Survey on sweetened yogurt producing process at elovi viet nam joint stock company

THAI NGUYEN UNIVERSITY OF AGRICULTURE AND FORESTRY ADVANCED EDUCATION PROGRAM ……    …… NGUYEN THI TUYET NHUNG TOPIC TITLE: SURVEY ON SWEETENED YOGURT PRODUCING PROCESS AT ELOVI VIET NAM JOINT STOCK COMPANY BACHELOR THESIS Study Mode : Full-time Major : Food Technology Faculty : Advanced Education Program Office Batch : 2016 - 2020 Type : On-the-Job Training (OJT) Thai Nguyen, 2021 THAI NGUYEN UNIVERSITY OF AGRICULTURE AND FORESTRY ADVANCED EDUCATION PROGRAM ……    …… NGUYEN THI TUYET NHUNG TOPIC TITLE: SURVEY ON SWEETENED YOGURT PRODUCING PROCESS AT ELOVI VIET NAM JOINT STOCK COMPANY BACHELOR THESIS Study Mode : Full-time Major : Food Technology Faculty : Advanced Education Program Office Batch : 2016 - 2020 Type : On-the-Job Training (OJT) Supervisor(s) : Dr Luong Hung Tien Thai Nguyen, 2021 Thai Nguyen University of Agriculture and Forestry Degree Program Engineer of Food Technology Student name NGUYEN THI TUYET NHUNG Student ID DTN1654190014 Thesis Title Supervisor Survey On Sweetened Yogurt Producing Process At Elovi Viet Nam Joint Stock Company Dr Luong Hung Tien Supervisor’s Signature ABSTRACT The purpose of this study was to understand the industrial-scale producing process of sweetened yogurt, survey and get direct access to industrial-scale working practices, quality management process of sweetened yogurt at Elovi Vietnam Joint Stock Company, Located at: Nam Pho Yen Industrial cluster, Thuan Thanh commune - Pho Yen town - Thai Nguyen province Elovi Vietnam Joint Stock Company is one of the leading enterprises in the field of production, processing and a leading liquid milk processor in Vietnam and in the region using the international standard technology and equipment which is the most advanced and synchronous production line from Tetra Pak Group - Sweden The ELOVI factory is operated and controlled according to update to production management standards and certificates with a team of professional staff who are partners of many large corporations in the world Keywords: Number of pages: Date of Submission: Yogurt, Milk ,Processing ,Lactic Acid, Industrail Scale ACKNOWLEDGEMENT For the completion of this thesis, I would like to thank: Thai Nguyen University of Agriculture and Forestry, Advanced Education Program of Faculty Food Technology has taught and imparted knowledge and skills to me during my studies here My heartfelt thanks go to my supervisor - Dr Luong Hung Tien for his dedicated and detailed instruction knowledge and apply it to this thesis Thank the directorate and departments of Elovi Vietnam Joint Stock Company, without your support, during my internship, and providing me with relevant information and data, I wouldn’t have been able to carry out my thesis Due to a lack of experience in the field as well as limited knowledge, the essay will not avoid shortcomings I look forward to receiving comments, suggestions, and criticisms from teachers to improve the thesis Finally, I wish you health, success, and happiness Sincerely thanks! Nguyen Thi Tuyet Nhung LIST OF ABBREVIATIONS Abbreviations Meaning ISO International Organization for Standardization HACCP Hazard Analysis and Critical Control Points CIP Cleaning In Plance Automatic machine cleaning system QA Quality Assurance QC Quality Control R&D Research and Development FAO Food and Agriculture Organization of the United Nations TCVN Vietnam Standard KPH Not Detect VNJSC Viet Nam Joint Stock Company TABLE OF CONTENT CHAPTER I INTRODUCTION 1.1 Rationale 1.2 Objectives 1.3 Contents of work 1.4 Detailed schedule 1.5 Timeline CHAPTER II LITERATURE REVIEW 2.1 General information about Elovi Viet Nam Joint Stock Company 2.1.1 Introduction of company 2.1.2 History and development of the company 2.1.3 Factory scale 2.1.4 Infrastructure: 2.1.5 Human factor 2.1.6 Map of the Elovi Viet Nam JSC's Governance Structure 11 2.2 Overview of Milk 11 2.2.1 Introduction about Yogurt 14 2.2.2 Classification of Yogurt 15 2.2.3 Chemical composition 15 2.2.4 The role and effects of yogurt 18 2.2.5 Lactic Bacteria 22 2.3 The trend milk production and consumption in Viet Nam and the world 24 2.3.1 Consumption Trends In Milk And Dairy Products In Viet Nam 24 2.3.2 Consumption Trends In Milk And Dairy Products In The World 25 CHAPTER III OBJECTIVE, CONTENTS AND METHODS OF RESEARCH 27 3.1 Object and scope of the study 27 3.1.1 Object of the study 27 3.1.2 Scope of the study 27 3.2 Location and time 27 3.2.1 Location 27 3.3 Research contents 27 3.4 Research methodology 28 3.4.1 Methods of collecting information 28 3.4.2 Observation method 28 3.4.3 Product Quality Management 28 CHAPTER IV RESEARCH RESULTS 35 4.1 Results of Survey on Sweetened Yogurt Producing process at Elovi Viet Nam Joint Stock Company 35 4.1.1 Explain process of yogurt production 36 4.2 Investigate some main stages in the production line of yogurt 44 4.2.1 Ingredients 44 4.2.2 Mixing 52 4.2.3 Standardize 55 4.2.4 Homogenizer 56 4.2.5 Pasteurization 59 4.2.6 Fermentation 62 4.2.7 Filling 64 4.2.8 Refrigerate and aging 65 4.2.9 Preservation 65 4.3 Results of determining the nutritional composition of the product 66 CHAPTER V DISCUSSION AND LESSON LEARNED 68 5.1 Discussion 68 5.2 Learned 68 CHAPTER VI CONCLUSION 70 REFERENCE 71 APPENDICES LIST OF FIGURES Figure 2.1 The organizational map of Elovi VN JSC Governance Structure .11 Figure 2.2: Lactobacillus bulgaricus .23 Figure 2.3: Streptococcus thermophilus 23 Figure 4.1: Tetra Pak® High Shear Mixer R200 -200 55 Figure 4.2: Tetra Alex 30G Systerm .56 Figure 4.3 : Tetra Therm Lacta B Systerm 59 Figure 4.4: A Part of Fermentation Systerm 62 Figure 4.5: Filling the box systerm 64 LIST OF TABLES Table 2.1 : Infrastructure of Elovi Viet Nam Joint Stock Company Table 2.2 The composition of the types of milk commonly used in milk processing technology .12 Table 2.3 Main components of one liter of milk[4] 13 Table 2.4: Chemical composition in milk .15 Table 2.5: Major biochemical changes occur during fermentation .21 Table 3.1: Acceptance Standard For Elovi company's Sweetened Yogurt 31 Table 3.2: The standard table of finished sweetened yogurt products 34 Table 4.1: Explain process of yogurt production 36 Table 4.2: Ingredients of sweetened yogurt (batch 5000kg) 52 Table 4.3: Acceptance Standard of Process water 45 Table 4.4: Acceptance Standard of Refined Sugar 46 Table 4.5 : Acceptance Standard of Skim Milk Power – SMP 47 Table 4.6: Acceptance Standard of Anhydrous milk fat (AMF) 48 Table 4.7: Acceptance Standard of Yeast like Yo-mix 495 51 Table 4.8: Indicators of nutritional composition of product 66 Table 4.9: Content of nutrients in yogurt products .66 Table 4.10: Average nutrional information per 100 g 66 Table 4.11: Compare average nutrional information per 100 g on the market .67 Before production can commence it is necessary to sterilize the unit by circulating hot water for 20 minutes After pre-sterilization, the unit is cooled down and stabilized to production temperatures If there is a time gap between pre-sterilization and production, the unit could be set in hibernation mode This is an energy conservation mode in which the energy consumption is decreased up to 85% compared to the hot water circulation mode by reducing the power, steam, and water consumption [2] When downstream equipment is ready, production can start Processing parameters Standard temperature programs Inlet temp °C Pasteurisation temp., °C 95 Holding time, s 300 Separation and homogenisation temp., °C ~60 Outlet temp., °C 43 Deaeration temp., °C ~64 Heat regeneration, % 90 * Purpose: Pasteurized at 95°C for 300s to kill microorganisms, increase hydration of casein (good water retention, limit water separation, improving their ability to form a gel structure, smooth and firm milk) * Methods of implementation: Milk after homogenization is pumped to a double-shell pasteurizer, where thanks to the heat passing between the two shells, the temperature of the milk solution increases very quickly High temperature at 95℃/300s 60 Next, quickly cool in the heat exchanger chamber with cold water, lower the milk temperature to 43℃ and then put it in the fermentation tank to wait for the yeast culture * Main changes: - Physical: milk temperature increases, milk volume increases, viscosity decreases - Physical chemistry: the fat is completely melted and a film appears, and at the same time causes adhesion on the surface of fatty platelets - Chemistry: a melanoidin reaction occurs, making the milk dark, but due to the large amount of water in the milk, it can be observed The decomposition reaction of vitamins occurs in the presence of oxygen or the presence of metals such as iron, copper, etc - Biological: microbial cells are completely destroyed, inhibiting the activity of spores - Biochemistry: completely inactivate the enzymes in milk - Sensory: change in color, smell, taste, state *Common problems and how to fix them Problems: During the pasteurization process, there is often a power failure or tower water loss, or the wrong measurement of the milk supply valve Remedy: By regularly visiting, paying attention and taking timely handling measures 61 4.2.6 Fermentation Figure 4.4: A Part of Fermentation Systerm Capacity: 8000 liters / fermentation cycle Include: - 01 yeast culture tank with volume of 1,000 liters - 02 fermentation tanks with a volume of 4,000 liters/tank - The quality of the product depends a lot on the quantity and quality of the microorganisms used For yogurt products, the company uses a mixture of strains: Streptococcus thermophilus and Lactobacillus bulgaricus Experience shows that yogurt will reach the best standard (pH, taste, aroma) when the ratio of Streptococcus thermophilus/Lactobacillus bulgaricus is 1:1 or 2:1 When the ratio of Lactobacillus bulgaricus is higher than Streptococcus thermophilus will lead to yogurt with a sour taste due to its high acidity [6] - Microbial strains are directly inoculated into the fermentation liquid, avoiding the contamination of other microorganisms - The pasteurized milk liquid enters the fermentation tank and is fermented at 43℃ 62 - At the fermentation tank, the yeast was added in bag form (Yo-mix 495) with the use rate of 200U/1000 liters (0.0003%) The number of cells is 400 − 500 million/g of yeast seed powder Activity: 1g of yeast can coagulate liter of milk after 10 − 12 hours - Method of inoculation: transplanted directly into the fermentation tank Advantages: avoid contamination of yeast strains through transitional cultures, the product meets the requirements Disadvantages: microbial strains used in powder form should have low biological activity, long fermentation time When pH = 4.45 − 4.55, stops the fermentation The pH value is an indication of when the fermented product reaches the producer's expected quality and once the fermentation product reaches that value Stop the fermentation by pumping the yogurt through the chiller to lower the yogurt temperature to < 25°C Fermentation time at 43°C is about hours * Main changes: - Forming lactic acid, reducing the pH of milk solution, leading to coagulation of casein in milk - Convert part of casein to peptone, amino acid - Produces flavoring substances, which are by-products of fermentation, contributing significantly to the quality of the final product * Influencing factors: microbial breed, number of microorganisms, temperature, time and external factors 63 4.2.7 Filling - After finishing the fermentation process, the fermented milk is pumped through the plate-type cooling system, the output temperature of the fermented milk is ≤ 25°C to stabilize the yogurt gel, avoiding the adverse effects of the pouring process box later Then the fermented liquid is pumped into the tank waiting to be filling * Filling the box Turn on the ultraviolet light in the pouring room hour before pouring the product, because the product is poured in an open environment, ultraviolet rays have the effect of killing microorganisms in the environment of the pouring room - The company's yogurt filling machine is provided by IMA Company- France with modern technology has the ability to shape product boxes from plastic preforms, glue Figure 4.5: Filling the box systerm pre-assembled products and label boxes around product boxes When the plastic billet enters the system, it will pass through heating plates with a set temperature of 117oC, then blown to form a cup, after seconds, yogurt is poured into the box thanks to pre-quantified pistons (100 g/box) continues to the capping device on the transmission line with the gluing temperature of 202oC All these stages take place only for seconds then passes through the cutter forming milk blisters 64 - Products after coming out of the filling machine are measured into blisters, each blister consists of cups, 48 cups in carton After measuring, transfer to cold storage, cool and aging * Problem and how to fix it Problems: Often there is a problem with the lid membrane deviation, cutting line, missing milk volume, production date jump, reverse printed letters, Solution: Depending on the filling machine every 30 minutes, if you find an error, you must immediately report it to the staff operating the filling machine and take timely measures to avoid affecting the product when it is put on the market 4.2.8 Refrigerate and aging - Yogurt containers are cooled and aging at − 6oC ≤ 24 hours This is a very important stage to give the product the necessary taste and state Only after the end of this process will the finished yogurt be obtained 4.2.9 Preservation Ensuring the quality of yogurt is very important Because in yogurt, there are still lactic bacteria and can continue to work, reducing sweetness, increasing acidity affecting the taste of the product Cold storage to preserve yogurt with a temperature range from − 8℃, cold storage of yogurt also needs to ensure that the storage temperature does not drop to freezing, which will affect the structure as well as taste of milk - Yogurt needs to be stored at − 6oC in cold storage - Shelf life is 50 days Product standards - The product has a uniform structure, color and pleasant aroma typical of each product 65 - Fat content: 1.0 ± 1.5%, dry matter content: 16 ÷ 17% 4.3 Results of determining the nutritional composition of the product Table 4.8: Indicators of the nutritional composition of Sweetened Yogurt Products No Quality criteria Content Density ( g/ml) 1.06 ± 0.005 Lipids ( %) 1.0 ± 1.5 Dry matter content (%) 16 – 17 pH 4.15 ÷ 4.25 Table 4.9: Content of nutrients in yogurt products No Quality criteria Content Density ( g/ml) 1.06 ± 0.005 Lipids ( %) 1.25 – 1.47 Dry matter content (%) 16.3 – 17.1 pH 4.19 ÷ 4.24 Table 4.10: Average nutrional information per 100 g No Nutrional information Content Energy 100,7 (kcal) Protein 3.2 (g) Fat 2.3 (g) Hydrat cacbon 16.8 (g) Calcium 100 (mg) 66 4.3.1 What’s the difference between sweetened yogurt and yogurt without sugar In terms of nutritional value, in fact, unsweetened and unsweetened yogurt both offer the same health benefits: Provide abundant protein: Protein in yogurt includes both casein and whey protein, which are rich in essential amino acids that are good for the digestive system Fat: Fat in yogurt provides a variety of essential fatty acids for the body Carbohydrates: An abundant source of energy for the body The amount of lactose in yogurt is less than in raw milk due to fermentation, so when you are allergic to lactose, yogurt is one of the additional alternatives to raw milk Vitamins and minerals: With yogurt made from raw milk, this is an abundant source of important vitamins and minerals such as Vitamin B12, Calcium, Phosphorus, Riboflavin (Vitamin B2), Probiotic bacteria: Live bacteria that are beneficial to health, especially the digestive system, help strengthen immunity, reduce blood cholesterol, fight diarrhea, prevent constipation, improve lactose digestion Yogurt without sugar provides less kcal than sugared yogurt's kcal In the production of yogurt, sugar is often used as a neutralizing sweetener, reducing the fermentation of lactic acid For those on a weight loss weight: yogurt has no effect on weight loss but is beneficial for the weight loss process The abundant protein content in yogurt has also been shown to support weight loss by regulating hunger hormones to reduce appetite, boosting metabolism to burn more calories, keeping the body full for longer to encourage the body to consume fewer calories, while helping to preserve muscle during weight loss instead of storing fat, helping users handle digestive problems, and better manage their 67 energy intake into the body But be careful not to eat too much, because yogurt also contains a large amount of protein and fat, which also causes weight gain Table 4.11: Compare average nutrional information per 100g on the market Nutrional TH True Vinamilk information Moc Chau Elovi Milk Energy 97.7 kcal 64.8 kcal 106.3 kcal 100.7 (kcal) Protein 3.5 (g) 1.6 (g) 3.1 g 3.2 (g) Fat 2.5 (g) 1.6 (g) 2.7 g 2.3 (g) Hydrat cacbon 15.3 (g) 11 (g) 17.4 g 16.8 (g) Calcium 110 (mg) 50 (mg) 110 (mg) 100 (mg) When comparing Elovi sweetened yogurt with other popular yogurt products on the market are Vinamilk, TH True Milk and Moc Chau, Elovi yogurt has a high nutritional content, when the energy reaches 100.7 kcal much than Vinamik yogurt kcal, TH true milk 35.9 kcal The protein content of 3.2g in 100g of yogurt is higher than that of TH True Milk and Moc Chau sweetened yogurt products The moderate fat content of 2.3 (g) is suitable for diets despite being high in carbohydrates at 16.8 (g) Like other products on the market, Elovi sweetened yogurt provides rich calcium content, which is good for health at all ages CHAPTER V DISCUSSION AND LESSON LEARNED 5.1 Discussion Like other yogurt products on the market, Elovi Yogurt sweetened yogurt meets the needs of consumers with high nutritional value Yogurt is naturally fermented, rich 68 in calcium Provides nutrition, helps good digestion, calcium supplements to help strengthen bones The production process is strictly followed according to regulations, at each stage, there is a team leader, deputy team leader, technical staff, and QC staff to monitor workers, supervise production activities and check product quality Sensory parameters of yogurt at different stages of production Stable color, no strange color, no strange smell, no impurities Possessing advanced production technology, using modern equipment and machinery for production, improving product quality Strictly control factors affecting the quality of products in each stage to find ways to overcome limitations and improve labor productivity The process complies with ISO and HACCP standards, hygienic production conditions are ensured Customers can rest assured to use it because this is a fermented product that provides energy, as well as a number of beneficial microorganisms for the digestive system - a good product for health 5.2 Learned Learn more about the modern industrial-scale sweetened yogurt production process from input materials, processing to finished products How to operate, manage and organize the factory This is also an apprenticeship period to better understand what will in the future It is a time to learn and a great opportunity ability, practice soft skills, the ability to handle situations and communicate in real work, helping to quickly see knowledge gaps and promptly fix them At the same time, it is a good opportunity to step by step plan for the future 69 CHAPTER VI CONCLUSION During Survey On Sweetened Yogurt Producing Process at Elovi Viet Nam Joint Stock Company obtained the following results: - Product Quality Management Process - Learn the flow chart of technological production of sweetened yogurt products - Investigate some main stages in the production line: + Mix ingredients + Standardization + Homogeneous + Pasteurization + Fermentation + Filling products + Refrigerate and aging + Preservation 70 REFERENCE I English resources Effect of dairy powders fortification on yogurt textural and sensorial Marie Celeste Karam1, Claire Gaiani1*, Chadi Hosri2, Jennifer Burgain1 and Joël Scher1 Université de Lorraine, LIBio (Laboratoire d’Ingénierie des Biomolécules), avenue de la Forêt de Haye, BP 172, 54505 Vandoeuvre-lès Nancy, France Faculty of Agricultural Sciences, Department of Agricultural Engineering, Holy Spirit University of Kaslik, P.O Box 446 – Jounieh, Lebanon Documentation of machinery of Tetra pak II Vietnamese resources DAIRY VIETNAM: Website of Vietnam's dairy industry Dr Lam Xuan Thanh (2006), Textbook of dairy products technology Science and Technology Publishing House Documents of ELOVI Vietnam Dairy Company Le Thi Lien Thanh, Le Van Hoang, (2002), Milk processing technology and dairy products, Hanoi Science and Technology Publishing House TCVN 1695:1987, Refined sugar and white granulated sugar, State Science and Technology TCVN 7404:2004, Skimmed milk powder, Ministry of Science and Technology TCVN 7400:2004, Butter, Ministry of Science and Technology 10.TCVN 8140:2009, Milk, dairy products and hydrophilic starter strains, enumeration of citrate fermenting Lactic bacteria, colony counting technique at 25oC 11 TCVN 3215:1979, Food products, organoleptic analysis, scoring methods, Science and Engineering TCVN 3215:1979, Food products, sensory analysis, scoring methods, State science and technology 71 III Internet resources 12 Website of ELOVI Vietnam Dairy Company: elovi.com.vn 13 H.-D Belitz · W Grosch · P Schieberle (2009) : Milk and Dairy Products in book: Food Chemistry Springer 498−545 German Research Centre for Food Chemistry | DFA · Food Chemistry Prof Dr.- Ing 14 D Julian McClements and Eric A Decker Designing functional foods measuring and controlling food structure breakdown and nutrient absorption Woodhead Publishing Pages 148-170 15 W Weerathilake, D Rasika, J K U Ruwanmali, M Munasinghe Published 2014 The evolution , processing , varieties and health benefits of yogurt 16 H.-J Rehrn and G Reed in cooperation with A Puhler and P Stadler Copyright©VCH Verlagsgesellschatt rnbH,1993 Lactic Acid Bacteria Biotechnology 17 FAO (2021) DAIRY MARKET REVIEW Overview of global dairy market developments in 2020 April 2021 18 https://bfchem.vn/potassium-sorbate 19 https://www.iso.org/iso-22000-food-safety-management.html 20.https://academy.paulmueller.com/overview-of-plate-heat-exchanger technology 72 APPENDICES Guest house of ELovi VNJSC Sweet Yogurt of Elovi Viet Nam Warehouse material Joint Stock Packing of Sweetnened Yogurt Other products of the company ( KOSHI) Other products of the company ( ZINZIN) The company's wastewater treatment and filtration system Modern automatic yogurt filling machine system