Learn what causes gas buildup in dairy packaging—and how to stop it before it ruins your product, profits, and reputation.
What Are Blow-Ups?
In dairy processing, a blow-up refers to the swelling or bulging of sealed packaging due to gas formation inside the container. This can occur in yoghurt cups, lala pouches, fresh milk sachets, or vacuum-packed cheeses.
Though not always dangerous, blow-ups are a major red flag in quality control and usually indicate microbial spoilage. Consequences include:
- Consumer rejection
- Product recalls and waste
- Shortened shelf life
- Safety concerns
- Loss of trust in your brand
What Causes Gas Formation in Dairy Products?
Gas in dairy packages can be caused by biological fermentation or technical mishandling. Here are the key sources:
1. Microbial Contamination
Spoilage organisms like yeasts, coliforms, and gas-producing lactic acid bacteria metabolize sugars and release carbon dioxide (CO₂) or even ethanol, causing bloating or bubbling.
Common gas-producing microbes:
- Leuconostoc mesenteroides
- Candida spp. and Saccharomyces spp.
- Clostridium spp. in cheese
- E. coli and other coliforms in fresh milk
These microbes enter via:
- Inadequate pasteurization
- Contaminated water, equipment, or air
- Poor hygiene during filling and packaging
2. Starter Culture Overactivity
Thermophilic or heterofermentative cultures used in products like kefir may continue to ferment post-packaging, releasing unwanted gas if not carefully controlled.
3. Sugars or Fruit Additions
Unpasteurized or contaminated fruit purees, sugars, or stabilizers can become food sources for yeasts or mold.
4. Packaging or Sealing Issues
Poor sealing, overfilling, or inadequate headspace can trap gas or allow microbial growth.
Red Flags: How to Spot a Blow-Up
- Swollen or rounded yoghurt containers
- Puffed cheese vacuum packs
- Milk pouches that feel tight and ballooned
- Hissing when opened
- Off odors (yeasty, alcoholic, or sour)
✅ How to Prevent Blow-Ups in Dairy Production
To safeguard your product and reputation, focus on these six control points:
🧼 1. Maintain Strict Hygiene
- Sanitize all surfaces and equipment (CIP/SIP)
- Keep filler nozzles, mixers, valves, and tanks spotless
- Train staff on food safety best practices
- Control airflow and personnel traffic in clean zones
🌡️ 2. Ensure Proper Pasteurization
- Apply HTST: 72°C for 15 seconds, or per product specification
- Monitor time-temperature charts
- Validate heat exchangers regularly
🧫 3. Use the Right Cultures
- For yoghurt and lala, use homofermentative cultures that don’t produce CO₂
- For kefir and probiotic drinks, use cultures like Lyofast MT430 ANV UC5 and monitor fermentation time and pH
- Combine with Lyofast Y456 B1 when thicker consistency is needed
❄️ 4. Cool and Store Correctly
- Cool products immediately post-packaging
- Maintain storage temperature at 4°C or below
- Avoid temperature fluctuations during transportation
🧃 5. Control Post-Pasteurization Additions
- Pasteurize or test fruit flavors, stabilizers, and sweeteners
- Use aseptically packed or heat-treated ingredients
- Monitor yeast and mold counts in added ingredients
🛡️ 6. Use Natamycin – Nature’s Antifungal Shield
Natamycin is a natural antifungal preservative used in dairy to prevent the growth of yeasts and molds—two of the most common causes of gas formation.
Why Natamycin Works:
- 🛑 Stops yeast and mold growth
- 🌱 Clean-label friendly
- 🧀 Suitable for cheese coatings, fruit yoghurt, cream, and lala
- 🧪 Effective at very low concentrations (typically 5–20 ppm)
- 💡 Doesn’t interfere with starter cultures or flavor
At Dairy and Food Consulting Limited, we offer high-quality Natamycin for food-safe, long-lasting protection—helping you extend shelf life and reduce spoilage.
📋 Summary: 3 Keys to Prevention
| 🔑 Step | 💡 Outcome |
| Maintain hygiene | Eliminate contamination sources |
| Use proper cultures & cooling | Control fermentation and prevent overactivity |
| Apply Natamycin | Block yeast and mold growth naturally |
🛒 Trusted Solutions from Dairy and Food Consulting Ltd
We supply:
- ✅ Starter cultures for yoghurt, lala, and kefir
- ✅ Natamycin – the natural solution for yeast & mold control
- ✅ Expert support on fermentation & formulation
Thanks a lot for the information that keeps coming. Where can I get the natamycin
Hello, Contact us via: +254 721444283