Baran Borudt Production and Industrial Group provides complete processes for dairy production lines, which are used in the production of dairy products such as milk, pizza cheese, cheese, yogurt, etc.
Dairy production processes
✅ receive milk
The milk receiving unit, as the first milk receiving unit, is responsible for converting the raw milk entering the factory into pasteurized and standardized milk and cream.
Lines receiving milk
Trucks carrying milk enter the milk receiving station as soon as they enter the company. In order to prevent the occurrence of liposis, it is better to minimize the mechanical stress applied to the milk. Therefore, gravity discharge is preferred to other methods.
Pasteurized milk
The milk pasteurization process is a type of thermal process on milk that can completely destroy the tuberculosis bacillus without having any other undesirable effects on the milk. Since the tubercle bacillus is the most resistant pathogenic agent of milk, its destruction is considered to guarantee the destruction of other pathogenic agents as well. Tuberculosis bacillus is destroyed at a temperature of 72-75 degrees Celsius and a time of 16-20 seconds. Apart from pathogenic microorganisms, milk contains microorganisms that have a destructive effect on the taste and shelf life of other dairy products. Therefore, the second goal of the Pasteur process is to destroy these microorganisms. Since phosphatase enzyme is always present in raw milk and this enzyme is easily destroyed by the pasteurization process, the absence of phosphatase enzyme in pasteurized milk confirms the correctness of the process.
Pasteurized cream
There is little difference between pasteurized milk and cream. Due to the high viscosity of the cream, the pasteurization temperature of the cream is 80-85 centigrade and its holding time is 10 seconds. Due to the reactivation of the phosphatase enzyme immediately after cream pasteurization, this enzyme is not used to confirm pasteurization and the peroxidase test is used.
Pasteurized milk tanks
Raw milk is transferred to steel tanks after pasteurization. These tanks should be able to store milk and cream with different fat percentages. Pasteurized milk and cream are sent from these tanks to other units. The volume of milk sent to other units is measured with the help of sensors installed on the delivery lines.
✅ Washing
Sterilization and disinfection of lines is often done at the beginning of the day and before the start of production. This is done with 90-95°C water for 10-15 minutes.
A common washing program for dairy lines and equipment includes the following steps:
Rinse for 10 minutes. 30 minutes.
Rinse for 5 minutes.
Wash with 0.5-1% acid and 70 C for 20 minutes.
Rinse for 5 minutes.
Pasteurized milk
Sterilization and disinfection of lines is often done at the beginning of the day and before the start of production. This work is done with 90-95 centigrade water for 10 to 15 minutes.
According to the requirements and type of design, various layouts and designs can be imagined for the CIP unit; For example, a CIP unit can have a separate heater for each delivery line, or these heaters can be installed in the circulation path of each tank. Generally, the most comprehensive design of a CIP unit includes 5 tanks for soda, acid, hot water, fresh water and recycled water. However, it is emphasized that the best design should be obtained by considering the special features of each project.
✅ Uht valve
The use of heat treatment to produce a product with a long shelf life is called sterilization. In this process, with the help of heat, all heat-resistant microorganisms and enzymes are deactivated. These products have a very long shelf life and this helps dairy companies to sell their products in faraway areas. The main components of a sterile salon are a sterilizer, an aseptic tank, and an aseptic filler.
Sterilizer
Sterilizers are divided into two main categories, direct and indirect. In the direct type, food grade steam is injected directly into the milk and raises the temperature of the milk to 140-150 degrees Celsius. The milk is kept at this temperature before cooling for 8 seconds. After heat recovery, the milk enters a tank under vacuum and cools down to 80 degrees Celsius while expelling all the injected steam. Next, the milk is homogenized with the help of an aseptic homogenizer and cooled to 20°C. In the indirect sterilizer, the milk is heated to 110°C by recovering the heat from the outlet valve, and then in the heater section, with the help of water. Hot under pressure is brought to a temperature of 135 degrees and finally, after heat exchange with the inlet valve, at a temperature of about 20 degrees Celsius. It leaves the sterilizer. There are two retention times in this process; One for 90 seconds at a temperature of 90 degrees (before the main heater) to stabilize the proteins and another for 4 seconds at a temperature of 135 degrees to complete the sterilization process. Homogenization in this process must be done at a temperature of 75 degrees, and if this is done after the main heater, the homogenizer must be aseptic.
✅ It is us
The digestive system of some people does not have the lactase enzyme, and as a result, lactose does not convert into simpler sugars in the body of these people, which causes digestive disorders. Therefore, these people can consume a small amount of milk daily. But consuming cultured milk, in which lactose has been converted into simpler sugars through bacterial enzymes, will be harmless for these people. There are different types of yogurt, and the production process of two types of them, mixed and normal yogurts, will be mentioned below. The most important difference between these two yogurts is the fermentation stage. Normal yogurts are fermented and cooled in the package. In the production process of ordinary yogurts, after the initial stages of production are completed, the starter is added to the product and the temperature of the product is raised to 45 degrees Celsius, and then packaging is done. Then the packaged product is transferred to the greenhouse to complete the fermentation process. After reaching the desired taste and quality, the cooling operation must be done quickly to prevent the fermentation process from continuing. In this process, fermentation is done in special tanks and the product is packaged after cooling. In general, yogurt production consists of three main stages: mixing, pasteurization, and packaging-storage.
Mix
Since yogurt consists of various raw materials in solid and liquid phases, the mixing of these materials is of great importance and has a great impact on the quality of the product. After adding various liquids such as milk, cream, UF retentate, etc. to the mixing tank, solid additives are also added to the product and mixing is done with the help of tank stirrers. If this process is not done correctly, the heterogeneity of the content of the mixing tank causes the quality of the product to differ from one container to another; That is why the importance of this process is emphasized a lot.
Pasteurization
The milk is pumped from the balance tank to the pasteurizer and after heat transfer with the output product, it is heated up to 70 degrees in the first stage and then it is brought to 90 degrees by hot water in the second stage. The outlet valve from the second stage is directed to the vacuum tank and in this stage 10 to 20% of its water is separated and its temperature is reduced to 70 degrees. At this stage, the concentrated product enters the homogenizer and is homogenized at a pressure of 200 to 250 bar. After leaving the homogenizer, the homogenized product enters the pasteurizer again, and after reaching a temperature of 90-95 degrees Celsius, it enters the holder for 5 minutes. After the milk is pasteurized, it is first exchanged with the incoming milk and then the water reaches the desired temperature (normal yogurt 10 and stirred yogurt 45 degrees Celsius).
Packing and warehouse
In case of production of stirred yogurt, the filled containers enter the warehouse and are kept at a temperature of 5 degrees Celsius. But during the production of normal yogurt, the packed containers should be arranged on pallets with a distance from each other, so that there is a possibility of free flow of air between the containers, and after passing through the hot room, they enter the cold room. During this process, accurate temperature control guarantees quality. After reaching the required pH (about 4.5), the product should be cooled to 20 degrees. The cooling process is usually done in two stages, in the first stage the temperature of the product should be brought to 35 degrees within 30 minutes and then to 20 degrees within another 30 minutes. A typical inoculation process takes 3 to 3.5 hours. It is very important to know that during the 2 hours of the inoculation process, in order to prevent whey from separating from the product, the filled containers should never be exposed to shaking and vibration. Finally, the product should be stored in a refrigerator at a temperature of 5 degrees Celsius.
✅ Doogh
There are two methods to produce buttermilk; The production of buttermilk from milk and the other production of buttermilk from yogurt. Below is the method of producing buttermilk from milk. First, 1.5% fat milk enters the pasteurizer and after being pasteurized at a temperature of 85 degrees, it is cooled and leaves the pasteurizer at a temperature of 45 degrees and enters the fermentation tank. After finishing the milk, equivalent to pasteurized milk, the water is pasteurized under the same conditions and added to the milk in the fermentation tank. When the last part of the water is transferred to the fermentation tank, salt, dry matter and yeast are added to the water flow and it enters the fermentation tank at the same temperature of 45 degrees. The contents of the fermentation tank are given time to ferment. When the pH of the tank content drops to the desired level, the fermented product is sent to the pasteurizer for the second cooking. In the second cooking, the product flow from the fermentation tank enters the pasteurizer at a temperature of 45°C and after reaching a temperature of 85°C it is cooled to a temperature of 4°C and then leaves the pasteurizer. The final product is ready for packaging.
✅ Ice cream
First, all the required liquid components, such as milk and cream, are entered in the buffer tanks of the ice cream unit in the determined ratio. After the complete mixing of these components, the contents of the buffer tank are heated to 60 degrees by passing through the heater plate and enter the main mixing tank. At this stage, with the help of a blender, powdered ingredients such as sugar, milk powder, etc. are also added to the mixing tank and complete mixing is done with the help of a stirrer. After ensuring that the content of the tank is uniform, the material is sent to the pasteurizer and the pasteurization operation (temperature of 85 degrees and Helder for 15 seconds) is performed. The pasteurized product enters a three-walled tank for processing at a temperature of 4 degrees. In this tank, the ice cream mixture is slowly stirred at a temperature of 2 to 5 degrees for 4 hours. The purpose of this operation is to create the necessary opportunity for the reaction between water and milk proteins and fat crystallization. This helps to better combine air and ice cream and also increases the ice cream's resistance to melting. After completing this step, the product is sent to special freezers and packaging machines.