties of yoghurt and its freshness; d) possibility to rationalize
yoghurt distribution.
Disadvantages are: a) After defrosting the product loses its prolonged storage
life (e.g. compared with pasteurized yoghurt); b) the closed deep-cold channels
between dairies and consumers are required.
xi) Drying Yoghurt: Drying yoghurt is a very old method of the preservation of
yoghurt. At present drying of yoghurt is carried out by using modern machines
and processing. Dry yoghurt is particularly suitable for export to developing
countries, for use in warm regions and in countries with social-medical indications
such as hunger and protein deficiency. The use of yoghurt powder in the above
regions usually involves the erection of small scale production plants for its
reconstitution under hygienic conditions. The use of dried yoghurt for
manufacturing other foods and preparation may be present to considerable
extent, too.
Drying of yoghurt can be carried out by two methods: a) Freeze drying; b) spray
drying.
Freeze-Drying: Freeze-drying of fermented milks, including yoghurt, is carried out
in a similar way as used with lactic cultures. This method is featured by removing
water from the frozen product under a high vacuum. The freeze-dried yoghurt is
packaged under vacuum into suitable containers. The final product is a fine powder
which can be stored at room temperature until consumption. The reconstitution of
dried product is carried out by adding the original quantity of water and stirring with
the powder. The reconstituted freeze-dried yoghurt has a weaker consistency (the
addition of stabilizers may be needed, e.g. alginates), the reduced flavour in natural
yoghurt and lower numbers of the lactobacilli than the initial yoghurt from which it is
made.
Also, it is possible to make tablets using 46 per cent dried yoghurt, 50 per cent
water soluble dried starch, 3 per cent tale and 1 per cent steering: the last three
ingredients are sterilized before use. These tablets are usually used for the preservation
of yoghurt cultures, as an alternative to the sealed ampoules. In tablets coated with
paraffin wax, the flora retained its activity for 18 months, while non-waxed tablets
lost their activity within 9 months.
Spray Drying:Spray drying of yoghurt applies the same principle in removing water
as does drying of milk. As recognized, the drying time of milk is very short (about 30
sec) and high air temperatures are used, normally around 200oC. In the first phase
of the spray drying process, an intense evaporation gives the advantage that the
product receives a gentle thermal treatment, but in the final phase of drying, the
product is exposed to the relatively high temperatures which may have an adverse
effect on its quality (e.g. solubility).
In contrast to milk, spray-drying of yoghurt or other fermented milks is carried out
using a specially mild thermal treatment. The powder must be removed from the
drying chamber as rapidly as possible. Furthermore, it is recommended to the heat-
resistant strains of yoghurt bacteria, which can survive the spray-drying process. At
present there are two methods of spray-drying yoghurt. One method involves
concentrating the milk to 45-48 per cent total solids, homogenizing and cooling to
45oC, adding 1-15 per cent of cultures while stirring vigorously and spray-drying at
a temperature of 55-60oC in the drying zone.
74
Another method involves concentrating the yoghurt previously prepared (a real Packaging, Storage and
Common Defects of
yoghurt) and spray-drying at a temperature of 55-60oC in the drying zone. Yoghurt Fermented Kilks
powder reconstituted has practically the same nutritive value as the initial yoghurt
from which it is made. Due to the reduced lactose concentration, it is particularly
suitable for lactase deficient people. The reconstituted spray-dried yoghurt has a
considerably lower number of the live yoghurt bacteria than the initial yoghurt from
which it is made. The surviving rate of yoghurt bacteria during the drying process
could be expected to be about 20 per cent. However, when heat-resistant strains
are used in making yoghurt, the surviving rate may be considerably higher. A weaker
consistency of the reconstituted yoghurt can be improved by adding precooked
starch or alginates.
Check your Progress 3
1) Enlist different methods for prolonging the storage life of yoghurt.
...................................................................................................................
...................................................................................................................
...................................................................................................................
2) Give temperature and time of storage in different methods for prolonging shelf
life of yoghurt.
...................................................................................................................
...................................................................................................................
...................................................................................................................
3) Describe Chemical preservation method for yoghurt.
...................................................................................................................
...................................................................................................................
...................................................................................................................
4) What is drying yoghurt?
...................................................................................................................
...................................................................................................................
...................................................................................................................

3.9 LET US SUM UP

Packaging forms an integral part of food production, preservation, marketing and
distribution. Packs for fermented milk products have the purpose to protect the
product against mechanical, physical, chemical and microbiological effects. The
following minimum requirements my be quoted: liquid-tight, light protection, germ-
poor, odour-tight, oxygent-tight, acid resistant, structural strength, resistant against
ethereal oils and resistance of printing to water. The storage life of fermented milks
should be taken into account in evaluating these requirements. Short term storage of
the packaged product imposes lesser strict requirements than long term storage.
The storage ability of fermented products is influenced by the storage temperature
and to some extent by the growth of contaminants and the quality of packs. The
extent of after-acidification of fermented products depends upon the storage 75
Fermented Products temperature, properties of starter cultures and initial pH value. The microbial and
enzymatic spoilage can be prevented by the exclusion of air borne contamination by
yeasts and moulds. The storage of the fermented milk products should be carried
out without breaking up refrigeration channel. Aseptic manufacture has the purpose
to prolong the storage life of the product. Gassing with CO2 or N2 of the head space
in containers also extends the storage life of the product. When product is stored at
temperature higher than 10-15oC its over acidification can be prevented only by the
pasteurization. However, this treatment changes the original character of fermented
milks as fresh product. For special purposes drying of certain fermented products
such as yoghurt or its freezing can be applied.

3.10 KEY WORDS

Abiotic Spoilage : This spoilage occurs without the activity of
microorganisms and enzymes.
Aseptic packaging : Aseptic conditions during packaging are
maintained by using sterile air in the section
for cup forming, filling and sealing or cup filling
and capping.
Aseptic packs : Aseptic packs have been developed in order
to meet special requirements in the
manufacture of long-life products.
Biostabilization : Biostabilization is a method for prolonging the
storage life of fermented milk product. It
involves a regulation of the bacterial growth
and enzymatic activity. It enables the
production of long life yoghurt without heat
treatment of the gel or the addition of
chemicals.
Chemical Preservation : The method refers to the addition of chemicals
into foods in order to prevent the microbial
spoilage.
Enzymatic spoilage : Enzymatic spoilage is attributed to the activity
of enzymes present in fermented products.
These enzymes derive both from starter
cultures and contaminants. They adversely
affect the taste and consistency of the final
product.
Gassing : The filling with carbon dioxide or nitrogen of
the head space in containers of product in
order to improve the keeping quality of the
finished product by inhibiting the growth of
air borne contaminants such as yeast and
moulds.
Hygienic manufacture : This involves the application of common
hygienic measures in each production phase
such as milk, cultures, inoculation,
acidification, cooling, packaging, without the
76 use of special aseptic equipment.
Microbial spoilage
Packaging
Protective function
Thermoformed cups
Waxed carton packs
: Microbial spoilage refers to an alteration of Packaging, Storage and
Common Defects of
the outer appearance of fermented milk Fermented Kilks
products caused by microorganisms.
: Packaging helps to prevent spoilage, weight
losses, and enhance consumer acceptability.
It protects the food against contamination by
dust, microorganisms, toxic substances or
those factors which influence taste, flavour and
loss of moisture.
: The protective function of packs to the effect
of mechanical, physical, chemical and
microbiological factors.
: The thermoformed cups are produced by
using specially designed equipment for
automatic cup forming, filling, sealing and
punching.
: Carton packs coated with paraffin to perform
special function.

3.11 SOME USEFUL BOOKS/ REFERENCES

Ananthakrishnan, C.P. and Srinivasan, M.R. (1964). Milk products of India, Indian
Council of Agricultural Research, New Delhi.
Aneja, R.P., Mathur, B.N., Chandan, R.C. and Banerjee, A.K. (2002). Technology
of Indian milk products. A Dairy India Publication, Delhi.
Anon (1990). Technology of traditional milk products in developing countries, FAO
Animal Production and Health, Paper 85, FAO/ WHO, Rome, Italy.
Chandan, R.C. and Shahani, K.K. 1982. Cultured milk products, In CRC Handbook
of processing and utilization in agriculture, Vol. Animal Products. Ed. 1., Wolf,
CRC Press, Boca Ratn, FL., USA.
De, S. 1980. Outlines of Dairy Technology, Oxford University Press, New Delhi.
Joshi, V.K. and Pandey, A. (2004). Biotechnology: Food fermentation (Microbiology,
Biochemistry and Technology). Vol I and II. Educational Publishers, New Delhi.
Ladkani, B.G., Tiwari, B.D., Kanawjia, S.K. and Singh, S. (1993). Development
of a process for the manufacture of lassi powder. Annual Report, NDRI
Deemed University, Karnal.
Nakazawa, Y. and Hosono, A. (1991). Functions of fermented milk – Challenges
for the health sciences, Elsevier Science Publishers Ltd., England.
Patel, R.S. (1997). Process alterations in the manufacture of shrikhand, In advances
in traditional dairy products, CAS (DT), NDRI Deemed University, Karnal.
Rasic, J.L. and Kurmann, J.A. (1978). Yoghurt – Scientific grounds, technology,
manufacture and preparations. The Technical Dairy Publishing House,
Jyllingevbej, Denmark.
Tamime, A.Y. and Robinson, R.K. (2004). Yoghurt Science and Technology, 2nd
Edn. CRC, Press, Washington, DC. 77
Fermented Products Tiwari, B.D. 1998). Technology of lassi, In advances in Traditional dairy products,
CAS (DT), NDRI Deemed University, Karnal.
Upadhyay, K.G. and Dave, J.K. (1997). Shrikhand and its technology. Indian
Dairyman, 28(9): 487.
Yadav, J.S., Grover, S. and Batish, V.K. (1993). A Comprehensive Dairy
Microbiology, metropolitan, New Delhi.

3.12 ANSWERS TO CHECK YOUR PROGRESS

Your answer should include the following points:
Check Your Progress 1
1. i. A package performs three main function: it contains the product, protect
the product from environmental hazards and helps in marketing the product.
ii. Packaging can be defined as a tool that protects and contains our goods
with the aim of minimizing the environmental impact of our consumption.
2. i. The specific sensitivities of contents such as moisture, oxygen, etc, factors
changing the contents viz. temperature, RH, pH, etc.
ii. Type, shape, biodegradability, filling and sealing properties.
iii. Ease of handling and should not contaminate the product.
3. The protective functions of packs are:
i. Chemical, microbiological, hygienic, mechanical, physical and
environmental protective functions.
ii. Marketing function.
4. i. Chemical protective function of packs is required: (i) aroma, odour and
oxygen tight; (ii) no adverse effect on the product, no corrosion and acid
resistance of packs and of materials for declaration.
ii. (i) Microorganisms should not pass through packs, acidification should
not be disturbed and prevention of contamination. (ii) protection against
microbiological effects through defective containers or improperly
packaging system.
5. i. The following mechanical protective function are required: (i) Resistance
against shocks, moisture and ability to resist transport and storage; (ii)
Water or liquid tight, suitable shape and the head space should be very
small.
ii. The following physical protective function are required: (i) effect of light
should be reduced through laminated foils. (ii) to prevent air borne
contamination by microorganisms.
iii. The following environmental protective function are required: (i) no
damaging effect on environment during burning of sweepings. (ii)
development of biodegradable plastics and other packaging materials.
(iii) Possibility of recycling of used packaging material.

78
6. i. Packs can be made of glass, plastics, carton and aluminum foils. Packaging, Storage and
Common Defects of
ii. The packs are made of different sizes and forms such as glass bottles, Fermented Kilks

glass jars, pre-fabricated cups readY-made cups), thermoformed cups,

plastic cups, waxed carton.
Check Your Progress 2
1. i. Microbial spoilage caused by mainly yeasts, moulds. Yeasts produce
colourless, flat and moIst colonies. Moulds develops white or blue colonies
and covers whole surface. Whereas, Geotrichum canadidum forms film
of white yellow colonies on the surface of the product.
ii. The enzymatic spoilage is caused by the enzymes produced by
microorganisms such as yeasts, moulds, Geotrichum candidum and
yoghurt bacteria. They produce defects like yeasty flavour, gas formation,
whey separation, rancidity, bitterness and sourness.
iii. Abiotic spoilage is also known as chemical spoilage which occurs without
the activity of microorganisms and enzymes. The change in protein, fat,
lactose, vitamins, minerals, and in additives such as fruit base or other
flavourings is influenced by the gaseous oxygen and light.
2. There are a number of factors that can affect the keeping quality of yoghurt as
well as other fermented milk products. These factors can be grouped into (i)
external factors and (ii) internal factors. The external factors are influence of
temperature, effect of air, impact of light, effect of packaging material and storage
conditions. The internal factors are after-acidification of fermented milks,
consistency and viscosity, flavour and colour of the products. These factors
should be elaborated while answering.
3. The typical flavour of dahi is due to presence of diacetyl which is formed during
fermentation. The green or yoghurt type flavour defect in dahi is due to
accumulation of acetaldehyde. The oxidized flavour defect is due to
contamination with copper or exposure to light. Yeasty and cheesy defects are
due to contaminating yeast growth. Rancid off flavour defect is due to high
lipolytic activity, whereas, insufficient flavour is caused by poor quality starter
culture. An acidic or sour taste is developed because of using high amount of
starter cultures.
4. The common body and texture defects are weak, grainy, chalky or powdery
and wheying off. The weak body defect is mainly due to insufficient heat
treatment of the mix and too low solids not fat content in the product. Grainy
texture formation is caused by too high acidity and poor solubility of skim milk
powder. Whereas, chalky/ powdery texture is due to excessive use of milk
powder and poor quality of powder. Wheying off is also a very common defect
in fermented milk product which is mainly caused by the development of
excessive acidity.
Check Your Progress 3
1. The different methods for prolonging the storage life of yoghurt are aseptic
manufacture, biostabilization, preservation by heating, drying, freezing and
addition of chemical agents such as sorbic acid, potassium sorbate, sodium
sorbate, etc.
2. The storageability of yoghurt can be enhanced by employing the following
methods: 79
Fermented Products i. The aseptically manufactured yoghurt can be kept well upto 4-6 weeks at
0-5oC.
ii. By employing biostabilization and gassing methods, yoghurt can be stored
good upto 4-6 weeks.
iii. Pasteurized yoghurt can be kept well for many weeks at 15-20oC.
iv. Frozen yoghurt keeps well for 3-12 months whereas dried yoghurt can
be kept good at room temperature for many months.
3. In order to prevent microbial spoilage certain chemicals are added to yoghurt;
such as addition of sorbic acid and sorbates for inhibiting the growth of moulds.
The concentration of sorbic acid used to prolonged storage life of cultured milk
usually amounts to 0.025 – 0.15 per cent. Carbonation is done to prolong the
shelf life of fermented beverages.
4. Drying yoghurt is a very old method of preservation of yoghurt. Dried yoghurt
is particularly suitable for export to developing countries.
Drying of yoghurt can be carried out by two methods: (i) Freeze drying; (ii) Spray
drying.
Freeze Drying: Freeze drying of fermented milks, including yoghurt, is carried out
in a similar way as used with lactic cultures. This method is featured by removing
water from the frozen product under high vacuum. The freeze dried yoghurt is
packaged under a vacuum into suitable containers.
Spray Drying: Spray drying of yoghurt applies the same principle in removing
water as does drying of milk. Spray-drying yoghurt or other fermented milks is
carried out using a specially milk thermal treatment. In this method milk is concentrated
to 45-48 per cent total solids, homogenizing, cooling to 45oC, adding 10-15 per
cent of cultures while stirring vigorously and spray drying at a temperature of 55-
60oC in the drying zone. Another method involves concentrating the yoghurt previously
prepared and spray drying at a temperature of 55-60oC in the drying zone.

80