Innovative Yogurt Production Method Reduces Costs and Enhances Shelf Life

In a significant advancement for the dairy industry, researchers at the Technical University of Denmark's (DTU) National Food Institute have developed a new yogurt production technique that not only reduces the amount of bacterial culture needed but also extends the product's shelf life. This innovative method presents a promising solution to the challenges faced by dairies in maintaining product quality and managing production costs.

The research, led by Associate Professor Christian Solem, who has specialized in lactic acid bacteria for over 25 years, was inspired by a simple question: could lactic acid bacteria be allowed to acidify milk without undergoing growth? According to Solem, this eureka moment led to a method that utilizes only 20% of the traditional starter culture. The process involves two stages of fermentation, initiating at the standard temperature of 42°C before incrementally raising it to 51°C. At this elevated temperature, bacteria cease to divide but continue producing lactic acid, effectively controlling the acidification process and eliminating undesirable post-acidification, which can degrade yogurt quality.

The significance of this research is underscored by the global yogurt consumption rate, averaging nearly 12 kilograms per person annually. Traditional yogurt production methods have been criticized for their high costs associated with starter cultures and the limitations imposed by short shelf lives, typically ranging from 3 to 4 weeks. The new technique not only mitigates these issues but also has the potential to dramatically enhance shelf life, although precise figures for the extension are yet to be determined.

Postdoctoral Researcher Shuangqing Zhao, the corresponding author of the study published in the journal Food Bioscience, remarked that the method successfully addressed the post-acidification problem across various starter cultures, which had previously been known to cause sourness and separation in yogurt. Furthermore, the method eliminates up to 99.9% of yeast and mold spores, contributing to a more stable product. This innovation is particularly vital for improving logistics and reducing food waste.

The financial implications for dairies are substantial, as the reduction in starter culture usage—from 0.18 grams per liter to just 0.036 grams—can lead to significant cost savings in an industry characterized by tight profit margins. Enhanced shelf life not only enables better inventory management but may also allow for larger, more continuous production runs without the frequent need to clean and reconfigure equipment.

According to the researchers, the method could be implemented immediately by dairies, requiring no new technology, merely an adjustment in temperature control during production. This accessibility makes the new technique an attractive option for dairies seeking to optimize their operations while maintaining product quality.

In summary, this breakthrough in yogurt production signifies a leap forward in dairy technology, promising to reshape the industry landscape by addressing cost, quality, and sustainability challenges. As the research progresses, the long-term benefits of this method could lead to a more efficient and environmentally friendly approach to yogurt manufacturing.

For further details, the full study can be found in the journal Food Bioscience under the title: "Smoking hot – Heat-induced uncoupling of growth & acidification in yoghurt production helps save costs and results in reduced post-acidification and improved shelf life" (Liuyan Gu et al., 2025).