New method may transform yoghurt production

New research from DTU in Denmark could change the way the food industry manufactures dairy based yoghurt—making it both more cost-effective and more sustainable. Researchers have developed a simple yet powerful method that has the potential to reduce the use of expensive bacterial cultures by up to 80%, while also extending shelf life.

A new method for producing yoghurt has been developed by a research team at the DTU National Food Institute, and it all began with a straightforward question.

“We’ve studied lactic acid bacteria and their energy metabolism for years, but one day it struck us: what if we let the bacteria acidify without allowing them to grow? It was something of a eureka moment,” says Associate Professor Christian Solem, who has researched lactic acid bacteria for more than 25 years and co-author of a new paper in Food Bioscience describing their findings.

The method has been tested on a smaller scale in the laboratory at the DTU National Food Institute, and the researchers see no reason why it cannot be immediately implemented by dairies. It requires no new technology—only an adjustment of the temperature control during production.

“In principle, dairies could adopt the method as early as tomorrow. We have not observed any drawbacks, apart from the process taking an hour or two longer – and you will have a more stable and sustainable product,” says Christian Solem.

The research holds great potential, as it is estimated that, on average, each person globally consumes nearly 12 kilograms of yoghurt annually.

A two-step fermentation technique

Traditional yoghurt production involves adding a relatively large amount of yoghurt starter culture to milk, which is then fermented at 42°C for 4–6 hours. The desired acidity is then reached, and the yoghurt is cooled. However, the process is known to present several challenges:

• High costs for starter culture.
• Limited shelf life.
• So-called “post-acidification”, where the yoghurt continues to acidify during storage, affecting both quality and longevity.

With the new method, researchers use just 20% of the usual amount of starter culture. The milk is first fermented at 42°C, as per standard procedure, and then the temperature is raised to 51°C for a few hours. At this elevated temperature, the bacteria cease to divide, but continue to produce lactic acid.

“It’s like putting the bacteria on a treadmill—they’re not going anywhere, but they’re still working. This allows us to control the acidification while avoiding undesirable post-acidification,” explains Christian Solem.

The 51°C step also acts almost as a mild pasteurisation phase.

“We eliminate up to 99.9% of yeast cells and mould spores, which would otherwise significantly shorten the yoghurt’s shelf life,” says Christian Solem.

Goodbye to post-acidification – hello to extended shelf life

Post-acidification is among the most serious quality concerns in yoghurt production. It causes the product to become overly sour, bitter, and prone to phase separation—characteristics often associated with spoiled yoghurt.

“We’ve tested the method on three different starter cultures, including some particularly prone to post-acidification. In all cases, the issue was resolved,” says Postdoctoral Researcher Shuangqing Zhao, corresponding author of the study.

The exact extension of shelf life has not yet been determined, but according to the researchers, it is expected to far exceed the current 3–4 weeks. This could have significant implications for both long-distance transport and food waste reduction.

Substantial benefits for dairies

At present, dairies use up to 0.18 grams of starter culture per litre of milk. Given the scale of production, the cost of bacterial cultures can be considerable.

“We reduce the use of starter culture by a factor of five. That’s a substantial saving, and it matters in an industry where profit margins are tight,” says Christian Solem.

Moreover, the extended shelf life improves planning and logistics:

“Yoghurt is typically produced in large batches, and each production run requires cleaning and reconfiguration. With longer shelf life, larger and perhaps even more continuous production becomes feasible,” he adds.

About the paper

The article is available online in the scientific journal Food Bioscience: “Smoking hot – Heat-induced uncoupling of growth & acidification in yoghurt production helps save costs and results in reduced post-acidification and improved shelf life”.

Authors: Postdoctoral Researchers Liuyan Gu, Belay Tilahun Tadesse, and Shuangqing Zhao, as well as Associate Professor Christian Solem—all from the DTU National Food Institute.