small scale greek yogurt production

CAPSTONE EXPERIENCE 2014 Nicolette Ciasullo (BE), Lauren Green (BE), Farah Iqbal (BE), and Amanda Kreger (BE) SMALL SCALE GREEK YOGURT PRODUCTION INTRODUCTION Greek yogurt market has grown to $2 billion per year industry in recent years, and market growth is expected to continue to rise No standard identity of “Greek” yogurt by FDA • No mandatory straining step • Whey toxic byproduct is sustainability issue • Milk protein concentrates often used in industrial production Sustainability will become growing concern in yogurt industry PLANT DESIGN OBJECTIVES Create a process to expand production of Lafayette-based Parthenon Greek Restaurant Goal is to sell packaged yogurt in local grocery stores; e.g. Marsh and Payless Perform small-scale experimental procedure to measure: pH, viscosity, lactic acid, and rheology Perform scale-up optimal design of plant and economic analysis to give highest rate of return • Alternative design options • Optimal design/Equipment sizing • Economic Analysis EXPERIMENTAL DESIGN Model non-constant temperature fermentation: • Ferment yogurt at four temperatures: 90°F, 100°F, 110°F, 120°F • Record pH hourly for 8 hours Analyze rheology of products from fermentation experiment: • Flow sweep: 25°C, 0.01 to 20 1/s • Strain sweep: 25°C, 1.0 Hz, logarithmic sweep, strain percent 0.5% to 10.0% • Frequency sweep: 25°C, 0.02 to 35 Hz ALTERNATIVE DESIGNS Cases examined to optimize economics • Case 1: Heat exchanger, fermenter, packaging • Case 2: Jacketed vessel, fermenter, packaging • Case 3: Heat exchanger, packaging • Case 4: Batch vessel for all operations Jacketed Mix Tank Homogenizer Jacketed Mix Tank Fermentation Tank Optional Fermentation Tank Filling Machine Cold Room Employee Entry, Locker Space Protective Clothing Bathroom Storage Boiler Chilled Water Air Compressor Raw Material Store (Ingredients) Packaging Store Hand Wash Sink Drainer Wash Sink Rinse Sink Drainer Hand Wash Sink Drainer Wash Sink Rinse Sink Drainer Additions Area Loading/Unloading Area Cold Store Compressor Room Drain Drain Shear Employee Entrance Modified from: DairyCo. (2008). Yogurt/Ice Cream/Pasteurized Milk - A beginner’s guide to processing. Society of Dairy Technology. Retrieved from www.dairyco.org.uk/non_umbraco/download.aspx?media=1667 Unit Operation Flow Diagram ECONOMIC ANALYSIS IMPACT & SUSTAINABILITY Design process eliminates whey waste because of lack of straining step Product adds to already huge national Greek yogurt market Product fits with trend to buy local food, and adds to local economy Product adds to local economy $2 billion per year in national Greek yogurt market Greek yogurt was19% of yogurt market in 2011, growing from 2% of market in 2008 Few full fat Greek yogurt producers • Less competition in market • Less available market Acknowledgements: Dr. Okos & Jim from the Parthenon

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Page 1: SMALL SCALE GREEK YOGURT PRODUCTION

C A P S TO N E E X P E R I E N C E 2 0 1 4

Nicolette Ciasullo (BE), Lauren Green (BE), Farah Iqbal (BE), and Amanda Kreger (BE) SMALL SCALE GREEK YOGURT PRODUCTION

INTRODUCTION

Greek yogurt market has grown to $2 billion per year industry in recent years, and market growth is expected to continue to rise

No standard identity of “Greek” yogurt by FDA • No mandatory straining step • Whey toxic byproduct is sustainability

issue • Milk protein concentrates often used in

industrial production Sustainability will become growing concern in

yogurt industry

PLANT DESIGN

OBJECTIVES

Create a process to expand production of Lafayette-based Parthenon Greek Restaurant

Goal is to sell packaged yogurt in local grocery stores; e.g. Marsh and Payless

Perform small-scale experimental procedure to measure: pH, viscosity, lactic acid, and rheology

Perform scale-up optimal design of plant and economic analysis to give highest rate of return

• Alternative design options • Optimal design/Equipment sizing • Economic Analysis

EXPERIMENTAL DESIGN

Model non-constant temperature fermentation: • Ferment yogurt at four temperatures:

90°F, 100°F, 110°F, 120°F • Record pH hourly for 8 hours

Analyze rheology of products from fermentation experiment:

• Flow sweep: 25°C, 0.01 to 20 1/s • Strain sweep: 25°C, 1.0 Hz, logarithmic

sweep, strain percent 0.5% to 10.0% • Frequency sweep: 25°C, 0.02 to 35 Hz

ALTERNATIVE DESIGNS

Cases examined to optimize economics • Case 1: Heat exchanger, fermenter, packaging • Case 2: Jacketed vessel, fermenter, packaging • Case 3: Heat exchanger, packaging • Case 4: Batch vessel for all operations

Jacketed Mix Tank

Hom

ogen

izer

Jacketed Mix Tank

Fermentation Tank

Optional Fermentation

Tank

Filling Machine

Cold Room

Employee Entry, Locker Space

Prot

ectiv

e Cl

othi

Bathroom

Storage Boiler Chilled Water Air Compressor

Raw Material Store (Ingredients) Packaging Store

Hand Wash Sink

Drainer Wash Sink

Rinse Sink

Drainer Hand Wash Sink

Drainer Wash Sink

Rinse Sink

Drainer

Additions Area

Loading/Unloading Area

Cold Store Compressor

Room

Drain Drain

Shear

Employee Entrance

Modified from: DairyCo. (2008). Yogurt/Ice Cream/Pasteurized Milk - A beginner’s guide to processing. Society of Dairy Technology. Retrieved from www.dairyco.org.uk/non_umbraco/download.aspx?media=1667

Unit Operation Flow Diagram

ECONOMIC ANALYSIS

IMPACT & SUSTAINABILITY

Design process eliminates whey waste because of lack of straining step Product adds to already huge national Greek yogurt market Product fits with trend to buy local food, and adds to local economy Product adds to local economy $2 billion per year in national Greek yogurt market Greek yogurt was19% of yogurt market in 2011, growing from 2% of market in

2008 Few full fat Greek yogurt producers

• Less competition in market • Less available market

Acknowledgements: Dr. Okos & Jim from the Parthenon

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