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Reducing costs and preserving texture in yogurts by using YoFlex® Acidifix® culture

YoFlex® Acidifix® cultures allow the implementation of a „warm fill” process, a technological flow that preserves the texture formed during fermentation and reduces the need for proteins and texturizers. 

Study objective Evaluating the way YoFlex® Acidifix® culture:

  • Maintain yogurt texture under warm fill processing conditions
  • Reduce the use of stabilizers and texturizers
  • Allows for a decrease in protein content between 0.3–0.6%
  • It brings significant savings to processors

Methodology

The study compares two processes:

A. The traditional process

B. The Warm Fill Process with YoFlex® Acidifix®

A. The traditional process

Include pumping stage, heat exchanger passage, buffer tank, mixing, cooling, and cold packaging.
These steps lead to the loss of up to 50% of the texture formed during fermentation.

B. The Warm Fill Process with YoFlex® Acidifix®

Simplified flow:

  • fermentation
  • Minimum pumping
  • mixing
  • hot melt wrapping

Results

pH Stability YoFlex® Acidifix® cultures:

  • Stabilize pH after fermentation
  • prevents further declines
  • allows hot packing without risk of over-acidification

Texture preservation

  • Stabilize pH after fermentation
  • prevents further declines
  • allows hot packing without risk of over-acidification.

Cost reduction Through natural texture stabilization:

  • The traditional process loses up to 50% of texture due to mechanical forces (shearing & pumping)
  • The warm fill process preserves texture by eliminating disruptive steps.

Advantages for manufacturers

Technological advantages

YoFlex® Acidifix® radically transforms the yogurt production flow:

  • Texture forms during fermentation and is preserved, not artificially rebuilt.
  • The process is shorter, simpler, and with fewer losses

Economic advantages

By reducing texturizers and proteins, manufacturers can consistently achieve:

  • Operational and raw material costs are visibly decreasing
  • High quality stability, market differentiation through a „cleaner” formula”