The reconstituted milk yogurt production line offered by Taizy is designed to assist dairy manufacturers in establishing a small-scale yogurt production line, which utilizes milk powder as its primary raw material.
For developing markets such as those in Africa, where the supply of fresh milk is relatively scarce, this “milk powder solution” represents an ideal choice for dairy processing operations.
Production Process Flow: From Powder to Yogurt
The 300L-500L powder reconstituted milk yogurt production line follows a precise 6-stage process that transforms milk powder into premium yogurt. Each stage is critical for achieving consistent quality and optimal texture.
| Stage | Process | Ekipman | Key Parameters |
|---|---|---|---|
| 1 | Mixing & Preheating | High-shear Mixing Tank | 50-60°C, 2840r/min |
| 2 | Homogenization | High-pressure Homogenizer | 20-25MPa, 500L/h |
| 3 | Pastörizasyon | Sterilization Tank | 85-95°C, 15-20min |
| 4 | Fermentation | Fermentasyon Tankı | 42-45°C, 6-8h |
| 5 | Cooling & Filling | Cooling Tank & Filler | 4°C, 800-1000 cups/h |
| 6 | Cleaning | CIP Cleaning System | Acid/Alkali wash |
Stage 1: Powder Preheating & High-Shear Mixing
The production begins with mixing milk powder and water in the high-shear mixing tank. This critical stage ensures complete dissolution of milk powder and a uniform mixture before further processing.
Process Description:
- Milk powder is added to the tank with a precise water ratio
- High-speed stirring (2840 rpm/min) ensures complete dissolution
- The heating system raises the temperature to 50-60°C
- Preheating improves subsequent homogenization efficiency
Stage 2: Homogenization
The mixed milk enters the high-pressure homogenizer, which breaks down fat globules to create a smooth, uniform texture. This stage prevents fat separation and ensures a consistent mouthfeel.
Process Description:
- Milk passes through the homogenizing valve at 20-25MPa pressure
- Fat globules reduced to 0.2-2μm size
- Prevents cream separation during storage
- Improves texture and mouthfeel consistency
Stage 3: Pasteurization (Sterilization)
The homogenized milk enters the sterilization tank for high-temperature short-time (HTST) pasteurization. This stage eliminates harmful bacteria and ensures product safety.
Process Description:
- Milk heated to 85-95°C for 15-20 minutes
- Kills vegetative bacteria and pathogens
- Denatures whey proteins for better texture
- Prepares milk for fermentation
Stage 4: Fermentation
The pasteurized milk enters the fermentation tank, where lactic acid bacteria convert lactose to lactic acid, transforming milk into yogurt.
Process Description:
- Cool milk to 42-45°C for fermentation
- Add starter culture (Lactobacillus bulgaricus & Streptococcus thermophilus)
- Ferment for 6-8 hours until pH reaches 4.5-4.6
- Cool to 4°C to stop fermentation
Stage 5: Cooling & Filling
The fermented yogurt is cooled and filled into cups using an automated disk-type cup filler. This stage ensures consistent product weight and efficient packaging.
Process Description:
- Cool yogurt to 4°C in the cooling tank
- Filling machine dispenses precise volume into cups
- Automatic capping with aluminum foil or lid
- Output: 800-1000 cups per hour
Stage 6: CIP Cleaning System
The CIP (Clean-in-Place) cleaning system automatically cleans all equipment without disassembly, ensuring hygiene and efficiency.
Process Description:
- Water rinse to remove milk residue
- Alkali wash (NaOH solution) for protein removal
- Acid wash (HNO₃ solution) for mineral scale removal
- Final water rinse to remove cleaning agents
- Sanitize with hot water or sanitizer
Complete Equipment List of Reconstituted Milk Yogurt Production Line
300L Powder Reconstituted Milk Yogurt Production Line Equipment
| Ekipman | Model/Size | Kapasite | Ana Özellikler |
|---|---|---|---|
| High-Shear Mixing Tank | 300L | 300L/batch | 2840r/min, 2.5m² heating |
| Single Filter | Single | – | 0.15m² filtration area |
| Homojenizatör | 500L | 500L/saat | 25MPa max pressure |
| Sterilization Tank | 300L | 300L/batch | 60-90°C, 0.55kW motor |
| Fermentasyon Tankı | 300L | 300L/batch | ±0.5°C doğruluk |
| Dolgulama Makinesi | Disk Tipi | 800-1000 cups/h | 50-300ml capacity |
| Milk Pumps | 3 sets | – | 0.37kW, 1t/h flow |
| CIP System | 300L | – | Acid/Alkali/Hot water tanks |
| Piping & Valves | Custom | – | Stainless Steel 304 |
500L Powder Reconstituted Milk Yogurt Making Line Equipment
| Ekipman | Model/Size | Kapasite | Ana Özellikler |
|---|---|---|---|
| High-Shear Mixing Tank | 500L | 500L/batch | 2840r/min, 2.5m² heating |
| Double Filter | Double | – | 0.15m², 5t/h capacity |
| Homojenizatör | 500L | 500L/saat | 25MPa max pressure |
| Sterilization Tank | 500L | 500L/batch | 60-90°C, 0.55kW motor |
| Fermentasyon Tankı | 500L | 500L/batch | ±0.5°C doğruluk |
| Dolgulama Makinesi | Disk Tipi | 800-1000 cups/h | 50-300ml capacity |
| Milk Pumps | 4 sets | – | 0.37kW, 1t/h flow |
| CIP System | 500L | – | Acid/Alkali/Hot water tanks |
| Piping & Valves | Custom | – | Stainless Steel 304 |
Equipment Technical Specifications
High-Shear Mixing Tank Specifications
| Özellik | 300L Tank | 500L Tank | Unit |
|---|---|---|---|
| Malzeme | Stainless Steel 304 | Stainless Steel 304 | – |
| Plate Thickness | 3 | 3 | mm |
| Power Supply | 380V/20kW | 380V/24kW | Voltage/kW |
| Boyutlar | 1200×1100×1700 | 1500×1150×1900 | mm |
| Tank Diameter | 1000 | 1000 | mm |
| Tank Height | 650 | 850 | mm |
| Stirring Speed | 2840 | 2840 | r/min |
| Heating Area | 2.5 | 2.5 | m² |
| Stirring Motor | 0.55 | 0.55 | kW |
Sterilization & Fermentation Tank Specifications
| Özellik | 300L Tank | 500L Tank | Unit |
|---|---|---|---|
| Malzeme | Stainless Steel 304 | Stainless Steel 304 | – |
| Plate Thickness | 3 | 3 | mm |
| Power Supply | 380V/20kW | 380V/20kW | Voltage/kW |
| Boyutlar | 1000×1100×1650 | 1500×1150×1900 | mm |
| Tank Diameter | 850 | 1000 | mm |
| Tank Height | 750 | 650 | mm |
| Stirring Speed | 36 | 1400 | r/min |
| Stirring Motor | 0.55 | 0.55 | kW |
| Temperature Range | 60-90 | 60-90 | °C |
| Material Inlet/Outlet | DN38 | DN38 | mm |
Homogenizer Specifications
| Özellik | 500L Homogenizer | Unit |
|---|---|---|
| Flow Rate | 500 | L/h |
| Maximum Pressure | 25 | MPa |
| Working Pressure | 20 | MPa |
| Motor Power | 4 | kW |
| Boyutlar | 1010×616×975 | mm |
| Malzeme | Stainless Steel 304 | – |
| Gerilim | 380V/50Hz | – |
Filling Machine Specifications
| Özellik | Disk Type Filler | Unit |
|---|---|---|
| Boyutlar | 1300×1300×1750 | mm |
| Filling Capacity | 50-300 | ml |
| Production Capacity | 800-1000 | cups/hour |
| Malzeme | Stainless Steel 304 | – |
| Disk Speed | 13-16 | cups/minute |
| Ağırlık | 200 | kg |
CIP Cleaning System Specifications
| Özellik | 300L CIP System | 500L CIP System | Unit |
|---|---|---|---|
| Malzeme | Stainless Steel 304 | Stainless Steel 304 | – |
| Kalınlık | 2-3 | 2-3 | mm |
| Power Supply | 380V/20kW×3 | 380V/20kW×3 | Voltage/kW |
| Control | Manual valves | Manual valves | – |
| Tanks Included | Acid+Alkali+Hot water | Acid+Alkali+Hot water | – |
Advantages of Powder Reconstituted Milk Yogurt Production Line
| Advantage | Description | Business Impact |
|---|---|---|
| 1. Flexible Production | Can switch between whole milk and skim milk powder formulas | Adapt to market demand easily |
| 2. Consistent Quality | Automated process control ensures batch-to-batch consistency | Higher customer satisfaction |
| 3. High Efficiency | 800-1000 cups/hour filling speed | Lower production cost per unit |
| 4. Easy Cleaning | CIP system enables cleaning without disassembly | Reduced labor and downtime |
| 5. Space Saving | Compact equipment design | Lower factory rental costs |
| 6. Hygienic Design | Stainless steel 304 construction | Meets food safety standards |
| 7. Energy Efficient | Optimized heating and cooling systems | Lower utility bills |
| 8. Easy Operation | PLC dokunmatik ekran kontrolü | Minimal training is required for the employee |
Common Problems & Solution
| Sorun | Cause | Çözüm |
|---|---|---|
| Separation | Inadequate homogenization | Increase pressure to 25 MPa |
| Grainy Texture | Incomplete powder dissolution | Extend mixing time, increase temperature |
| Slow Fermentation | Cold milk or old culture | Check inoculation temperature, use fresh culture |
| Slow Fermentation | Insufficient solids or over-fermentation | Adjust powder ratio, reduce fermentation time |
| Off-Flavor | Contamination or old milk | Improve hygiene, use fresh milk powder |
What Are the Advantages of Using Milk Powder to Make Yogurt?
Compared to fresh milk, using milk powder as a raw material for yogurt offers numerous advantages, making it the preferred choice for industrial-scale yogurt production:
- Stable and Consistent Raw Material Quality: The composition of fresh milk varies depending on the season, the pasture, and the livestock feed used. In contrast, milk powder undergoes a standardization process that allows for the precise adjustment of fat and protein levels, ensuring that every batch of yogurt possesses a consistent texture and flavor profile.
- Lower Costs and Easier Transport: Milk powder remains stable at room temperature, making it significantly easier and more cost-effective to transport; it also boasts a much longer shelf life. In regions where local milk supplies are limited or logistics networks are still developing, milk powder often represents the only viable raw material option.
- Production Flexibility and Formula Control: Using milk powder as a raw material enables manufacturers to “customize” yogurt products to meet specific market demands. Manufacturers can increase the total solids content to enhance the yogurt’s thickness, adjust fat levels to achieve a smoother mouthfeel, or incorporate whey protein to boost the overall protein content.
- Stable and Uninterrupted Production: Fresh milk supplies are heavily influenced by seasonal factors and pasture yields, which can sometimes lead to production delays. The use of milk powder, however, ensures uninterrupted production throughout the year, eliminating concerns regarding seasonal shortages in milk supply.
- Enhanced Food Safety Assurance: During the spray-drying process used to produce it, milk powder undergoes a sterilization step, thereby offering greater control over microbiological safety. This allows manufacturers to more easily meet the stringent export standards required by high-end markets, such as those in the European Union and the United States.
Investment Considerations About Milk Powder Yogurt Production Line
When investing in a 300L-500L reconstituted milk yogurt production line, consider these factors:
1. Production Scale Matching
Choose the 300L line for startups with 500-1000L/day capacity needs. Select the 500L line for established businesses requiring 1000-2000L/day capacity. This yogurt production line milk powder solution is ideal for small-scale yogurt production businesses looking to minimize initial investment while maintaining quality.
2. Raw Material Availability
Ensure a reliable supply of high-quality milk powder. Consider local sourcing to reduce transportation costs and ensure freshness. For dairy processing equipment in Africa, powdered milk solutions are particularly important, as local milk sources are limited.
3. Yogurt Processing Plant Cost
Compare the yogurt processing plant cost between powder and fresh milk solutions. Powder line typically requires lower initial investment due to reduced infrastructure needs (no cold chain, smaller storage facilities).
4. Yogurt Making Machine Price
When evaluating reconstituted milk yogurt production line price, consider the complete system including mixing, sterilization, fermentation, and CIP cleaning. The powder solution often offers better value due to simpler infrastructure requirements and lower operational complexity.
5. After-Sales Support
Choose an equipment supplier with reliable after-sales service, including installation support, operator training, and spare parts availability. For small-scale yogurt production in developing markets, local service support is critical.
Conclusion: Why Choose Powder Yogurt Production
The 300L-500L powder yogurt production line offers dairy manufacturers a flexible, efficient, and cost-effective solution for yogurt production. From milk powder to finished product, the complete process ensures consistent quality, high efficiency, and easy operation.
This reconstituted milk yogurt production line solution is particularly ideal for small-scale yogurt production in Africa and other developing markets where dairy processing equipment needs to be reliable, cost-effective, and easy to operate.
Ready to start your yogurt production? Contact Taizy today for a free consultation and customized equipment recommendation based on your production goals, yogurt processing plant cost requirements, and yogurt-making machine price budget.
In addition, we offer yogurt production lines with other production capacities; please click the link to view them: