《利樂（Tetra Pak）：2024一條乳基與植物基酸奶的混合生產線白皮書（英文版）（32頁）.pdf》由會員分享，可在線閱讀，更多相關《利樂（Tetra Pak）：2024一條乳基與植物基酸奶的混合生產線白皮書（英文版）（32頁）.pdf（32頁珍藏版）》請在三個皮匠報告上搜索。

1、 General Dairy and plant-based yoghurt production on a single hybrid line White paper General Publisher Tetra Pak Processing Systems AB SE 221 86 Lund,Sweden Published May 2024 Tetra Pak International S.A No part of this publication may be duplicated in any form without the source being indicated.3

2、CONTENTS INTRODUCTION _ 4 Who is this white paper for?_ 4 Where are you now?_ 5 What youll learn _ 6 Yoghurt terminology and the law _ 6 FERMENTED PRODUCTS GROWTH OPPORTUNITIES _ 7 Global yoghurt trends _ 7 New opportunities _ 9 WHAT DAIRY AND PLANT-BASED _ 10 YOGHURT PRODUCTION HAVE IN COMMON _ 10

3、How raw materials and ingredients affect processing _ 12 WHAT MAKES A LINE“HYBRID”CAPABLE OF BOTH DAIRY AND PLANT-BASED PRODUCTION?_ 16 Extraction _ 16 Product formulation _ 18 Heat treatment _ 19 Starter culture addition and fermentation _ 21 Smoothing&cooling _ 22 Buffering,fruit dosing&filling _

4、22 Extra processing steps for ambient products _ 23 CLEANING IN PLACE(CIP)_ 24 ALLERGENS AND PRODUCT CHANGEOVERS _ 25 HYBRID LINES IN SUMMARY _ 28 TETRA PAK YOUR GO-TO PARTNER FOR YOGHURT PRODUCT INNOVATION _ 29 REFERENCES _ 31 4 INTRODUCTION Who is this white paper for?There are many diverse indust

5、ry groups who are interested in broadening their knowledge of fermented plant-based foods and beverages,in particular yoghurt products,in order to expand their production capabilities and product flexibility.We see that many dairy producers are interested in plant-based products,in keeping with curr

6、ent market trends.Thus this white paper is targeted to any producer who wants to produce both dairy-based and plant-based yoghurt products on a single hybrid line.The principles we lay out apply both to new lines and the adaptation of existing lines.In both cases,there is the added benefit of future

7、-proofing your yoghurt production by increasing flexibility,but also challenges such as the risk of allergen cross-contamination.This white paper has been written for:Marketing managers who aim to launch new product formulations,expand consumer appeal,and maintain flexibility in their product portfo

8、lio Production managers concerned with productivity,efficiency and flexibility of production lines R&D managers responsible for creating new formulations and products Project managers responsible for installing a new plant,or adapting existing lines Quality assurance managers Environmental and safet

9、y managers concerned with environmental impacts,sustainability issues,product safety and consumer safety especially regarding allergens.5 Where are you now?If you are already well established in traditional dairy production,you have already mastered many of the hygienic aspects and have a good sense

10、 of dairy yoghurt production.This white paper will fill the gaps in your food technology know-how so that you are able to start working with plant-based yoghurt products.This can be challenging,because plant-based fermentation production hasnt yet achieved the degree of standardisation and efficienc

11、y that is well established in the dairy industry.This is partly because of the huge variety of raw materials and partly because it is a relatively young product category.As a result,there is still a lot to be done to establish best practices for product quality and processing efficiency.Making the l

12、eap to plant-based yoghurt will also involve understanding the varying composition and functionality of raw materials and ingredients such as thickeners,and how these ingredients are impacted by different processing steps.Finally,if you are a newcomer to the food industry,but have creative ideas for

13、 new fermented foods,this white paper will provide the overview you need to move ahead with your plans.6 What youll learn This material,developed by our dairy and plant-based processing experts,puts our combined knowledge at your disposal,providing you with a competitive edge.It will help you unders

14、tand how the production processes required for dairy and plant-based products differ,how they depend on input characteristics and formulations,and how to make adjustments to optimise production of both types of products.This includes reviewing:The technology and equipment involved capabilities,chall

15、enges and solutions The compromises and risk management involved in investing and running a“hybrid line”what decisions do you have to make,and what is the impact of these decisions?The technology requirements at an early stage of design,which can reduce your time to market and investment costs,thus

16、reducing the risk.With more than 100 years of experience in dairy products and more than 40 years in plant-based production,we are ready to share our knowledge with you.Yoghurt terminology and the law Terminology is important.When we refer to plant-based yoghurt in this white paper,we mean fermented

17、 plant-based products that are similar in taste,appearance,and texture to traditional dairy-based yoghurt.But please note that in many markets the term“yoghurt”is reserved for dairy products,so in some markets,producers are experimenting with other labels for new product lines,such the novel word“gu

18、rt”.You should verify your own market and legal requirements before deciding which term to use in communications and advertising,when referring to plant-based yoghurt products.7 FERMENTED PRODUCTS GROWTH OPPORTUNITIES Global yoghurt trends Whether dairy-based or plant-based,fermented foods such as y

19、oghurts and yoghurt-like products are increasing in popularity world-wide.The global yoghurt market for all types,including both dairy and plant-based,and ranging from plain yoghurt to flavoured yoghurt drinks,was valued at$98 bn in 2020.It is projected to grow to$172 bn by 2031 with a compound annu

20、al growth rate(CAGR)of 5.5%from 2022 to 2031.Even stronger growth is seen in India,where the market is expected to grow at a CAGR of 7.4%to 2031,to large extent due to the industrialisation of fermented products traditionally made at home.The increasing interest in yoghurt products is largely driven

21、 by the health benefits associated with the traditional dairy product,such as:Dairy products naturally contain high quality protein including all essential amino acids,and the increased content in many yoghurt types make it a great source of protein.They are good sources of calcium and vitamins D an

22、d B12.They contain live bacteria,which has a positive impact on immunity and gut health.Health is a key driver for increased yoghurt consumption,in particular among younger people seeking to maintain a healthier lifestyle.To meet consumer demand,plant-based yoghurt-like products are often formulated

23、 to mimic the health benefits of yoghurt,ensuring that they are in many ways an alternative to traditional dairy products.The market growth in yoghurt goes hand-in-hand with an increased variety of products,and producers must provide a continuously broader product assortment.The high innovation rate

24、 also leads to a move into premium product ranges,allowing producers to command higher consumer prices.For instance,yoghurts are now also seen as an indulgence product,being consumed as desserts even in markets where they were traditionally only used as an ingredient in cooking.8 Why the interest in

25、 plant-based yoghurt?The market for plant-based yoghurt products is growing even faster than dairy-based,for reasons that range from nutritional and economic to regulatory and environmental.The global market is forecast to exceed$5 bn by 2030,reflecting a CAGR of 10%between 2020 and 2030.Consumers a

26、re increasingly aware of the impact of their diet on physical and mental health,and therefore look for alternatives to many traditional food products.Consumers will continue to seek out products both dairy and plant-based that balance their intake of carbohydrates,proteins and other nutrients in a w

27、ay that enhances their health.And plant-based products are suitable for the growing number of people following vegan lifestyles.Many consumers are choosing more sustainable products,with the aim to fight climate change by reducing their environmental impact,even if this means paying a premium for en

28、vironmentally friendly brands and products.The environmental effects of greenhouse emissions coming from the dairy industry are under particular scrutiny.In many cases this means that plant-based products,in their role as“dairy alternatives”are often perceived as not only good for the consumer but a

29、lso good for the planet.However,it is important to consider the full value chain when evaluating a food products impact on the environment,as consumers will value some plant-based proteins more than others due to their lower environmental footprint.We must consider the environmental impact of achiev

30、ing a given nutritional value,but also how and where different raw materials are produced.9 New opportunities We are seeing the confluence of several trends here:tasty products targeting health concerns,plant-based diets,sustainability,and animal welfare.Plant-based products may be consumed as part

31、of any meal during the day,just like dairy products.North America and Europe are rapidly developing markets for plant-based products in general and plant-based yoghurt in particular.But there is also a long tradition and significant growth of plant-based products in East Asia(particularly based on s

32、oya),and these three combined markets account for 65%of global production.Research by the Plant Based Foods Association in the US show that 35%of Americans are actively decreasing their dairy and meat consumption.And the increasing health consciousness of consumers is responsible for the increase in

33、 veganism in the Asia and Pacific markets,again giving opportunities to grow plant-based yoghurt consumption.The Middle East and Africa are also seen as developing markets for plant-based yoghurts.There is a general growth in the availability of convenience foods in these markets,which is helping cr

34、eate an opportunity for the launch of new,innovative products.10 WHAT DAIRY AND PLANT-BASED YOGHURT PRODUCTION HAVE IN COMMON Yoghurt exists in almost endless varieties.Everything from low-viscous,almost milk-like and drinkable,to thick,mouldable textures can be produced by varying the production pr

35、ocess.Though most yoghurts are chilled products containing live and active yoghurt bacteria,there are also products that are heat-treated after fermentation,so that they can be stored and distributed at ambient conditions(often referred to as“thermised yoghurt or“ambient yoghurt”).The most common ty

36、pe of chilled yoghurt production process is that of stirred-type yoghurt,aimed at preserving as much texture as possible in the yoghurt,while simultaneously giving the product a spoonable,shiny and homogeneous consistency.At first glance,the production lines used for stirred dairy yoghurt and plant-

37、based yoghurt products look very similar.In some cases,particularly if the plant-based product is based on a concentrate(“paste”,“compound”or“syrup”),they might even appear identical,and it is only when we focus on specific processing steps,design details and parameters,that the different needs and

38、requirements of these products become clear.But lets start with commonalities:While it is possible to ferment the milk or the liquid plant base using only a starter culture,other ingredients are often added to influence the composition,flavour,texture,stability and viscosity of the final product.Thi

39、s formulation of the liquid is often done by mixing.The formulated liquid is heated before fermentation.While the heat treatment can have a slightly different overall purpose for dairy and plant-based products,in both cases it ensures that the final product is safe to consume,as well as eliminates m

40、icroorganisms that might otherwise compete with the starter culture during fermentation.Homogenisation is applied as a part of the heat treatment,uniformly decreasing the size of fat/oil droplets in the liquid.After adding the starter culture,the product is left to ferment for a number of hours unti

41、l the desired pH level is reached.In addition to acidity,the fermenting culture produces aroma compounds that contribute to the flavour of the final product.11 In order to store/buffer the product before filling,the fermentation is slowed down by cooling the product.It is also simultaneously smoothe

42、d to give it a more homogeneous,smoother texture.For flavoured products,fruit preparations or aromas are dosed inline into the fermented product as it is pumped into the filling machine from the buffer tank,or directly in the filling machine.Finally,the filled product is cooled to refrigerator tempe

43、rature in cold storage,from which it can then be distributed to retailers under chilled conditions,with a shelf life of about one month.Figure 1 Example of production line for plant-based yoghurt for chilled distribution Alternatively,the product can undergo a second heat treatment after fermentatio

44、n and cooling,designed to inactivate the fermenting bacteria.Followed by ultra-high hygienic or aseptic filling,this creates a product that can be stored and distributed at ambient temperatures,with a shelf life of 4-12 months.Figure 2 Example of production line for plant-based yoghurt for ambient d

45、istribution Plant-based base Formulation Homogenisation&heat treament Culture dosing Fermentation Smoothing&cooling Buffering Heat treatment Aseptic buffering Filling Plant-based base Formulation Homogenisation&heat treament Culture dosing Fermentation Smoothing&cooling Buffering Fruit dosing Fillin

46、g 12 How raw materials and ingredients affect processing There are many different types of plants that can be used to create plant-based yoghurts,but the most common ones today are soya beans,oats,almonds,coconut and peas and sometimes blends of different raw ingredients.Some plant-based proteins ar

47、e more favoured than others for fermented products.Mouthfeel and flavour are paramount:consumers look for a smooth texture and pleasant taste.Another issue is their suitability based on protein content and potential allergens;yet another is their local availability and environmental impact throughou

48、t the full value chain.Whatever the raw material,their particular properties will influence the recipe,process and final product.Milk is rich in both protein(3.4%)and sugar(4.8%),while oat base is mainly rich in sugar but low in protein(the raw oat itself includes some protein but in the oat“base”ex

49、tracted for fermentation the level is lower).Almonds,on the other hand,are rich in fat but lower than milk in both protein and carbohydrates,and soya beans are rich in protein like milk but contain less sugar and fat.Figure 3 Examples of milk and plant-based extracts that can be used for yoghurt pro

50、duction 14 12 10 8 6 4 2 0 Total solids%Proteins%Fat%Sugar/carbohydrates%Fresh milk or recombined Soya from grinding Oats from flour/kerns,treated with enzymes Almond from paste 13 Even if the protein level is the same,the type of protein can be different,influencing the nutritional as well as funct

51、ional properties of the product.And some proteins are even classified as allergens,which means they can trigger allergic reactions in the consumer(read more about allergens in a later section).Plant-based products can contain small particles of various sizes,such as plant fibres,depending on the ext

52、raction process.This can affect mouthfeel and product stability as well as the choice of processing equipment and the ease of cleaning that equipment.As milk and plant-based products have different origins,they also have different microbiological flora,which can affect,for instance,the heat treatmen

53、t program required to create a safe product.Adding yoghurt starter culture to milk results in fermentation and formation of the protein network that gives the yoghurt its characteristic texture and appearance.Even so,it is common in many countries to add stabilisers and thickeners to fermented dairy

54、 products.These additives will then contribute to the final texture and stability of the product.The use of these ingredients might be motivated by cost optimisation(replacing protein/fat in the product with less expensive components),or used to prolong shelf life by improving product stability(for

55、instance in regions with an unreliable cold chain).Fermenting liquid plant base alone using a starter culture does not automatically result in a yoghurt-like product.In fact,other ingredients often need to be added to aid the fermentation or influence the flavour,texture and stability of the final p

56、roduct.If there isnt sufficient sugar in the plant base this must be added(or created through hydrolysing starch)for fermentation to proceed.If the protein level is low,or the protein is of the wrong functional type,the fermented product will not have the viscous texture associated with yoghurt.The

57、protein content can be boosted by adding protein isolate,while thickeners or stabilisers can be added to compensate for weak gel-forming ability.Adding starch,for instance,has long been a popular and relatively inexpensive means of producing a more viscous texture.More and more producers are finding

58、 ways to create products without adding starch,but it is still a very common ingredient.In some cases,adding protein to a plant-based yoghurt is done for the sake of the nutritional protein content rather than its impact on texture.The fat level of the product is often adjusted by adding oil/fat to

59、give a fuller and smoother mouthfeel.14 Many formulations for plant-based products also contain ingredients like minerals and vitamins to increase the nutritional value of the product,as well salt and sugar to adjust the flavour,even in an“unflavoured”product.The actual starter culture also differs

60、between dairy and plant-based products.In dairy products the fermenting starter culture always contain the same two bacteria(Streptococcus thermophilus and Lactobacillus bulgaricus)and in many countries the use of these bacteria is a legal requirement for products sold as“yoghurt”.The plant-based pr

61、oducts are generally less regulated.Besides ensuring efficient fermentation,many starter cultures for plant-based yoghurts aim to create flavour compounds similar to those found in dairy products,even though the raw material is different.Today there are also starter cultures available for the plant-

62、based range that partly compensate for the weaker gel-building abilities of the raw material by having texturising properties themselves,making it possible to create thicker textures without the addition of other ingredients.Ingredient properties must be taken into account when designing a yoghurt p

63、roduction line of any type.For instance,warm-swelling starch is often the main thickener used for plant-based products.Depending on the type and amount of starch added,the viscosity of the product can develop in different stages.As Figure 4 shows,most of the viscosity development for a dairy product

64、 takes place in the fermentation tank,and then later during the first day of cold storage.But for some types of plant-based products containing starch there is a significant viscosity increase immediately during the heat treatment that follows the formulation.Others build viscosity first in the ferm

65、entation tank or not until the product has been filled and placed in cold storage(compare the two plant-based starch systems in Figure 4).Knowledge of the ingredients and the starch system is therefore essential to the final design of a production line and heat treatment.15 Figure 4 Example of how d

66、ifferent starch systems may influence product viscosity throughout the yoghurt processing line,compared to the behaviour of typical dairy yoghurt.The formulation of an ambient fermented product has different requirements than a chilled fermented product.Not only does it have to deliver an acceptable

67、 product quality after the second heat treatment,but it also has to ensure that product quality remains stable during the significantly longer shelf life expected of the product,and at ambient storage conditions.This is generally achieved through the additional dosage or change of type of stabiliser

68、s and thickeners included in the product.Together these biological and chemical differences mean that requirements on processing lines for dairy and plant-based products are different,which we explain in the following sections.Plant-based starch system#1 Plant-based starch system#2 Dairy Treatment S

69、torage Packaging Buffering Fermentation Milk/base Viscosity 16 WHAT MAKES A LINE“HYBRID”CAPABLE OF BOTH DAIRY AND PLANT-BASED PRODUCTION?How can a yoghurt line qualify as a hybrid production line,capable of alternating between dairy-based and plant-based production?In this section we introduce the e

70、lements of a hybrid line step-by-step,evaluating each process for how it handles dairy vs plant-based materials,what challenges it must meet,and how processing components can be adapted or configured to reach a desired result.Extraction While dairy yoghurt starts with milk in various forms that are

71、the products of well-known standardised processes,plant-based processes start by extracting the relevant proteins and other ingredients from the raw material.This process is commonly referred to as“extraction”,and results in a liquid base.The extraction can be done directly at a production site.Alte

72、rnatively,producers can purchase ready-made extracts in the form of concentrates(compounds or syrups),powders or pastes from ingredient suppliers.Using an extraction line provides an opportunity to tailor the liquid base to specific requirements in order to customise your product.However,suitable ex

73、traction capability may require an additional investment.Syrup Powder Paste 17 The extraction process looks very different depending on what type of plant raw material is used,but it typically involves:Grinding including mixing with water Enzymatic treatment for starch-rich raw material,such as oats

74、 Separation of insoluble solids Heat treatment The process and parameters used in the extraction will have an impact on the product composition,taste,mouthfeel and even functionality of proteins and carbohydrates.It is a crucial step for the final product quality and can impact the rest of the produ

75、ction line.Figure 5 shows an example from oat-based production.Figure 5 Oat extraction process More information about the extraction process of oat base can be found in the Tetra Pak white paper “Oat-based beverages”.Dry handling Grinding or mixing Hydrolysation Deactivation&cooling Separation Stora

76、ge Beverages Fermented products Prepared foods Frozen desserts Cheese alternatives Plant-based creams 18 Product formulation The formulation step is commonly carried out using a mixer where the different ingredients(powders or liquids)are incorporated in the plant-based or dairy liquid.The starting

77、point for formulation in a dairy line is typically pasteurised milk where the fat level has already been adjusted(standardised)to the required level.The powder volumes added are often low and consist of powders that are easy to mix and dissolve(sugar or milk powder concentrates),meaning that many pr

78、oducers do the mixing cold.After mixing,the product is still a low-viscosity liquid.For plant-based products the ingredient list could be longer and the amount of ingredients higher than for dairy products.Some ingredients may require warm mixing,and the addition of oil and certain stabilisers typic

79、ally need high-shear mixing to create a mix that is homogeneous and lump-free.For this reason,a high-shear mixer is recommended as well as a mixing station that includes heating functionality.In the case of the product formulation step,it is therefore often the plant-based products that have the hig

80、hest requirements on the equipment used.A mixing station with a high-shear mixer and heating functionality is beneficial also for dairy products,even if it is not strictly necessary.19 Heat treatment The formulated liquid base,whether dairy or plant-based,is heat-treated before fermentation,accompli

81、shing three major changes:It eliminates pathogenic bacteria that would be able to grow and multiply in the final product.This is a legal requirement.The heat treatment will also reduce the overall microbial load,which gives the starter culture competition-free conditions to ferment the product when

82、it is added.It denatures proteins,which is of great importance to dairy products,as this will significantly improve the texture and stability of the final product.In fact,the protein denaturation is what determines the heat treatment program for these products.For plant-based products denaturation o

83、f proteins doesnt always have a direct connection to the final product quality.Not only is there generally less protein in plant-based products,but their functionality differs from those of dairy.In addition,the plant-based liquid is often already heated to high temperatures in the extraction proces

84、s,meaning that the heat treatment before fermentation is just part of the total heat load applied to the product before fermentation,and protein denaturation may therefore already have taken place.It activates the functionality of different stabilisers and thickeners,for instance starch.As mentioned

85、 earlier,stabilisers and thickeners are not strictly necessary in all fermented products,but are often added as a way to improve the final product quality in terms of texture and stability.Heat treatment of dairy products is often done by heating the milk to 60-65C,at which temperature the product i

86、s homogenised at a pressure of 200 bar or higher.Sometimes the homogenisation step is preceded by passing the milk through a deaerator to reduce the amount of air in the product.The product is then heated further to 90-95C and held for 5-10 min before it is cooled down to fermentation temperature(43

87、C)and transferred to the fermentation tank.Starter culture is added after the heat treatment to start the fermentation.The fermentation time varies between 4-8 hours,depending on the recipe.Heat treatment of plant-based products can often be done using the same steps and temperatures as for dairy,bu

88、t the holding time at 95C can vary from 1-10 min depending on the recipe(primarily depending on what type and amount of starch/thickener is used).If the product contains starch this will impact the exact homogenisation temperature.20 Like dairy products,in most cases the fermentation time is 4-8 hou

89、rs.If the fermentation time is longer,it may be necessary to apply a significantly higher heat treatment temperature to ensure a final product that is safe for consumption.The exact heat treatment program needed is decided on a case-by-case basis.While the dairy heat treatment unit is typically base

90、d on a plate heat exchanger,we recommend a tubular heat exchanger for plant-based products.This is partly due to the fact that plant-based products might contain particles or fibres,which risk getting stuck in the channels of a plate heat exchanger,but mainly because certain plant-based products qui

91、ckly build up layers of deposits,or fouling,on the plate surface when heated.This in turn means that the production runs will be short before the unit has to be cleaned.With tubular systems,the impact of fouling will be smaller,and the cleaning interval can be extended.Even if no fibres or particles

92、 are present,the product might still produce fouling;but if you can accept a short operational time,then a plate heat exchanger could still work for plant-based products.On the other hand,a tubular heat exchanger can be used for both plant-based and dairy production with very limited or no impact on

93、 final product quality.The remaining drawback compared to a plate heat exchanger might then be a higher investment cost and slightly higher steam consumption cost.You would have to compare this with the costs related to shorter run times,additional CIP,as well as a higher service cost on a plate-bas

94、ed system.So if you are building a hybrid line capable of handling both,we would recommend tubular heat exchangers from the start,as replacing a plate-based heat exchanger for a tubular one at a later stage could be difficult and costly.There can also,as we explained,be differences in the heat treat

95、ment program(temperature and time)and how the heat exchanger is configured,but it is possible to take this into consideration from the start.21 Starter culture addition and fermentation Starter cultures are added to both dairy and plant-based products either using a starter dosing system inline on t

96、he way to the fermentation tank,or directly into the fermentation tanks.In both cases the starter culture is frozen or freeze-dried and the amounts added are similar.If you use an inline starter culture system,the same design can typically be used for both yoghurt types.Fermentation takes place in i

97、nsulated tanks into which the product is pumped after heat treatment.For both dairy and plant-based products it is important that no warm product is left standing still in the connecting pipe.As previously mentioned,the fermentation time of dairy products is in most cases in the range of 4-8 hours,w

98、hich is also the typical for plant-based products,although some products have significantly longer fermentation time.Normally insulation of the fermentation tank is sufficient to ensure that the product temperature is kept constant in the tank during fermentation.Only in extreme cases(fermentation t

99、ime 10 hours)would the fermentation tank need to be equipped with a heating jacket to maintain fermentation temperature.Dairy products still have very low viscosity when entering the fermentation tank and the starter culture is added.However,after fermentation,when the product is agitated before the

100、 tank is emptied,the dairy product is considerably more viscous,as a protein network or“gel”has been formed.The network is very sensitive to mechanical shear too much mechanical treatment can break it down irreparably,resulting in a less viscous and less stable final product.The fermentation tank ag

101、itation and emptying system is therefore designed to apply minimal possible shear to the product after fermentation,while still making it possible to empty the tank efficiently.Plant-based products can have a similar viscosity to dairy products or be even more viscous when they enter the fermentatio

102、n tank,depending on the starch system used.During fermentation,depending on what type and what amount of protein the product contains,protein networks may form that increase viscosity,but that is not always the case.A plant-based product containing starch is generally less sensitive to mechanical sh

103、ear than a dairy-based product,and therefore less in need of low-shear design.Applying high hygiene design to the whole process line downstream from the heat treatment step is important for both plant-based and dairy products.The hygienic design of the fermentation tank is particularly important,as

104、the product in the tank risks infection by bacteriophages,as well as mould and yeast contamination.Sterile air overpressure and a hygienic sampling valve are therefore recommended,to be able to track the fermentation efficiently and safely.Thus in most cases it is possible to use the same fermentati

105、on tank and agitator design for dairy and plant-based products.22 Smoothing&cooling When the desired pH has been reached via fermentation,the product is emptied from the fermentation tank and sent to the cooler.On its way to the cooler the product is smoothed,to remove any graininess and make the pr

106、oduct more homogeneous and glossier.For dairy products,simple and relatively inexpensive smoothing valves and slot strainers are often used for this step,but sometimes more flexible dynamic texturising devices are installed.For plant-based products the whole range of smoothing devices are also used,

107、but for a line that will be used for both dairy and plant-based products it would be a good idea to add the flexibility of a dynamic texturiser.The product is cooled to slow down the fermentation and to be able to store,or“buffer”,the product before filling.For dairy products sensitive to mechanical

108、 shear,a plate heat exchanger configured for low shear is used to cool the product to 20C.The design has been shown to minimise the mechanical shear of the product while still cooling the product sufficiently to slow down fermentation,causing minimal breakdown in terms of product viscosity and stabi

109、lity.A plant-based product containing starch is not as sensitive to the mechanical shear applied by the cooler,and can therefore sometimes be cooled to lower temperatures without impact on product quality.Provided that the plant-based product does not contain fibres or particles,a plate-based cooler

110、 designed for dairy yoghurt can be used for cooling both plant-based and dairy products.If fibres or particles are included,then a tube-based system is preferred.However,this is seldom the case.Buffering,fruit dosing&filling For buffering,fruit addition and filling,the key factor is the difference i

111、n how viscosity develops in plant-based vs.dairy products.Plant-based products can often have higher viscosity at this point,while dairy products develop a lot of viscosity in the package after filling.If the dosing of fruit preparation is done inline when the product is pumped from buffer tank to f

112、illing machine,higher viscosity of the product can make the fruit preparation more difficult to disperse in the product.The static mixer solution often used in dairy installations is,however,typically sufficient for the viscosity range of both plant-based and dairy products.Since every filling machi

113、ne normally has a fillable viscosity range,if the plant-based products fall within the range of the existing filling machine then it is possible to use it for those products.23 Extra processing steps for ambient products To create a product that can be stored and distributed at ambient temperatures,

114、the fermenting bacteria must be inactivated through a heat treatment step.Fermented products are often sensitive to heat treatment,as there is a risk for separation or a sandy mouthfeel.The key for success is working with product formulation and gentle processing.Typically the heat treatment applied

115、 is 75C,15-30 seconds.In some formulations new ingredients(including stabilisers)are added after the fermentation,often in the form of a water-based slurry,so the heat treatment then needs to be done at a higher temperature.The exact temperature program will depend on the type and amount of ingredie

116、nts added.This principle is the same whether the product is dairy or plant-based.The design of the second heat treatment and other process requirement are very formulation-dependent.Provided that the final products are similar in physical properties,the same equipment can often be used for both prod

117、ucts.24 CLEANING IN PLACE(CIP)In a dairy yoghurt production line,most of the product surfaces are cold and in the only heating step,the yoghurt milk heat treatment,the product temperature does not exceed 100C.This means that the line is not normally very challenging to clean in place,with relatively

118、 little fouling from proteins and minerals.It is common to use a standard cleaning station with lye and acid,and cleaning solutions and final rinse water are usually reused.You can often use the same type of CIP station and the same type of cleaning solutions for dairy and plant-based production lin

119、es for fermented products.But it may be a bit more complex for hybrid lines handling both types of products.Milk composition differs from plant-based composition on key elements.The differing levels of protein,fats and carbohydrates may determine the choice of cleaning procedures(cleaning solution c

120、oncentration,circulation time and temperature).While that is certainly manageable,special cases may arise if higher pasteurisation temperatures and longer processing times are used for your plant-based yoghurt mix compared to that for dairy yoghurt milk.It may be necessary to use a cleaning program

121、like that used for plant-based UHT beverages.This includes a booster in addition to lye(sodium hydroxide)and acid and requires a different design of the CIP system and/or pasteurisation unit.25 ALLERGENS AND PRODUCT CHANGEOVERS Allergens are a concern for the food industry today.Approximately 1-2%of

122、 the adult population have a true food allergy and this figure is higher for children,about 5-8%.Food allergies occur when the bodys immune system reacts to certain proteins(allergens)in food.Very small amounts can trigger an allergic reaction in a sensitive consumer and possibly be fatal.Food aller

123、gens often withstand processing conditions and cannot be compared with microorganisms which will be inactivated when heated to relevant temperatures.The following 14 common allergens require labelling according to EU regulation 1169/2011:Dairy and most plant-based materials contain allergens.As you

124、can see from the list above,there are plant-based raw materials in many different allergen groups,which means there is also a risk for cross-contamination between plant-based products.Cereals containing gluten (wheat,rye,barley,and oats)Crustaceans Eggs Fish Peanuts Soya beans Milk Mustard Sesame Nu

125、ts(almonds,hazelnuts,walnuts,cashews,pecans,Brazil nuts,pistachios,and macadamia nuts)Celery Sulphur dioxide or sulphite(10 mg/kg or 10 mg/litre)Lupin Molluscs 26 Whenever products intentionally contain allergenic ingredients,these must be labelled following the legislation that is applicable in eac

126、h country.The next step to consider is the likelihood of unintentional presence of allergens by cross-contamination,which can be caused in several ways:Inadequate cleaning of shared processing/packaging equipment Contamination via air particles and dust of allergenic food Improper production sequenc

127、ing Raw material handling Reusing cleaning liquids for lines processing products from different allergen groups Improper rework management The risk of cross-contamination can be extremely difficult to manage,so advisory labelling should be considered,for example May contain traces of nuts or May con

128、tain traces of milk proteins”.But labelling on its own does not eliminate risks.The following sections offer advice for improving removal of allergens.Hygienic design Good hygienic design is of utmost importance.The supplier of the processing equipment must make sure the equipment is designed accord

129、ing to the relevant hygienic standard and with an appropriate cleaning program,but the responsibility for the food produced is always with the food producer.Regardless of design,there will always be equipment that might be difficult to clean,such as heat exchangers,pumps and valves.The processing eq

130、uipment and line should be assessed for the level of risk associated with areas that are difficult to clean.Such areas require extra attention to ensure that they are cleaned adequately.Cleaning program An efficient cleaning program is essential for avoiding cross-contamination with allergens.The ef

131、ficiency of the cleaning program is not only related to the cleaning detergents;all other parameters are just as important,i.e.temperature,time and flow rate.These parameters are often collectively referred to as“the Sinners Circle.27 Cleaning solutions in a CIP system are often reused,except for UH

132、T sterilisers.Our recommendation is to not reuse the cleaning solutions for a hybrid line,to avoid the risk of cross-contamination.Reusing rinse water from washing equipment containing an allergen should be avoided if there is risk for cross-contamination of food from another allergen group or food

133、not containing allergens.Cleaning validation Cleaning validation is essential to the allergen control plan.Cleaning validation demonstrates that the established cleaning program reduces the risk of cross-contamination and will perform according to predetermined criteria.The validation procedure alwa

134、ys starts with a visual inspection of difficult-to-clean areas.After that there are different ways to proceed,but it is recommended to analyse the final rinse water after CIP of an allergenic food product.This could be followed by swabbing of food contact surfaces,especially targeting hard-to-clean

135、areas.Many food products contain small particles,and this is especially common within the area of plant-based products(for example,based on almonds).There is always a risk that small particles remain in the equipment after cleaning,and these particles might contaminate another product.Since the part

136、icles are few,they will not be detected in the small sample volumes of the food product or the rinse water.These particles will also not be detected by surface swab tests.The most common methods for analysing food allergens are either based on protein detection or DNA detection.Methods include ELISA

137、(enzyme linked immunosorbent assay)for specific proteins,and PCR(Polymerase Chain Reaction)for DNA detection.It is the responsibility of food producers to ensure that the test kit is validated for the allergen of concern in their food matrix,also taking into consideration the sensitivity of the alle

138、rgen test kits,the effect of thermal treatment and cleaning chemicals.There is no legal definition for“how clean is clean”,that is,if the cleaning program removes the allergens to an accepted safe level,partly because currently there are no thresholds for“accepted safe level”established for food all

139、ergens.It is also not possible to demonstrate a result better than the sensitivity of the detection methods.Test results should always be treated with caution,as different factors such as thermal processing and cleaning solutions might interfere with the result.The responsibility for overall risk as

140、sessment and the quality of the food produced is always with the food producer.28 HYBRID LINES IN SUMMARY Consumption of fermented products,and in particular plant-based yoghurt-like products,are projected to grow over the next 10 years.The perceived health benefits are appreciated by consumers in a

141、ll areas of the world.A production line capable of producing both plant-based and dairy products makes it possible for producers to have greater production flexibility leading to higher line utilisation.It can be a way for existing dairy producers to upgrade their existing line or new producers to i

142、nvest in a line that has high product flexibility.From a technical point of view,it is possible to build a line capable of producing both dairy and plant-based products.These production processes share many steps,where a similar design can be applied.For a few of these processing steps,a hybrid line

143、 requires design choices that suit the more demanding of the two products.This means that a hybrid line will have a higher investment cost,but the difference is modest in comparison to the full line investment.Both dairy products and many plant-based products contain allergens.Allergen management is

144、 therefore crucial in a hybrid line producing both products,and puts high demands on the producer.Tetra Pak has developed CIP programs and other techniques that help reduce the risk of cross-contamination,but the responsibility for overall risk assessment and the quality of the food produced is alwa

145、ys with the food producer.Tetra Pak has the processing knowledge and expertise to advise you on how to build new lines or adapt your existing lines to create a hybrid line,through:Added or replaced components New settings and processing parameters Recommended ingredients Recommended cleaning procedu

146、res Hybrid lines may be a great option for some food producers,as long as it is possible to assess and manage the risks of cross-contamination.Based on our long experience with a wide range of both dairy and plant-based fermented products,we can provide the right guidance every step of the way.The r

147、esulting products will depend on how the customer operates the line and manages quality assurance.29 TETRA PAK YOUR GO-TO PARTNER FOR YOGHURT PRODUCT INNOVATION Tetra Pak has over a century of dairy experience and more than 40 years of plant-based experience delivering food processing and packaging

148、equipment around the world.Our customer and solution experience is based on deep understanding and extensive specialist knowledge,combining technology with food application knowledge.In both the dairy and the plant-based world,we know the ins and outs of taste and mouthfeel,fibre mechanics and break

149、down,heat treatment and stability,protein yield,sedimentation and enzyme deactivation.We are able to offer customised solutions targeting your requirements,and can help you design or upgrade lines based on your specific processing needs,with the lowest total cost of ownership.We have delivered proce

150、ssing solutions and equipment for several decades to customers expanding their production to include ingredients such as oats,rice,nuts,cereals,legumes and seeds.Our network of technology specialists can help you deliver competitive,sustainable and nutritious plant-based products based on the optima

151、l choice of raw materials and ingredients for a given product and region.In practical terms,if you have a particular processing issue with particular ingredients,we likely have some relevant expertise and test data from our global network on ingredient characteristics and processing parameters.At ou

152、r 12 Product Development Centres(PDCs)around the world,you can carry out product trials together with our specialists with unique comprehensive expertise in food processing.You can experiment with recipes and use the latest processing equipment.For more information about our PDCs,visit https:/ 30 Th

153、anks to our well established industrial and technology profile,we can support your innovation and production,helping you meet the changing tastes and demands of your marketplace.The right plant design and processing design can offer you unlimited new business opportunities through new products,impro

154、ved quality,and lower costs.We offer:Extensive knowledge of processing technologies,as well as how to implement them PDCs and dedicated technology specialists Valuable knowledge and experience through partnerships with suppliers of technology,ingredients and supplies Processing modules and line conc

155、epts for a wide range of technologies for mixing,heating,filtration,separation,homogenisation and more.End-to-end offerings,handling everything from incoming raw ingredients to pallets of finished products on your loading dock.As an innovator,we actively explore and develop the challenges of the foo

156、d and beverage industry.We collaborate with customers,universities,and other business partners to develop new applications and find the best solutions for producing new products with flexibility.For more information,visit 31 REFERENCES March 2022 Plant-based Yogurt Market:Global Industry Analysis,Si

157、ze,Share,Trends&Forecast to 2030()June 2020 Tetra Pak white papers available to download from:Plant-based products https:/ Oat-based beverages https:/ Understanding ambient yoghurt https:/ Plant-based yoghurt-style products https:/ Clean label yoghurt https:/ 32 Tetra Pak and Protects Whats Good are trademarks belonging to the Tetra Pak G Tetra Pak International S.A,Tetra Pak Processing system AB,2024.05