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1、 General Plant-based yoghurt-style products White paper The role of ingredients and process control General CONTENTS Introduction _3 Who is this white paper for?_ 3 Why the interest in plant-based products,and fermentation in particular?_ 4 Three major challenges when producing yoghurt-style product
2、s from a plant base _ 5 General overview Producing yoghurt-style products from plant-based material_6 Creating a base in the plant world _6 Oat base _7 Soya base_9 Almond base _ 10 Challenge 1 Optimizing viscosity and other characteristics with the right ingredients _ 11 Other ingredients_ 12 Mixing
3、 and formulation technology _ 12 Challenge 2 Optimizing heat treatment to ensure food safety and quality _ 14 Heat treatment essential for food safety and quality _ 14 Heat treatment depends on recipes and ingredients _ 14 Choice of heating technology _ 15 Challenge 3 Optimizing fermentation paramet
4、ers _ 16 The role of fermentation _ 16 Adding culture _ 16 Fermentation time is critical _ 16 Post-fermentation steps also essential for quality and safety_ 18 Smoothing or homogenization _ 18 Cooling _ 18 Adding fruits and particles _ 18 Heat treatment after fermentation _ 19 Final cooling and effe
5、cts on texture _ 19 Summary_ 20 Three major production challenges _ 20 Getting the technology right _ 21 Tetra Pak An innovation leader in fermented plant-based products _ 22 Were ready to help _ 22 Technology and line expertise _ 22 Contact persons _ 23 3 INTRODUCTION Who is this white paper for?Th
6、is white paper provides a general background on preparing plant-based yoghurt-style products,which are winning popularity among some consumers.We address the needs of R&D managers,production managers,marketing managers,business developers,procurement managers,CEOs,and food technology specialists who
7、 are considering expanding their product portfolios in this direction.We recognize that there are many diverse industry groups who are interested in broadening their knowledge of fermented plant-based foods and beverages.If you are already well established in traditional dairy production,you have al
8、ready mastered many of the hygienic aspects,and have a good sense of dairy yoghurt production.Hopefully this white paper will fill the gaps involving the specific food chemistry knowledge that is required when working with plant-based foods.You may find that working with plant-based foods is challen
9、ging,and that the industry hasnt yet achieved the degree of standardization and efficiency that you are used to in dairy.If you are already running fruit,still drinks,or vegetable-based lines for beverage production,then you are used to processing steps involving water,and much of the hygiene involv
10、ed.But if your experience is mainly with high-acid production,you may encounter challenges in running low-acid processes,which present special Issues with cleaning,etc.Making the leap to fermented plant-based products will also involve understanding the special roles of thickeners,fermentation and h
11、eat treatment.Finally,if you are a newcomer to the food industry,but have creative ideas for new fermented beverages and foods,especially fortified and functional products,this white paper should provide the overview you need to forge ahead with your plans.There arent yet any books to learn from in
12、this area,and very few consultants to hire.Well welcome your questions.4 Why the interest in plant-based products,and fermentation in particular?Fermented plant-based products are increasingly available around the world,and the range of such products is increasing every day.This document will focus
13、on products that look,taste and feel like “stirred yoghurt”,the type eaten with a spoon;well refer to them as plant-based yoghurt-style products to avoid any confusion.The market is growing for plant-based alternatives,for reasons that range from nutritional and economic to regulatory and environmen
14、tal.From the food manufacturers perspective,it is all about providing consumers with an optional nutritional source.As health concerns rise globally,the main consumption drivers of plant-based products are perceived health benefits and the opportunities to explore new flavours and tastes from around
15、 the world.A preventive approach focused on strengthening our own and our families immune systems has reached a new height.This approach favours nutrients from natural sources and less calorific sources,as plants are seen by many as a powerful alternative to artificial supplements.Another driver is
16、environmental sustainability and its positive impact on water and energy consumption,climate change,waste and pollution.Many countries are increasing environmental restrictions on dairy farm pollution and enacting stricter animal welfare regulations.Greenhouse gas emissions in animal food chains are
17、 under particular scrutiny.Consumers have increasingly integrated thinking about sustainability into some of their purchasing decisions and are increasingly willing to pay for brands that are known as environmentally friendly.At the same time,some plant-based proteins are more favoured than others,a
18、nd it is important to consider the full value chain when evaluating a food products impact on the environment.Consumers can currently choose among many different plant-based ingredients in the marketplace,from the more traditional soya,to oats,coconut and even peas.Mouth feel is paramount:consumers
19、look for a smooth texture and pleasant taste and will not compromise.We are seeing the confluence of several trends here:tasty products targeting health concerns,plant-based diets,veganism,sustainability,and animal welfare.Plant-based products may be consumed as breakfast food supplements or snacks.
20、Terminology and the law When we write“yoghurt-style products”in this white paper,we mean“fermented plant-based products that are similar in taste,appearance,and texture to traditional dairy-based yoghurt”.But please note that the term“yoghurt”is reserved in many markets for dairy products.So you sho
21、uld verify your own market and legal requirements before deciding which term to use in communications and advertising,when referring to plant-based yoghurt-style products.5 In many markets they command premium prices over ordinary milk products.And fermentation is often regarded by consumers as an a
22、dded value both for spoonable and drinkable products.At Tetra Pak we have seen an increased interest in production of fermented plant based products,while at the same time there is little knowledge generally available on a commercial basis.As you will see in the following pages,testing recipes,formu
23、lations and processing parameters is a wise course to follow.Three major challenges when producing yoghurt-style products from a plant base In order to illustrate successful production,we have identified three major technology and production challenges:1.Optimizing viscosity and other characteristic
24、s with the right ingredients,including thickeners 2.Optimizing heat treatment to ensure food safety and quality 3.Optimizing fermentation parameters,including the culture addition Most importantly,it is also about making sure that the solutions to these challenges viscosity,heat treatment,and fermen
25、tation are coordinated in a way that optimizes the whole production process.Essentially,your ingredients(especially thickeners),heat treatment,and fermentation time and culture are the keys to a successful design.Throughout our discussion of ingredients and processing,we will return again and again
26、to these three challenges,why they occur,and how they can be met.But before we go into these challenges,we should get acquainted with the general overview of how to produce plant-based yoghurt-style products,as well as how to create the base from plant ingredients.6 GENERAL OVERVIEW PRODUCING YOGHUR
27、T-STYLE PRODUCTS FROM PLANT-BASED MATERIAL There are numerous ways that processing fermented plant-based products differ from dairy-based products,and these differences increase as you consider the many formulations that are possible.Fermented plant-based products have to be optimized for taste,text
28、ure and nutrition by adding additional ingredients and/or adapting processing methods.Figure 1 shows the process of producing yoghurt-style products from a plant-based base,which we describe step-by-step in the following pages.This white paper will give you a quick overview of some important differe
29、nces,why they present challenges,and how they can be overcome or compensated.Figure 1.The major steps in producing yoghurt-style products from plant-based material In dairy yoghurt the viscosity is mainly built up from a protein network created by the pH drop during fermentation.But in plant-based p
30、roducts the main texture often comes from starch or other thickeners,even though some products get some texture from the protein network.In general,the higher the protein level,the higher the contribution is to the texture.For example,a soya base is often rich in protein,perhaps 3%protein compared t
31、o about 1%for an oat base.This means that the proteins in the soya-based fermented product will contribute more to the protein network than in an oat-based product.Getting all these process parameters balanced is where the technology and food know-how play a role,but since this plant-based yoghurt-s
32、tyle production area is still new,there are no off-the-shelf solutions.Combining food application knowledge with recipe and process expertise is currently the best way forward,as this white paper will demonstrate.Creating a base in the plant world Plant-based means that the product is based on plant
33、 material such as oats,soya beans,almonds,rice,peas,coconuts,buckwheat,etc.The base you create can be used to formulate many different products,where yoghurt-style products can be one,beverages or cooking cream could be another.The technology principles are the same for most starch-rich materials,wh
34、ich means that the principles for using oats can also be applied to rice and other starch-rich ingredients.The principles for nuts and nut-like products are the same as for almonds.That said,there can still be a big difference in processing parameters,even when the technology principles are the same
35、.Starch-rich materials can be enzymatically treated to give the sugar needed for fermentation,while other materials like almonds need added sugar.7 Protein-rich materials like soya will have a relatively high buffering capacity,which means the fermentation time might be longer than for oats or rice.
36、The base for a plant-based yoghurt-style product can be made from a variety of different plant raw materials.For our purposes here,we will focus on the three most common base ingredients:oats,soya beans and almonds.We will begin by comparing their basic composition,as in Table 1,before going into mo
37、re details.Table 1.Differing composition of oats,soya and almonds,showing percentages by weight(wt%)Oat base Oats are available in a variety of forms.For example,some forms of oats might have an extra-high fat level or an extra-high beta-glucan level.The oat base comes from an extraction line with e
38、nzymatic treatment.There are three alternatives for the raw material,as shown in Table 2.The first option is to use oat kernels or oat flakes and continuously feed them into a grinding unit together with hot water.The second option is to mix oat flour into hot water.In both cases the result is a hot
39、 oat slurry.The third option is to buy a ready-made oat compound,where the ingredient supplier has already performed the extraction and enzymatic treatment,so all you have to do is add water to the desired level.That is by far the easiest choice,but the raw material cost might be rather high.Oats So
40、ya Almond Proteins(wt%)17 38 19 Fats(wt%)7 18 49 Carbohydrates(wt%)66 30 26 Moisture(wt%)10 14 6 8 Table 2.Advantages and disadvantages among oat ingredients for oat base creation The oat base can be tricky to handle.What we have demonstrated in our laboratories and in customer installations is that
41、 the processing design and parameters for the oat base must take into account the raw materials(kernels,ground flour,or ready-made compositions);the need to enzymatically control how starch and proteins behave during processing;and using specialized equipment for high shear mixing,fibre separation a
42、nd deaeration.Figure 2 below shows the most common way to create an oat base.Figure 2.Overview of the process for making an oat base(For more detailed information on oat preparation and processing,see the 2020 white paper from Tetra Pak entitled“Oat-based beverages processing challenges&techniques”d
43、ownloadable at White paper:Oat-based beverages strategies&processing challenges|Tetra Pak)The first step is to create a hot oat slurry from oat and hot water.It can be done either by high-shear mixing of oat flour into hot water,or by continuously grinding oat grains or flakes with hot water.The tem
44、perature of the slurry is normally 60-65C.The oat-to-water mass ratio is typically 1:5 but can also be higher.Raw material Advantages Disadvantages Oat kernels or oat flakes continuously fed into a grinding system together with hot water Low raw material cost Largest investment cost and the most com
45、plex operation Oat flour mixed with hot water in a high shear mixer Lower investment cost and easier operation than kernels or flakes.Might be a little more flexible.Easier to reach higher dry matter levels,above 20%.Higher raw material cost than kernels or flakes A ready prepared oat compound from
46、an ingredient supplier Very convenient.Fast path to market.Lowest investment cost.Highest raw material cost 9 The oat starch swells immediately,and the viscosity increases.To decrease the viscosity,enzymes(alpha amylases)are added to cut down the starch into smaller molecules(dextrins)and access the
47、 sugars in the starch.It is beneficial to add these enzymes as early as possible,preferably before the starch swelling has taken place.When starting from grains or flakes,the enzymes are added in the grinding unit together with the water.When starting from flour they are added to the enzymation tank
48、s.When the enzymes have been added,the viscosity goes down very rapidly.After the grinding/mixing a second enzyme is added directly into the enzymation tank.This is typically a glucosidase or maltase,which will further cut down the starch and dextrins into sugar molecules.Depending on the enzyme,the
49、 resulting sugars will be either glucose or maltose.The activity of the enzymes needs to be controlled in order to achieve the desired sweetness.To stop the enzymatic activity,the enzymes are deactivated with a high temperature treatment,usually up to 100C depending on the enzyme.The insoluble fibre
50、s are then removed with a decanter,and the result is an oat base that can be used for a large variety of beverage or yoghurt-style products.Soya base Soya consumption styles and preferences vary around the globe,due to a variety of agricultural traditions and climate influences.In some regions,it is
51、 considered a main protein base,while in others,it is regarded as a healthy alternative.Soya beans are alive and nature helps them with enzymes(lipoxygenase)that protect the seeds and give the young plants a safe start.However,these enzymes also cause processing problems and must be controlled to ac
52、hieve the right taste(beany or low-beany taste)and other properties in the final product.The raw materials commonly used for producing a soya base are:Extraction of soya beans,whole or dehulled,ground with hot water,fibre phase removed.Mixing soya isolate,soya concentrate or powder with hot water in
53、 a high-shear mixer to formulate a soya base.The first alternative,using wet grinding,is shown in Figure 3.It has the largest investment cost and the most complex operation,but the raw material cost will be low(similar to oat extraction,without the enzymatic part).Figure 3.Overview of the process fo
54、r making a soya base 10 Trypisin inhibitors(TI),which are naturally occurring in soya,retard the absorption of protein by the human body.To de-activate them,the soya base is heat-treated before it is further processed.The second alternative,using a concentrate,has a lower investment cost and easier
55、operation,and might also be a little bit more flexible,but comes with a higher raw material cost.More information can be found in the Soya Handbook,available at https:/ Almond base As with soya beans,there are options when making an almond base,as Figure 4 shows.The most common way starts with almon
56、d paste,which may be made from roasted or unroasted almonds,depending on the desired taste profile.The almond paste is generally highly viscous,so some preheating of the paste is advisable before adding it to the mixer.Some producers start from whole almonds,making the paste themselves by dry grindi
57、ng the almonds(roasted)in two steps to a fine paste or slurry,with particle size less than 50m.If unroasted almonds are used,a wet grinding is performed similar to the grinding process for oats,but with a different final grinder.This is followed by removal of the fibre phase via separation(decanter)
58、.Due to the low starch/high fat content in almonds(and other nuts),no enzymatic process is required.Figure 4.Overview of the process for making an almond base Beyond base creation Now that we have examined the fundamentals of base creation with three different plant origins,we can look more deeply i
59、nto our three primary challenges:Optimizing viscosity and other characteristics with the right ingredients,including thickeners Optimizing heat treatment to ensure food safety and quality Optimizing fermentation parameters,including the culture addition 11 CHALLENGE 1 OPTIMIZING VISCOSITY AND OTHER
60、CHARACTERISTICS WITH THE RIGHT INGREDIENTS Consumers want a certain viscosity,texture,mouth feeling and appearance in the plant-based yoghurt-style products they prefer.Viscosity is one of the central drivers here.When the protein content is not high enough to ensure that fermentation alone will ach
61、ieve the desired viscosity(consistency)of the plant-based products,other ingredients must be added to achieve the desired characteristics.Generally,thickeners play a key role in plant-based yoghurt-style formulations,and these are most commonly starches.Depending on the choice of ingredients at this
62、 stage,there may be additional requirements for particular heat treatment and fermentation parameters.Starch A wide range of native and modified starches are available,which all have their advantages and disadvantages.Modifications of starches are often made so that they will work under certain proc
63、essing conditions,for example,high temperature or high shear.These modifications will also decide what is required for the starch to develop high viscosity,and when and where in the process it will happen.Some starches will create high viscosity before fermentation,while others will have an effect a
64、fter cooling in the package.The development of viscosity is also a challenge from a technical processing point of view,as the equipment must be designed to handle the increased viscosity.Starch is dispersed in the base before heat treatment and the starch granules swell during heat treatment.The sta
65、rch thus binds water and increases the viscosity of the product.Swelling temperature depends on the type of starch used,but can be as low as 50-55C.Mechanical treatment such as pumping or mixing of the swelled starch granules can reduce the effect of the starch on final stability and viscosity,so it
66、 is important that your homogenization temperature takes into account the type of starch and swelling temperature.Pectin Pectin comes in two forms,LM and HM(low and high degree of esterification).LM pectin is often used in plant-based yoghurt-style products to increase viscosity and water-holding ca
67、pacity(stability).The LM pectin interacts with the protein network and calcium(often added)in the base.Gellan gum Gellan gum interacts with itself to create a network in the plant-based product base that increases the viscosity and/or suspends particles.It also increases water holding capacity(stabi
68、lity).It is often used in combination with pectin;the two can be dry mixed and added together,preferably with some sugar,if that is part of the recipe.12 Other ingredients Sugar Depending on the raw plant material,sucrose,glucose and maltose are commonly added sugars.If the raw material already cont
69、ains a lot of starch(e.g.oats or rice),the sugar is produced from the starch with an enzymatic process while manufacturing the plant base.The sugar composition can be further controlled by the choice of enzymes.The fermentation culture is often dependent on a specific sugar for its functionality,so
70、recipes need to be adapted accordingly.Fat Raw plant materials contain varying amounts and types of fat.Oats contain little fat,so it is common to add rapeseed(canola)or sunflower oil to oat products,while for almond and other nut-based products,additional fat may not be required.Emulsifiers Emulsif
71、iers are commonly used,mixed separately with oil and then added to the hot base as a single mixture during formulation.Flavours and aromas Sometimes the product is flavoured with aromas,alone or as a taste enhancer,e.g.vanilla and different liquid fruit aromas.These are often added in the base befor
72、e heat treatment.Proteins and total solids To increase the protein content it is common to add high-protein powders.To increase the Total Solids,the easiest way is to add more flour in the mixing,or higher amount of grain/flakes to the grinding unit.Yet another way to increase the protein content or
73、 the total solids is to use membrane filtration.For example,the base can be concentrated with ultrafiltration(UF)or reverse osmosis(RO),depending on the desired composition.Mixing and formulation technology For mixing it is recommended to use a high-shear mixer with a connected tank.The high shear i
74、s needed to dissolve ingredients like stabilizers,thickeners and minerals,rapidly and efficiently,and to emulsify added fat.To minimize air incorporation,a vacuum mixer is recommended,but not critical.Before mixing,the dry ingredients are normally dry-mixed,and the emulsifier added to the fat(temper
75、ature 60-70C).13 The base(oat,soya,etc.)is normally warm,typically 60-70C.The ingredients are added and mixed into the base,which is circulated over the connected tank.Below are examples of recipes for yoghurt-style products based on oats(Table 3),soya(Table 4),and almonds(Table 5).Table 3.Oat-based
76、 recipe(example)Table 4.Soya-based recipe(example)Oat yoghurt-style product Stirred type%by weight Soya yoghurt-style product Stirred type,chilled%by weight Oat base 93 Soya base 91 Oil 2 Sugar 8 Sugar 1 Pectin 0.1-0.2 Starch 4 CaHPO4 0.1-0.3 Culture Culture Flavour&colour Flavour&colour Table 5.Alm
77、ond-based recipe(example)Almond yoghurt-style product Stirred type%by weight Almond base 10 Sugar 9 Water 76.75 Starch 4 Lecithin 0.25 Culture Flavour&colour 14 CHALLENGE 2 OPTIMIZING HEAT TREATMENT TO ENSURE FOOD SAFETY AND QUALITY Plant-based raw materials differ a lot from milk in protein structu
78、re,protein levels and carbohydrates,among other things.So even if heat treatment,fermentation and packaging may seem similar to dairy yoghurt production,these processes have to be adapted for plant-based materials.Depending on the plant origins and the recipe,one or more heat treatments may be neces
79、sary,and they must be closely coordinated with the choice of ingredients and fermentation parameters.Heat treatment essential for food safety and quality When all ingredients are mixed,the product base should be heat-treated,for four principal reasons:1.Killing all pathogens to ensure a safe product
80、 for the consumer.2.Killing microorganisms that might compete with the starter culture that is going to be added to ferment the base.3.Coagulating proteins so that they give a better contribution to the product network.This point is important for milk yoghurt,but not fully investigated for plant-bas
81、ed products.It is likely to be more important for high-protein products where the proteins have a high contribution to the final structure and viscosity.4.Swelling the starch or other added stabilizers/thickeners.Heat treatment depends on recipes and ingredients The heat treatment is strongly determ
82、ined by the recipe,especially the type of starch and any other thickeners and stabilizers.Some thickeners cannot tolerate high temperature,while others need a very long holding time to be activated.A very common temperature and time combination is 95C/5 minutes,but this must be adapted to develop th
83、e functionality in the thickener while still maintaining food safety requirements.Establishing the right thickening system is critical to the heat treatment.It is important to know what the thickeners require in terms of temperature and holding time,and what it cannot handle.It is also important to
84、know when the desired viscosity will develop.There are starches and other thickeners that do not develop viscosity until they are cooled down after fermentation.In these cases,the viscosity is designed to develop in the package.Other thickeners will develop their full viscosity already after the hea
85、t treatment that is applied before the fermentation.It is important to design the heat treatment to fit the thickening system,but never go below what is acceptable from a food safety point of view.15 Choice of heating technology Because most plant-based bases develop high viscosity during the heat t
86、reatment,both plate and tubular heat exchangers can be used.However,this must be evaluated case by case,as different thickening systems behave differently.The homogenizer position(upstream/downstream),configuration and pressure settings can all play a role in crafting the final product.A deaerator i
87、s recommended,but is not necessary;some starter culture strains do ferment faster with less oxygen.After the heat treatment,the base is cooled down to the fermentation temperature,normally around 40C,depending on the culture used,and pumped to the fermentation tanks.You are welcome to consult with u
88、s at Tetra Pak for additional guidance.16 CHALLENGE 3 OPTIMIZING FERMENTATION PARAMETERS Fermentation is a complex challenge,because it must take place under controlled conditions and it must be stopped in time.These conditions must be specified in product development and coordinated with the thicke
89、ning system and other parameters.The role of fermentation Bacteria cultures,also known as starter cultures,are added to the heat-treated base(inoculation)and allowed to grow under controlled conditions(fermentation).These cultures might be traditional dairy yoghurt cultures,consisting of a mix of St
90、reptococcus thermophilus and Lactobacillus bulgaricus,but other cultures are also commonly used for plant-based products.During fermentation,the bacteria consume the sugars in the base and produce lactic acid,lowering the pH level,and changing flavours and aromas.But theres an important difference:w
91、ith a plant base,this pH drop does not contribute as much to the viscosity of the product as in dairy-based yoghurt.This leads to the necessity of adding ingredients to improve viscosity.There are plant-based products with live bacteria,and others where the bacteria have been inactivated in a heatin
92、g step after fermentation.The benefit of inactivating the culture is a more stable product with a longer shelf life.A third option is to inactivate the culture but add probiotic bacteria before filling,although these products are commonly sold as chilled.Adding culture After the heat treatment,the p
93、roduct is inoculated with a starter culture before fermenting to the desired pH.The culture can be added either inline before the tank,yielding better hygiene,but resulting in a higher cost;or it can be added via the manhole.The high viscosity of the base can make it difficult to blend the starter c
94、ulture homogeneously into it,so the agitator needs to be running during the culture addition.To minimize the risk of unwanted microbial growth,it is important to add the starter culture as soon as possible,and it is recommended to start the addition as soon as the level is high enough to start the a
95、gitator.The agitator should be kept running until all the base has been pumped into the tank.Fermentation time is critical During fermentation,the added starter culture microorganisms create organic acids that lower the pH.Different products will have a different final pH.To ensure food safety the f
96、inal pH must be below 4.6;below that level there are no remaining pathogenic(dangerous)microorganisms that can multiply.Typical pH values are 4.3-4.5.17 The fermentation time of plant-based products varies a lot,depending on the type of base,protein content,initial pH,desired final pH,oxygen level,e
97、tc.Typical fermentation times are 4-10 hours,and the fermentation progress is tracked through sampling and measuring pH or titratable acidity.Long fermentation times may require higher initial heat treatment.Choosing an optimal culture together with the right fermentation time and temperature is the
98、 key to success in this step.We always recommend working closely with us and the culture supplier to optimize the parameters.The line capacity and design,including the number and size of fermentation tanks,are also of great importance for both food safety and quality.To be able to scale up the ferme
99、ntation to commercial operation,we strongly recommend product trials at pilot scale.You are welcome to consult us at Tetra Pak for additional guidance,or to arrange product trials at one of our Product Development Centres.NOTE:There is a risk for Bacillus cereus growth if the fermentation time is lo
100、ng.In that case,a heat treatment with a higher heat load is necessary.You are welcome to consult us at Tetra Pak for additional guidance.18 POST-FERMENTATION STEPS ALSO ESSENTIAL FOR QUALITY AND SAFETY Depending on the recipe and the desired shelf life,additional steps after fermentation may be requ
101、ired to ensure the right levels of quality and safety,before the product is distributed.Smoothing or homogenization After fermentation the product is generally jellified and syneresis may occur.It is normal to agitate the product to make it more homogenous and pumpable.Smoothing is used to break up
102、small protein clusters and lumps.By applying shear to the product at a warm temperature,the clusters are disintegrated,and the result is a smooth and shiny product.Both commercial production and pilot scale tests have shown that most plant-based fermented products benefit from smoothing.The smoothin
103、g device can be a dynamic component,designed for smoothing,or a simpler solution such as a back-pressure valve or a strainer.Drinkable plant-based yoghurt-style products are often homogenized before cooling down to packing temperature.Cooling The fermented product is cooled down and packed,possibly
104、with the addition of fruit compounds or other flavourings before cooling.It is cooled through a plate heat exchanger typically to 10-25C and pumped to a buffer tank before the filler.As the viscosity changes with temperature,the temperature is often decided by the viscosity limitation in the filling
105、 machine.The cooling is an important step,as it stops,or at least slows down the fermentation.The pH development at the end of the fermentation depends on the culture.Some cultures slow down close to the target pH,while others continue down to a lower pH.It is important that the cooling capacity mat
106、ches the batch size,in order to prevent the pH from dropping too low,and thus over-acidifying the product.Adding fruits and particles The plain product can be mixed with a fruit preparation containing fruit and water,often mixed with a large quantity of sugar,and sometimes stabilizers.The stabilizer
107、s normally ensure that fruit pieces remain well-distributed throughout the entire volume of the preparation during storage.The fruit preparation might also contain stabilizers to influence the final product quality(stability,viscosity,texture).Fruit compounds are commonly delivered in aseptic contai
108、ners and are dosed in-line between the product storage tank and filler.The fruit preparation used for plant-based yoghurt-style products should be aseptic,even if it is a chilled product.Fermented products today may include other particles such as nuts,grains,crumbs,pieces of chocolate,etc.These can
109、 be added as particle slurries,similar to fruit preparations.19 Heat treatment after fermentation Some producers heat-treat the product after fermentation,before filling.If the purpose is to inactivate the culture,a low heat treatment is enough,typically 63-75C/15 sec.If the purpose is to inactivate
110、 microorganisms that might have contaminated the product after fermentation,e.g.when adding additives,a higher heat load is recommended,typically 95C/15sec.If the heat-treated product is filled in an aseptic package,it can be distributed/stored at ambient temperature,but these products are normally
111、distributed and sold as refrigerated.Final cooling and effects on texture After filling,the product is transported to cold storage,where it is further cooled to 8C.If the production line has been correctly designed,the texture and viscosity of the yoghurt-style product will improve during the first
112、1-3 days due to a rebuilding of the protein network and interactions with stabilizers.It is recommended to keep fermented plant-based products at least 24 hours in the cold store to achieve optimal texture and viscosity before distribution or evaluation.20 SUMMARY This white paper has described some
113、 of the basic processes involved in production of plant-based yoghurt-style products.While currently riding on a wave of popular interest,this industry hasnt yet achieved the degree of standardization and efficiency that is well-established in dairy production,and there are numerous factors that int
114、eract with each other to influence the final form,quality and safety level of the product.We selected oats,soya and almond for illustrative reasons.The technology principles are stable for most starch-rich materials,so the principles for using oats can also be applied to rice and other starch-rich i
115、ngredients.The principles for nuts and nut-like items are the same as for almonds.Although the same principles can be applied,there is still a big difference in processing parameters.Exploring the new opportunities in plant-based yoghurt-style products involves understanding the special roles of sta
116、rches,heat treatment and fermentation,because only some texture is provided by the protein network(which varies depending on the plant used).The main texture comes from starch or other thickeners.Three major production challenges 1.Optimizing viscosity and other product characteristics with the righ
117、t ingredients,including thickeners.Depending on the thickener used,different heat treatments and mechanical processes are required for the thickener to develop the specified viscosity,texture,mouthfeel and appearance within the specified time limits.Some thickeners achieve high viscosity before ferm
118、entation,while others achieve it after cooling in the package.2.Optimizing heat treatment to ensure food safety and quality.Heat treatment is required to:a)Kill pathogens to ensure safety b)Kill microorganisms that might compete with the starter culture that is chosen for fermentation c)Coagulate pr
119、oteins so that they give a better contribution to the network d)Swell the starch or other added stabilizers/thickeners In addition,the heat treatment must fit the thickening system.3.Optimizing fermentation parameters,including the culture addition.During fermentation,microorganisms create organic a
120、cids that lower the pH.To ensure food safety the final pH must be below 4.6,signifying there are no pathogenic microorganisms that can multiply.The fermentation time of plant-based yoghurt-style products varies a lot,depending on the type of base,protein content,initial pH,desired final pH,oxygen le
121、vel,etc.Typical fermentation times are 4-10 hours,and longer fermentation times may require higher initial heat treatment.21 Choosing an optimal culture together with the right time and temperature is key to success in this step.Please keep in mind it is essential that the solutions to these challen
122、ges viscosity,heat treatment,and fermentation are also coordinated in a way that optimizes the whole production process.Getting the technology right Every step of the production process also requires special attention to equipment,often because of the increased viscosity and time sensitivity.For mix
123、ing,it is recommended to use a high-shear mixer with a connected tank.The high shear is needed to dissolve ingredients like stabilizers,thickeners and minerals,rapidly and efficiently,and to emulsify added fat.Because most plant-based bases develop high viscosity during heat treatment,it is common t
124、o use either plate or tubular heat exchangers but this depends on the behaviour of the thickening system selected.The homogenizer position(upstream/downstream),configuration and pressure settings can all play a role in crafting the final product.The equipment used for inoculation,cooling,adding ingr
125、edients and heat treatment may also have special requirements to ensure that hygienic standards are met,and that processing specifications are followed correctly.Because of the many parameters involved in producing a high-quality product,we strongly recommend product trials on a pilot scale.You are
126、welcome to consult us at Tetra Pak for additional guidance,or to arrange for product trials at our Product Development Centres.22 TETRA PAK AN INNOVATION LEADER IN FERMENTED PLANT-BASED PRODUCTS Tetra Pak has long been a trusted partner of the dairy,food and beverage industries.As an innovator,we ar
127、e dedicated to not only serving the current needs of these industries,but helping them explore new opportunities for growth.We collaborate with customers,universities,and other business partners to develop new technologies and solutions for producing products while keeping safety,cost-effectiveness
128、and flexibility in mind along with high regard for environmental sustainability.Were ready to help We are a global market leader in providing line solutions for plant-based products.Our strong application expertise within low acid,aseptic technology,as well as years of experience with oats and soya(
129、over 30 years!)combined with a broad portfolio,covering extraction,in-line blending,mixing,UHT treatment,aseptic storage and filling has enabled us to capture and optimize new plant-based trends.Ingredients and plant-based protein vary endlessly,and it is only your creativity that sets the limit.Bas
130、ed on your product ambitions and formulations,we can configure a complete line from product formulation to heat treatment and packaging to secure your product quality,running time and efficiency.Our ten Product Development Centres(PDCs)around the world can help you develop new recipes as well as opt
131、imize different process parameters.You can also start developing your product concepts at one of our six Customer Innovation Centres(CICs)and acceleration laboratory.In an inspirational and creative environment together with our experts,you can innovate product ideas while incorporating insights on
132、global and local trends and in harmony with packaging linked to your business needs.Technology and line expertise We offer complete line concepts and technology support for beverage,dairy and food producers,including fermented plant-based products,based on:Extensive knowledge of food processing tech
133、nology and ability to support its implementation Processing solutions(extraction units,in-line blending,high-shear mixers,pasteurizers/UHT,homogenizers,and more)and best-practice line concepts based on proven technologies End-to-end offerings from raw materials through processing,and all the way to
134、filling,packaging and palletized products.23 Contact persons Maria Norlin,Manager Centre of Expertise JNSD,Plant-Based&Other Beverages Maria.N Anders Lfgren,Technology Specialist,Centre of Expertise JNSD,Plant-Based&Other Beverages Anders.L Katarina Ternstrm,Manager Centre of Expertise Dairy Chilled&Fermented Katarina.T Katarina Lindgren,Technology Specialist,Centre of Expertise Dairy Chilled&Fermented Katarina.L 24 Tetra Pak and Protects Whats Good are trademarks belonging to the Tetra Pak G Tetra Pak International S.A,Tetra Pak Processing system AB,08-07-21