Have you ever wondered why a certain brand of milk lasts longer than the other or why the yogurt tastes creamier? The response is: the compliance of the manufacturer with the dairy processing requirements.

Production of dairy is a fine art. The quality, safety, and shelf life of the products are determined by every process of the milk production process, such as the way milk is collected in the farm, packaging, and storage methods.

It is not merely a matter of the production of milk or butter; it is a matter of fulfilling the consumers’ high standards of stringent rules and regulations, and profitability. The smallest hygienic lapse or failure of the equipment may lead to spoilage, recalls, or brand damage.

We will also deconstruct the dairy manufacturing regulations in this guide into phases and simplify them concisely and practically with references to real industry statistics.

What Is Dairy Manufacturing?

Dairy manufacturing can be defined as a process of collection, standardization, pasteurization, and packaging of milk-based products under controlled conditions. It is the science of keeping food fresh and safe to consume.

All parts of the world are producing dairy. Food and Agriculture Organization (FAO) reports that the milk production was about 965.7 million tonnes globally in 2023. This has been due to a stabilized production rate despite the influence of urban demand and production technology. 

This also means that there are stricter regulations and consumer expectations. To be competitive, dairy manufacturers must take into account three prerequisites:

• Consistent product quality

• Good and efficient production lines.

• Good distribution and packaging.

Now, here are the precise dairy manufacturing guidelines broken down in steps that you should adhere to:

1. Begin With Clean, Safe Raw Milk

Safe, high-quality dairy products begin their journey long before milk reaches the processing plant. It starts at the farm.

Bacteria start to proliferate immediately when milk has left the udder. Unless it is cooled fast, the microbial counts increase exponentially. Raw milk stored at 4 °C results in an increase in the number of bacteria from 4.37 log CFU/mL (23400 CFU/mL) to 6.15 log CFU/mL (1.4 million CFU/mL) within 96 hours, a more than 60-fold increase. This means that any delays in cooling can spoil an entire batch.

Essential Raw Milk Quality Practices

• Only healthy animals: Diseased cows may transmit bacteria, such as Salmonella or Listeria, which in turn lead to foodborne diseases. Farmers should monitor the health of their animals and quarantine any that are ill.

• Clean milking procedure: Udders must be thoroughly cleansed and dried before milking. To avoid contamination, the milking equipment should be sterilized.

• Correct milk storage: Milk should always be collected in stainless steel or food-grade containers- never plastic buckets, where bacteria can thrive.

• Immediate cooling: Milk must be cooled to 4–6°C as soon as it has been collected to reduce bacterial growth.

• Pretesting: Determine bacterial count, Somatic cell count, and potential adulteration. Disregard milk that does not pass quality tests.

By demanding high-quality raw milk, processors not only safeguard consumers but also lower the cost of processing and losses to spoilage down the line.

1. Adhere to Processing Standards

After milk enters the factory, precision is everything. All processes, such as heating, cooling, homogenizing, and pasteurizing, should be performed to perfection.

UHT Processing and Pasteurization

Pasteurization destroys pathogenic bacteria, and this process will not influence the flavor or nutritional content of milk. The traditional method warms milk up to 72 °C in 15 seconds and then rapidly cools the milk.

Ultra-High Temperature (UHT) processing is used to increase the shelf life of milk by heating it up to 135-150 °C in 26 seconds and instantaneously cooling it, and then aseptically packaging it.

The world is becoming dominated by UHT milk as it is convenient and can last several months without refrigeration. In fact, the UHT milk contributed as much as 41.3 percent of the total sales of the dairy market in Europe in 2024 due to the growing popularity of the long-life milk in the urban regions.

In the meantime, the market volume of the UHT milk in the world is 130.97 billion litres in 2024. It is also projected to grow to 205.42billion litres by 2033 – an indicator that UHT technology will be even more dominant in the future developments of dairies.

Homogenization

The pasteurization is followed by homogenization, which provides the milk with a uniform distribution of fats and avoids its separation. It is a process where high pressure (up to 2,500 psi) is used to dislodge fat globules into smaller, stable particles.

Avoiding Cross-Contamination

One of the most significant hazards in dairy manufacturing is cross-contamination. Raw and pasteurized milk should be totally separated.

• Take special pipes and tanks.

• Clean up all tools between batches.

• Maintain clean areas with positive air pressure to prevent the entry of airborne contaminants.

Any one slip can enable harmful microorganisms to penetrate the product again – reversing the days of patient labor.

1. Retain a High Standard of Hygiene at all Stages

It is not hygiene because the things are clean. It is a well-organised set of procedures that keeps milk safe at all touch points.

According to the World Health Organization (WHO), one out of every ten foodborne illnesses in the world is a result of dairy products that have been mishandled or contaminated during processing.

Facility Design and Layout

In the case of a well-designed dairy plant, cross-contamination will be avoided by splitting unclean and clean areas.

Equipment and floors should be made with smooth and non-porous materials that do not corrode, such as stainless steel.

Ensure good drainage and ventilation to avoid the buildup of molds and bacteria.

Have specific milk receiving, milk processing, milk packaging, and milk cleaning areas.

Employee Hygiene

The staff is an important component of food safety. Workers must:

• Wear clean uniforms, gloves, a hairnet, and masks.

• Wash your hands well before going into the processing areas.

• Wear no jewelry or accessories that may fall into the product.

• Take frequent medical exams to avoid the transmission of the disease.

Hygiene and safety training of employees should be a continuous process and not a one-time training.

Sanitation Procedures

Processing equipment should be based on a CIP (Clean-In-Place) system, which includes all processing equipment, e.g., pasteurizers, pipelines, valves, and tanks.

Automated cleaning is done at high temperatures with detergents and sanitizers so that it does not dismantle the equipment, but disinfects it completely.

1. Packaging

As bacteria are destroyed by pasteurization, packaging keeps them out. The time that milk or yogurt has to exit the filler depends on the right packaging. The right packaging defines the longevity of milk or yogurt and ensures they are safe and presentable to consumers.

Post-pasteurization contamination has been approximated to result in approximately 15 percent of product losses through spoilage and sensory defects in industrial environments, some of which are caused by packaging and equipment hygiene failures.

Filling machines make this step hygienic and efficient, reducing contamination and retaining freshness for extended shelf life.

We have automatic liquid filling machines, which are precise and fast. They are capable of working with various dairy products – fresh milk and flavoured beverages, yogurt, and cream. How? The required filling volumes can be altered, and the process of sealing can be fully automated. This minimizes the interaction of humans, hence ensuring a high level of microbial quality, like ≤10 CFU/ml Total Plate Count.

As an example, Sembsunpack’s Automatic Liquid Filling Machine is constructed of stainless steel to provide maximum durability and easy cleaning, and meets international dairy safety standards. 

Equally, there exists the Multifunctional Stainless Steel Filling and Packaging Machine. It is flexible to various packaging options, such as bottles, pouches, sachets, and so on. This is why it can suit both manufacturers focusing on retail and manufacturers focusing on bulk supply markets.

Combined, these systems assist dairy producers to realize consistent quality, extended shelf life, and enhanced consumer confidence – and to maximize production efficiency and decrease product waste.

What Is a Good Dairy Packaging?

• Food-Grade Materials: A food packaging material should not leach chemicals, taste food, or react with milk ingredients.

• Barrier Protection: Barrier properties are necessary to protect milk fats, as high oxygen and light impact the milk fats, causing off-flavors and loss of nutrients in the milk.

• Airtight Sealing: Helps to prevent contamination and to increase shelf life.

• Leak-Proof Design: Safety in handling and transportation.

The Role of Automation

Automated filling and sealing machines, such as those provided by SembsunPack Packing Machine, minimise human product manipulation, guaranteeing cleanliness and uniformity. It also reduces material wastage and increases speed. 

1. Labeling and Traceability

The labels are not only used to brand, but they are also a legal barrier for a manufacturer and a guide for a consumer.

The laws of dairy labeling usually demand:

Product name

• Net weight or volume

• Fat and solid content

• Batch or lot number

• Expiry and manufacturing dates.

• Address of manufacturer and license number.

Proper labeling makes sure that it is in line with the local as well as the overseas market standards. Sembsun provides in-line labeling systems that directly connect with filling lines, eliminating manual mistakes and enabling you to easily achieve regulatory traceability requirements.

Why Traceability Matters

Global Food Traceability Center states that firms that have well-established traceability programs address product recalls 50 times more quickly and lose 30 times less sales in an emergency.

Using batch numbers, QR codes, or barcodes, producers can trace any product to its origin. This instills confidence in the consumers and makes inventory management easier.

It is easy to incorporate a digital coding and labeling system in the automation of packaging machines to facilitate traceability.

1. Microbial and Chemical Testing 

Microbial testing involves examining samples with high sensitivity by comparing them to known samples or using a specific reference sample for precise results.

Dairy products are biogenic in nature, that is, they are always susceptible to microbial growth or chemical contamination.

Regular testing will also make sure that only safe and compliant products are placed into the market.

Microbial Testing & Safety Limits

• Ultra-high temperature (UHT) processed milk in international and regional dairy standards has very rigid microbiological standards to assure sterility and safety of the consumer:

• Total Plate Count (TPC): The European standard of the UHT/sterilized milk permits a count of 10 or fewer colony-forming units (cfu) per 0.1 mL (i.e, 10 or fewer cfu/mL) following incubation. 

• Coliforms (including E. coli): Should not be present / zero satisfactory in UHT milk according to hygiene indicators standards in different national drafts. 

• Yeast & Mold: Although explicit universal limits are not as frequently mentioned, the common practice (as well as microbiological explanation) presupposes that they should not be detected in high-quality UHT milk, as their occurrence indicates post-sterilization contamination or a failure of the packaging/sterility barriers.

When a product goes beyond any of these limits, it has to be reworked or destroyed, since it has ceased to serve the commercial standards of sterility and safety.

Chemical Testing

Chemical tests screen for:

• Precious metals (platinum, silver, gold)

• Pesticide residues

• Antibiotics and preservatives.

These pollutants are usually present in animal feed, water, or cleaning chemicals. Frequent testing protects the health of consumers and brand integrity.

To be accurate, dairy plants are recommended to cooperate with certified laboratories and adhere to ISO 17025 recommendations on testing.

1. Storage and Distribution 

Even ideally processed milk would spoil in case of failure of storage or transportation. Freshness is a prerequisite for maintaining the cold chain.

According to a recently conducted analysis, approximately 20 percent of dairy products are lost or wasted at some point in the supply chain. Although cold chain failures (when storing, during transportation, or refrigeration) are a primary cause, they are not the sole reason.

Storage Guidelines

• Pasteurized products: Refrigerate at less than 4 °C.

• UHT products: Keep at ambient temperatures (under 25 °C) without exposing to sunlight.

• Yogurt and cream: Must be refrigerated from packaging to delivery.

Warehouses should also be clean and well-ventilated and free of pests. Instrumentation with data loggers should be continuously done to monitor temperature and humidity.

Best Practices of Distribution

• Fresh milk and yogurt should be transported using insulated or refrigerated trucks.

• Packages should not be packed too tightly; this will trim down air circulation, and spoilage will be easier.

• Train delivery employees to treat dairy very carefully — drops cause cracks or breakage of seals or packaging.

A steady supply chain temperature allows manufacturers to increase shelf life, minimize waste, and achieve food safety.

1. Documentation and Quality Audits

Maintaining records is the mute power of an obedient dairyman. All the batches, test results, and cleaning schedules must be recorded.

Why Documentation Matters

In case there is a problem (such as spoilage or contamination) with more detailed records, it is easier to trace the problem. They are also used as evidence of compliance when auditing.

Maintain logs for:

• Milk collection and testing

• Maintaining and cleaning equipment

• Packaging batch codes

• Staff hygiene training

• Recalls or complaints of products.

Auditing and Quality Management

Internal audits will be used to check whether hygiene and safety procedures are being observed. External audits, which are usually founded on ISO 22000 or HACCP (Hazard Analysis and Critical Control Point) schemes, assist in confirming adherence to the international standards.

A well-documented system also opens opportunities to the export markets, where the system must be certified before it can be accepted.

Dairy Manufacturing Sustainability

Sustainability has become a business approach and not a buzzword. 

NIQ (NielsenIQ) Retail Measurement & Product Insights found that 61% of consumers believe that environmental problems hurt their immediate and future health, and many of them will purchase products with a recycling package label.

Green Measures to be taken in Dairy plants

• Replacing packaging materials with recyclable or biodegradable materials.

• Get back some heat from pasteurizers to save energy.

• Introduce the use of water recycling in cleaning and cooling of equipment.

• Reduce wastage of products by improving packaging design and forecasting.

Sustainable practices by manufacturers not only help cut costs but also attract environmentally conscious consumers, which is one of the major competitive advantages in the current market.

Wrapping It Up

The dairy production is a fine juggle of quality, hygiene, and innovation. Between the raw milk collection and the final packaging, each process will dictate the product’s safety, shelf life, and taste to the consumers. 

With dairy demand growing around the world, there is no longer room to consider process management and investment in innovative packaging technologies as an option anymore. Sustainability is a major part of the brand image, as 78 percent of consumers favor green packaging (2024 NielsenIQ). 

Not only do manufacturers who are focused on the efficient cold chain system, automation, and environmentally friendly practices reduce the level of waste, but they also enhance customer confidence. The future of the dairy industry consists of integrating food safety excellence and smart, sustainable solutions. 

Through collaboration with trusted packaging companies such as Eastern Packaging, dairy farmers can guarantee that all the drips of milk that are distributed possess the attributes of purity, accuracy, and attention to farm-to-shelf.

Make Your Dairies More than Good with Sembsun Packaging Machinery

Do not allow your hard work to be ruined by poor packaging or the lack of labels. We are not only in filling machines but also offer end-to-end packaging and labeling platforms that will keep dairy brands safe, compliant, and competitive at Sembsun Packaging Machinery.

You need liquid fillers, an aseptic, and a labeling machine. Sembsun has a solution that meets your requirements. Our machines help you:

• Close the gap to maintain freshness

• Labeling should be built into the system

• Ensure regular speed, hygiene, and product integrity

You can upgrade your existing line or define a new dairy plant. Our professionals will assist in selecting the most appropriate machine, which will meet your production requirements.

Contact us and find out the automated packaging solutions that will keep your dairy products fresh, safe, and ready to be sold to the market- each time around.