How to Construct a 200L Yogurt Making Process: Complete Setup Guide

The industrial yogurt making process can better meet the needs of modern companies for dairy manufacturing. A 200L yogurt production line is the ideal entry point for small businesses, dairy farm diversification, and market testing. This comprehensive guide covers equipment configuration, facility requirements, utility specifications, and installation procedures to help you construct an efficient 200L yogurt making process.

200L Yogurt Project Requirements

Before constructing a 200L yogurt production line, define these key project parameters:

Design Specifications

Parameter	Specification	Notes
Design Capacity	200L per day	Liquid milk handling capacity
Production Time	8-10 hours/day	Single shift operation
Daily Output	400-600 cups (200g each)	Depends on packaging format
Product Type	Plain, stirred, or set yogurt	Determine equipment configuration
Packaging Format	Cup, bag, or bottle	Affects filling machine selection

Control System Options

Control Type	Description	Cost	Best For
Push-Button	Manual control with buttons	Standard	Simple operations, budget-conscious
Semi-Automatic	Partial automation with manual intervention	+15-20%	Growing businesses
PLC Full Automatic	Programmable logic controller	+30-40%	Consistent quality, data logging

Product Type Considerations

Product Type	Equipment Requirements	Processing Difference
Stirred Yogurt	Standard fermentation tank with agitator	Mix after fermentation
Set Yogurt	Individual cup filling before fermentation	Fill then ferment in cup
Drinking Yogurt	Lower viscosity, extended homogenization	Additional homogenization pass

200L Yogurt Production Line Equipment Configuration

Core Equipment List

Equipment	Capacity	Specifications	Estimated Cost
Raw Milk Cooling Tank	200L	SUS 304, with cooling system	$3,000-5,000
Duplex Filter	500L/hr	100 mesh, SUS 304	$1,500-2,500
Preheating Tank	200L	Electric or steam heating	$2,000-3,500
Homogenizer	300L/hr	150-250 bar pressure	$4,000-6,000
Pasteurization Tank	200L	85°C, 30 min holding	$5,000-8,000
Fermentation Tank	200L	Temperature controlled 42°C	$6,000-9,000
Filling Machine	500 cups/hr	Semi-automatic	$4,000-7,000
CIP Cleaning System	Match line	Basic system	$3,000-5,000
Total Equipment Cost			$28,500-46,000

Optional Equipment

Equipment	Function	Cost
Milk Pump (stainless steel)	Transfer between stages	$500-1,000
Plate Cooler	Rapid cooling after pasteurization	$2,000-3,500
Culture Dosing System	Accurate culture addition	$1,000-2,000
Cold Room (2-6°C)	Finished product storage	$3,000-6,000

Yogurt Processing Flow Chart

The flow chart above illustrates the complete yogurt making production process. TS stands for Temporary Storage.

Detailed Process Parameters

Stage	Temperature	Duration	Key Control Points
1. Milk Reception	4°C	30 min	Test quality, record data
2. Filtration	4-10°C	15 min	100 mesh filter
3. Preheating	40-50°C	20 min	Even heating
4. Homogenization	60-70°C	10 min	150-250 bar pressure
5. Pasteurization	85°C	30 min	Hold temperature
6. Cooling	42-45°C	20 min	Rapid cooling
7. Inoculation	42-45°C	10 min	2-3% culture
8. Fermentation	42°C	6-8 hours	pH 4.5-4.6
9. Filling	4-6°C	Continuous	500 cups/hr

Plant, Energy, and Installation Requirements

Facility Requirements

Requirement	Specification	Notes
Floor Area	20-30 m²	Enough for entire production line
Ceiling Height	3-4 meters	Sufficient for tank installation
Floor Loading	500 kg/m²	Support equipment weight
Floor Finish	Epoxy coating	Non-slip, chemical-resistant
Wall Finish	Smooth, washable	Up to 2 meters height
Drainage	Floor drains with traps	Proper slope (1-2%)

Layout Recommendation

Zone	Area	Equipment
Raw Milk Reception	5 m²	Cooling tank, filter
Processing Area	10 m²	Preheating, homogenizer, pasteurizer
Fermentation Area	5 m²	Fermentation tank
Filling Area	5 m²	Filling machine, sealing
Cleaning Area	3 m²	CIP system, chemical storage
Total	28 m²

Utility Requirements

Electrical Supply

Parameter	Specification	Notes
Voltage	380V/50Hz three-phase	Standard industrial power
Total Power	15-25 kW	Depends on equipment configuration
Distribution	Separate circuits per equipment	With overload protection
Control Panel	IP65 rated	Dust and water resistant

Water Supply

Parameter	Specification	Notes
Daily Consumption	600-1000L	3-5L per liter of yogurt
Water Quality	Drinking water standard	WHO or local equivalent
Water Pressure	2-4 bar	For cleaning and processing
Water Treatment	Filtration + UV recommended	Ensure water quality

Compressed Air

Parameter	Specification	Notes
Pressure	6-8 bar	For pneumatic controls
Flow Rate	100-200 L/min	Depends on equipment
Air Quality	Oil-free, filtered	Food-grade requirement
Compressor	1.5-2.2 kW	With air dryer

Steam (Optional)

Parameter	Specification	Notes
Pressure	0.3-0.5 MPa	For heating and sterilization
Flow Rate	30-50 kg/hr	Depends on heating method
Steam Generator	20-30 kW	Electric or gas fired

Pipeline Requirements

Before equipment installation, prepare the following utility pipelines:

Pipeline	Purpose	Specification
Power Cable	Electrical supply to each control cabinet	Sized per equipment load
Steam Pipeline	Heating and sterilization	Insulated, 0.3-0.5 MPa
Compressed Air Pipeline	Pneumatic controls	6-8 bar, oil-free
Ice Water Pipeline	Rapid cooling	1-3°C, insulated
Circulating Water Pipeline	Temperature control	10-15°C
Clean Water Pipeline	Processing and rinsing	Drinking water standard
Water Softening Pipeline	CIP system	Softened water
Drainage Pipeline	Waste water disposal	Proper slope, traps

Installation Procedure

Phase 1: Preparation (1-2 weeks)

1. Site Preparation: Clean and prepare floor, install drainage
2. Utility Installation: Run electrical, water, air, and steam pipelines
3. Equipment Delivery: Receive and inspect all equipment
4. Layout Marking: Mark equipment positions on floor

Phase 2: Equipment Installation (1-2 weeks)

1. Position Equipment: Place tanks and machines according to layout
2. Level and Secure: Level equipment and anchor to floor
3. Connect Utilities: Connect electrical, water, air, and steam
4. Connect Pipelines: Install interconnecting milk pipelines
5. Install CIP System: Connect cleaning system to all equipment

Phase 3: Commissioning (1 week)

1. Electrical Testing: Test all electrical connections and controls
2. Water Testing: Run water through all pipelines and tanks
3. Leak Testing: Check all connections for leaks
4. CIP Testing: Run cleaning cycle to verify system
5. Trial Production: Run first production batch with water

Phase 4: Validation (1 week)

1. First Production: Run first yogurt production batch
2. Quality Testing: Test product for quality parameters
3. Parameter Adjustment: Fine-tune temperatures and timing
4. Operator Training: Train production team on operation
5. Documentation: Complete installation and validation records

Case Study: 200L Yogurt Line in Saudi Arabia

Shuliy successfully installed a 200L yogurt production line in Saudi Arabia, providing a complete turnkey solution based on the customer's investment needs. The project included:

Item	Specification
Capacity	200L/day
Product	Plain and flavored yogurt
Packaging	200g cups
Control System	PLC automatic
Installation Time	3 weeks
Training	5 operators trained
Production Start	4 weeks from order

Conclusion

Constructing a 200L yogurt making process requires careful planning of equipment configuration, facility layout, utility requirements, and installation procedures. With proper planning and professional support, you can establish an efficient production line within 4-6 weeks.

Contact Shuliy Machinery for a customized 200L yogurt production line solution. Our experienced team will provide complete design, installation, and training services based on your specific requirements.