Unit 2244: Comprehensive Dairy Processing

1. Introduction to Dairy Processing

• Overview of the dairy industry
• Importance of dairy processing in food supply and economy
• Key concepts: raw milk to finished product
• Overview of major dairy processing operations

2. Milk Composition and Quality

• Components of milk: water, fat, protein, lactose, minerals, vitamins
• Factors affecting milk composition (breed, feed, lactation stage, environment)
• Milk quality parameters: microbiological, chemical, physical
• Methods for assessing milk quality (somatic cell count, bacterial count, acidity, adulteration tests)
• Importance of milk quality for processing and product safety

3. Dairy Product Manufacturing

• Butter manufacturing
  • Cream separation and churning
  • Salt addition and packaging
• Cheese production
  • Types of cheese and classification
  • Coagulation, cutting, cooking, pressing, ripening
• Yogurt manufacturing
  • Starter cultures and fermentation conditions
  • Types of yogurt and additives
• Ice cream production
  • Mix preparation, pasteurization, homogenization, freezing, and hardening
• Other products: condensed milk, evaporated milk, dairy powders

4. Pasteurization and Homogenization

• Definition and objectives of pasteurization
• Common pasteurization methods (HTST, LTLT, UHT)
• Impact on microbial safety and shelf-life
• Homogenization process and mechanism
• Effects of homogenization on texture, stability, and product quality

5. Fermentation in Dairy Processing

• Role of fermentation in producing yogurt, kefir, and cheese
• Types of starter cultures: lactic acid bacteria, probiotics
• Fermentation biochemistry and metabolic pathways
• Control of fermentation parameters (temperature, time, pH)
• Quality and sensory attributes contributed by fermentation

6. Dairy Packaging and Storage

• Packaging materials: plastic, glass, cartons, biodegradable options
• Packaging techniques: aseptic, vacuum, modified atmosphere
• Storage conditions for different dairy products
• Influence of packaging and storage on shelf-life and quality
• Handling and distribution considerations

7. Dairy Industry Regulations and Standards

• Overview of regulatory bodies (FDA, EFSA, Codex Alimentarius)
• Key quality and safety standards (HACCP, GMP, ISO 22000)
• Labeling requirements
• Certifications and audits
• Compliance and consumer safety implications

8. Dairy Processing Equipment

• Common equipment types: separators, pasteurizers, homogenizers, fermenters, packaging machines
• Functions and operational principles
• Routine maintenance and cleaning practices
• Safety considerations and best operational practices

9. Dairy By-Products and Waste Management

• Types of by-products (whey, buttermilk, sludge)
• Environmental impact of dairy waste
• Sustainable waste management practices
• Valorization of by-products (animal feed, bioenergy, food ingredients)

10. Emerging Trends in Dairy Processing

• Plant-based dairy alternatives and hybrid products
• Functional dairy products (probiotics, enriched products)
• Automation and Industry 4.0 in dairy processing
• Sustainability initiatives and carbon footprint reduction
• Innovative packaging and preservation technologies