Table Content

No.

Pages

Content

1.0 Introduction

1.1 Introduction to industry chosen

2-8

1.2 Introduction to company chosen

9-11

2.0 Chemical or Biotechnology in industry

12-18

2.1 The technology involved in producing the product

19-21

2.2 The chemical reactions involved

21-23

2.3 The overall production flow sheet and equipment

24-27

2.4 The modes of operation

28-30

10

2.5 General costing of the production

30

11

31-32

12

2.6 The safety & health issues that should be taken care
of
2.7 The ethic issue if applicable

13

3.0 Conclusion/summary

34-35

14

4.0 References

36

33-34

1.0 Introduction
After all this time I finally got to come back to the Yakult (Malaysia) Sdn Bhd. This is my
second time following a visit to Yakult. Here I will write about Yakult (Malaysia) Sdn Bhd,
from the history, the process of manufacture, technology on Yakult production, and up to the
products Yakult own.
The purpose of the visit of this industry, to broaden students of introduction to chemical
engineering technology about science and about the world of work. Students are required to
actively collect information on industrial visits to gain knowledge about the process of
making Yakult and its contents as well as marketing. Industrial visits made to give an idea to
the students about the industry and production process in agribusiness with Yakult products.
1.1 Introduction to industry chosen
Nowadays, consumers are increasingly demanding foods with special properties, such as
pleasant flavour, low-calorie value or low fat content, and beneficial health effects. Within
this context, the food industry has been developing products with improved flavour and
appearance. Functional dairy products meet various nutritional requirements, along with
health benefits that are strengthened by the addition of probiotics.
The most important and frequently used functional food compounds are probiotics and
prebiotics, or they are collectively known as synbiotics. The word probiotic means for life
and the world health organization defines probiotics as live microorganisms which when
administered in adequate amounts confer a health benefit on the host. In the last two
decades, research in the probiotic area has achieved major progresses in the selection and
characterization of specific probiotic cultures and confirmed the health benefits associated
with them. Traditionally, fermented foods are the main source of probiotics and hence one of

the major dietary supplements of modern world. This microorganism defends against
pathogenic microorganisms. Other benefits attributed to probiotics include prevention of
cancer, travellers diarrhoea and lactose intolerance, stimulation of the immune system,
lowering of serum cholesterol levels, and improvement of vitamin synthesis. The species
which are the most frequently used as probiotics belong to the genera Lactobacillus and
Bifidobacterium. However, due to the short lifespan of probiotics, studies have been carried
out to evaluate the contribution of prebiotics to the viability of these microorganisms.
Some specific strains of lactic acid bacteria such as L. acidophilus, L. casei, B. longum, L.
fermentum, L. rhamnosus, L. reuteri, L. crispatus, L. plantarum, B. animalis, and B. lactis are
in the market and provide good profit for several companies. Fermented milk drinks
containing Lactobacillus acidophilus, Bifidobacterium, and Lactobacillus casei are well
known probiotic beverages produced in many countries as functional products. Dairy
products containing probiotic cultures such as Bifidobacterium sp. and Lactobacillus sp. have
been produced around the world for many years and it is estimated that currently more than
80 products containing these bacteria are being produced worldwide.
Besides their desired health properties, probiotics should meet several basic requirements for
the development of marketable probiotic products including their survival and activity in the
product, and stability during storage of the product. In addition, probiotics should not
adversely affect the taste or aroma of the product or acidification during the shelf life of the
product.
Flavour is a crucial characteristic of foods as the sensory properties play an important role in
product acceptance by consumers. In fermented dairy products, flavour perception is strongly
based on the volatile components. Although some fermented milk drinks are consumed in
their natural state, in Europe the most of these products contain sugar, fruit syrup or aroma.

Fruit syrup, which may also contain small fruit particles, could be added to the fermentate.
The fruit aroma, which is normally obtained in a concentrated form, will have a larger
aromatic effect in less acidic products; and it is added to long shelf-life products.
Minoru Shirota, a Doctor of Medicine, began his medical studies in 1921 at Kyoto Imperial
University (now Kyoto University). At the time, Japan had yet to achieve economic
prosperity, and unsanitary conditions caused large numbers of children to die of infectious
diseases.
Disturbed by that reality, Dr. Shirota, while still a medical student set his sights on the field
of preventive medicine, which aims to help people avoid sickness, and started down the path
of microorganism research.
In his research, Dr. Shirota discovered that lactobacilli were effective in suppressing harmful
bacteria within the intestines. He later became the first to successfully strengthen and culture
a strain of lactobacilli, which is now known as Lactobacillus casei strain Shirota.
Dr. Shirota, together with volunteers, then developed an inexpensive, goodtasting beverage,
so that as many people as possible could benefit from Lactobacillus casei strain Shirota,
which reaches the intestines alive and promotes intestinal health. That is how the Yakult
lactobacillus based beverage was born in 1935 and was the beginning of the Yakult that is
loved throughout the world.

Shirota-ism: The root of our business

History
1930-Dr. Minoru Shirota succeeds in strengthening and culturing lactic acid bacteria, useful
for maintaining health (Lactobacillus casei strain Shirota).
1935-Yakult is manufactured and introduced to the market.
1938-Yakult is registered as a trademark.
1940-Local offices of the Association for Promotion of Preventive Bacteria Strain Shirota are
established in various parts of Japan for the purpose of marketing and distributing
Yakult.
1955-Yakult Honsha Co., Ltd. is established (Nishi Hatchobori, Chuo-ku, Tokyo).
Research Institute is established in Kyoto.
1963-Yakult launches its unique Yakult Lady home delivery system.
1964-Yakult Taiwan Co., Ltd. begins operations as the companys first overseas operation
base.
1967-Research institute is established in Kunitachi, Tokyo (later known as Yakult Central
Institute).
1968-The company takes over the management of the Sankei Atoms baseball team (now the
Tokyo Yakult Swallows).Yakult is introduced to the market in a new plastic container.
1970-Joie fermented milk is introduced to the market.
1971-The company begins the full-scale sale of cosmetics.
1972-New head office building is completed in Higashi Shimbashi, Minato-ku, Tokyo.
Program of regular visits to senior citizens by Yakult Ladies begins.
6

1975-Biolactis Capsules ethical drug is introduced to the healthcare industry, thereby

marking Yakults entrance into the pharmaceutical business.
1978-Mil-Mil fermented milkdeveloped through the direct culture of bifidobacteriais
introduced to the market.
1979-Yakult Seichoyaku intestinal regulatoran over-the-counter medicineis introduced
to the healthcare industry.
1980-Company stocks are listed on the Second Section of the Tokyo Stock Exchange.
Toughman health drink is introduced to the market.
1981-Company stocks are listed on the First Section of the Tokyo Stock Exchange.
1992-Yakult Bioscience Research Foundation is established.
1994-The manufacture of irinotecan hydrochloride, a cancer chemotherapeutic agent, is
approved, and the drug is introduced to the healthcare industry under the brand name of
Campto.
The company receives the Minister for Health and Welfare Award for distinguished
volunteer service on behalf of the program of regular visits to senior citizens.
1995-Parabio Series premium-quality skincare product line is introduced to the market.
1997-The company receives the Minister for Agriculture, Forestry, and Fisheries
Award (in the Consumer Division) at the Excellent Corporations of Food Industry
Awards.
1998-Yakult is approved by the Ministry of Health and Welfare for labeling as Foods for
Specified Health Uses.

Bansoreicha is introduced to the market.

1999-Yakult 400 fermented milk drink is introduced to the market.
2004-Entered into a strategic alliance with Groupe Danone.
2005-Research center is established in Europe (Belgium).
Oxaliplatin, a cancer chemotherapeutic agent for the treatment of advanced colorectal
cancer, is approved under the name of Elplat.
2006-The name of Yakults brand of cosmetics is changed to Yakult Beautiens.
Our new corporate slogan is decided: In order for people to be healthy, everything
around them must also be healthy.
2008-Yakult receives a 2008 Good Design Long Life Design Award (G-Mark).
2010-Average global sales of dairy products surpass 30 million bottles per day.
2011-The three-dimensional trademark for Yakult containers is recognized.
Campto wins the Science Award from the Japanese Cancer Association.
2012-Yakult launches Yakult Space Discovery Project.
2013-Lactobacillus casei strain Shirota obtains GRAS Certification from the US FDA (Food
and Drug Administration).
Yakult and Danone terminate strategic alliance agreement and sign a memorandum of
cooperation.
New Yakult is launched.
2014-Yakult Honsha publishes its first Company history.
8

1.2 Introduction to company chosen

The Yakult Company

Yakult Malaysia General

Yakult was born over 75 years ago and since then has been loved by 28 million of consumers
overseas. However, in Malaysia, Yakult is still a young and growing company. Yakult Ace
was launched here just a few years ago in 2004

Yakult (Malaysia) Sdn Bhd is a wholly owned subsidiary of Yakult Honsha, Japan. Yakult
has committed millions of ringgit to establish and operate our one and only local factory in
Seremban, Negeri Sembilan and our Head Office in Glenmarie, Shah Alam. Since then, we
have opened branch offices in Johor Bahru, Melaka, Penang, Kuantan, Ipoh, Seremban and
Kota Bharu.
Yakult (M) Sdn Bhd currently employs over 180 people throughout Malaysia. Our employees
include production workers, sales consultants, customer service officers, administrative staff,
managers and human resources personnel.

Yakults Product
Yakult is a high quality probiotics in the form of a cultured milk drink. Yakult contains the
probiotic bacteria "Lactobacillus casei Shirota" (popularly known as the "Shirota strain").
With over 30 billion live Shirota strain in each bottle, Yakult has among the highest
concentrations of probiotics compared to other probiotic products on the market (most
probiotic drinks and supplements claim to contain at most 1 to 10 billion live probiotic
bacteria per serving or per capsule).
The Shirota strain is scientifically proven to be among the 'strongest' strains of beneficial
bacteria, and has been shown to benefit human health.
In Japan, Yakult is acknowledged by the Japanese Ministry of Health as a "Food for
Specified Health Usages" with approved health claim "The Lactobacillus casei Shirota strain
reaches the intestines alive, so this product maintains good health by increasing beneficial
bacteria, decreasing harmful bacteria and improving the intestinal environment".
Free of preservatives, colourings and stabilizers, Yakult is the right choice for those looking
for high quality probiotics for good health.

10

Yakult Ace
Our first product for the Malaysian market, Yakult Ace cultured milk drink, is a premium
version of the standard Yakult cultured milk drink available in other countries worldwide.
Yakult Ace has a higher concentration of the beneficial bacteria Lactobacillus casei Shirota
(3 times more!) and contains added nutrients: calcium, niacin and vitamins B6, B12 and D.

Yakult Ace
Our first product for the Malaysian market, Yakult Ace cultured milk drink, is a premium
version of the standard Yakult cultured milk drink available in other countries worldwide.
Yakult Ace has a higher concentration of the beneficial bacteria Lactobacillus casei Shirota
(3 times more!) and contains added nutrients: calcium, niacin and vitamins B6, B12 and D.

11

2.0 Chemical or Biotechnology in industry

Biotechnology and Yakult
At Yakult biotechnology broadly describes the processes which use biology (living things) to
make food products. This includes foods with the potential to help protect against disease.
Biotechnology improves foods by enhancing their nutritional profile
What are Probiotics?
Probiotics are foods containing beneficial living microorganisms which we consume to
benefit our health by improving the balance of our intestinal flora. The majority of probiotic
bacteria used in food production are 'Lactic Acid Bacteria' such as species of Lactobacillus
and Bifidobacteria. Yakult contains Shirota strain, a strain found only in our product.
The Shirota strain has been specially selected for its "strength" - in other words, its ability to
survive through our stomach and bile acids to reach the intestines alive to deliver its health
benefits.
A probiotic must meet these strict requirements:

Proven to be safe for human consumption

Able to live and multiply in our intestines

Be able to survive the gastric and bile acids to reach the intestines alive

Scientifically proven to have a beneficial effect on our health

Be available in sufficient numbers throughout the 'shelf-life' of the product

Affordable and easy to consume

The Shirota in Yakult are scientifically proven to:

Help regulate our bowel movement to avoid constipation and diarrhea

12

Help maintain the balance of good and bad bacteria in our intestines

Help to reduce production of toxins in our body

Help enhance our body's immunity to reduce risk of infections and reoccurrence of
cancer cell

Drinking Yakult daily helps to top up our beneficial bacteria. In our busy lives, managing our
bacteria is a smart, easy way to help take care of our bodies.
Probiotic in Agricultural Biotechnology
Probiotic foods are a group of functional foods with growing market shares and large
commercial interest. Probiotics are live microorganisms which when administered in
adequate amounts confer a beneficial health benefit on the host. Probiotics have been used for
centuries in fermented dairy products. However, the potential applications of probiotics in
non-dairy food products and agriculture have not received formal recognition. In recent
times, there has been an increased interest to food and agricultural applications of probiotics,
the selection of new probiotic strains and the development of new application has gained
much importance. The uses of probiotics have been shown to turn many health benefits to the
human and to play a key role in normal digestive processes and in maintaining the animals
health. The agricultural applications of probiotics with regard to animal, fish, and plants
production have increased gradually. However, a number of uncertainties concerning
technological, microbiological, and regulatory aspects exist.
Probiotics are live microbes that can be formulated into many different types of products,
including foods, drugs, and dietary supplements. Probiotic is a relatively new word that is
used to name the bacteria associated with the beneficial effects for the humans and animals.

13

The term probiotic means for life and it was defined by an Expert Committee as live
microorganisms which upon ingestion in certain numbers exert health benefits beyond
inherent general nutrition. FAO/WHO Expert Consultation believes that general guidelines
need to provide to how these microorganisms can be tested and proven for safety and
potential health benefits when administered to humans.
Lactobacillus and Bifidobacterium are most commonly used probiotics in food and feed
(Table 1). Other microorganisms such as yeast Saccharomyces cerevisiae and some
Escherichia coli and Bacillus species are also used as probiotics. Lactic acid bacteria (LAB)
which have been used for food fermentation since the ancient time, can serve a dual function
by acting as food fermenting agent and potentially health benefits provider. LAB are GRAS
(general recognized as safe) with no pathogenic, or virulence properties have been reported.
For the use of LAB as probiotics, some desirable characteristics such as low cost, maintaining
its viability during the processing and storage, facility of the application in the products,
resistance to the physicochemical processing must be considered.
Lactobacillus species

Bifidobacterium species

Others

L. acidophilus
L. amylovorus
L. brevis
L. casei
L. rhamnosus

B. adolescentis
B. animalis
B. breve
B. bifidum
B. infantis

L. crispatus

B. lactis

L. delbrueckii subsp. bulgaricus

B. longum

Bacillus cereus
Clostridium botyricum
Enterococcus faecalis
Enterococcus faecium
Escherichia coli
Lactococcus lactis subsp.
cremoriss
Lactococcus lactis subsp. lactis
Leuconostoc mesenteroides
subsp.
dextranicum
Pediococcus acidilactici
Propionibacterium
freudenreichii
Saccharomyces boulardii
Streptococcus salivarius subsp.
thermophilus
Sporolactobacillus inulinus

L. fermentum
L. gasseri
L. helveticus
L. johnsonii
L. lactis
L. paracasei

Table 1. Probiotic microorganisms.

14

Characteristics of probiotics
Characteristics of probiotics will determine their ability to survive the upper digestive tract
and to colonize in the intestinal lumen and colon for an undefined time period. Probiotics are
safe for human consumption and no reports have found on any harmfulness or production of
any specific toxins by these strains. In addition, some probiotics could produce antimicrobial
substances like bacteriocins. Therefore, the potential health benefit will depend on the
characteristic profile of the probiotics. Some probiotic strains can reduce intestinal transit
time, improve the quality of migrating motor complexes, and temporarily increase the rate of
mitosis in enterocytes.
The most common probiotics are Lactobacillus and Bifidobacterium. In general most
probiotics are gram-positive, usually catalase-negative, rods with rounded ends, and occur in
pairs, short, or long chains. They are non-flagellated, non-motile and non-spore-forming, and
are intolerant to salt. Optimum growth temperature for most probiotics is 37C but some
strains such as L. casei prefer 30 C and the optimum pH for initial growth is 6.5-7.0. L.
acidophilus is microaerophilic with anaerobic referencing and capability of aerobic growth.
Bifidobacterium are anaerobic but some species are aero-tolerant. Most probiotics bacteria
are fastidious in their nutritional requirements. With regard to fermentation probiotics are
either obligate homofermentative (ex. L. acidophilus, L. helvelicas), obligate
heterofermentative (ex. L. brevis, L. reuteri), or facultative heterofermentative (ex. L. casei,
L. plantarum). Additionally, probiotics produce a variety of beneficial compounds such as
antimicrobials, lactic acid, hydrogen peroxide, and a variety of bacteriocins. Probiotics
should have the ability to interact with the host microflora and competitive with microbial
pathogens, bacterial, viral, and fungal.

15

Probiotics health benefits

Probiotic research suggests a range of potential health benefits to the host organism. The
potential effects can only be attributed to tested strains but not to the whole group of
probiotics. Probiotics have shown to provide a diverse variety of health benefits to human,
animal, and plans. However, viability of the microorganisms throughout the processing and
storage play an important role in transferring the claimed health effects. Therefore, the health
benefits must be documented with the specific strain and specific dosage.
Food applications of probiotics
Today an increase in knowledge of functional foods has led to develop foods with health
benefits beyond adequate nutrition. The last 20 years have shown an increased interest among
consumers in functional food including those containing probiotics. The presence of
probiotics in commercial food products has been claimed for certain health benefits. This has
led to industries focusing on different applications of probiotics in food products and creating
a new generation of probiotic health foods. This section will summarize the common
applications of probiotics in food products.
Dairy-based probiotic foods
Milk and its products is good vehicle of probiotic strains due to its inherent properties and
due to the fact that most milk and milk products are stored at refrigerated temperatures.
Probiotics can be found in a wide variety of commercial dairy products including sour and
fresh milk, yogurt, cheese, etc. Dairy products play important role in delivering probiotic
bacteria to human, as these products provide a suitable environment for probiotic bacteria that
support their growth and viability. Several factors need to be addressed for applying
probiotics in dairy products such as viability of probiotics in dairy, the physical, chemical and

16

organoleptic properties of final products, the probiotic health effect, and the regulations and
labelling issues.
Non-dairy based probiotic products
Dairy products are the main carriers of probiotic bacteria to human, as these products provide
a suitable environment for probiotic bacteria that support their growth and viability.
However, with an increase in the consumer vegetarianism throughout the developed
countries, there is also a demand for the vegetarian probiotic products. Non-dairy probiotic
products have shown a big interest among vegetarians and lactose intolerance customers.
According to the National Institute of Diabetes and Digestive and Kidney Diseases (NIDDK)
of the U.S. National Institutes of Health, about 75% of the world population is lactose
intolerant. The development of new non-dairy probiotic food products is very much
challenging, as it has to meet the consumers expectancy for healthy benefits. Granato and
others have overview of functional food development, emphasizing non-dairy foods that
contain probiotic bacteria strains.
Agricultural applications of probiotics
Probiotics applications have been extended from human applications to diversity of
agricultural application. Agricultural applications include animal and plants.
The future of probiotics
Dairy based products containing live bacteria are the main vehicles of probiotics to human.
Non-dairy beverages would be the next food category where the healthy bacteria will make
their mark. Microencapsulation technologies have provided the necessary protection for
probiotics and moved them outside the pharmaceutical and supplemental use to become food
ingredients.
17

Biotechnology and probiotics

With the revolution in sequencing and bioinformatic technologies well under way it is timely
and realistic to launch genome sequencing projects for representative probiotic
microorganisms. The rapidly increasing number of published lactic acid bacterial genome
sequences will enable utilizing this sequence information in the studies related to probiotic
technology. If genome sequence information is available for the probiotic species of interest,
this can be utilized, e.g. to study the gene expression (transcription) profile of the strain
during fermenter growth. This will enable better control and optimization of the growth than
is currently possible. Transcription profiling during various production steps will allow
following important genes for probiotic survival during processing (e.g., stress and acid
tolerance genes) and identifying novel genes important for the technological functionality of
probiotics.
Increasing knowledge of genes important for the technological functionality and rapid
development of the toolboxes for the genetic manipulation of Lactobacillus and
Bifidobacterium species will in the future enable tailoring the technological properties of
probiotic strains. However, before wide application of tailored strains in probiotic food
products, safety issues are of utmost importance and have to be seriously considered for each
modified strain.

18

2.1 The technology involved in producing the product

Fermentation technology applications utilizing lactic acid bacteria
Development and application of lactic acid bacteria fermentation technology comprise a vital
area for our food materials development research initiatives, and they have applied this
technology to produce new achievements.
Yakult central institute identified that via a mixed culture of L. casei strain Shirota and
Lactococcus lactis, GABA (gamma amino butyric acid) could be effectively produced from
milk, and utilizing the blood pressure-lowering effects of GABA they subsequently
developed a fermented drink for people with mild hypertension.
For such applications of lactic acid bacteria fermentation technology, they are additionally
expanding research horizons to not only cover Probiotics, but also the development of new
materials beneficial in preventing lifestyle-related diseases, and the utilization in foods for
specified health use.
Details of Development Research on Probiotic Products

Discovery of beneficial microorganisms and physiological and biochemical research

Improvement of useful microorganisms

Detection and improvement of useful components in milk

Development of new fermentation technologies utilizing lactic acid bacteria

Relation between fermentation and cultured drink

The cultured milks are products made by use of special lactic acid bacteria cultures. They fall
into two broad categories. Besides that, it made by use of lactic acid bacteria which grow well
at ambient temperature (25-30C). Such as, lactic acid bacteria are known as Mesospheric

19

starter cultures. Next the other type of cultured dairy product is the one made by use of lactic
acid bacteria which grow well under warm conditions (38 - 45(C). The lactic acid bacteria
used are technically known as Thermophile starter cultures. Yoghurt or yoghurt like products
belongs to this group. The fermented milk products, also known as cultured dairy foods,
cultured dairy products, or cultured milk products, are dairy foods that have been fermented
with lactic acid, bacteria such as lactobacillus, lactococcus, and leuconostoc. Fermentation
process increases the shelf-life of the product, while to improve the taste and improving the
digestibility of milk. There is evidence that fermented milk products have been produced
since around 10,000 BC. A range of different Lactobacilli strains has been grown in
laboratories allowing for a wide range of cultured milk products with different tastes.
Bioreactors in Fermentation
Bioreactors are very used in many of the biotechnology processes; we have different types of
bioreactors everyone with their own advantages and disadvantages. A bioreactor is a vessel,
which is used to carry out one or more biochemical reactions to convert raw materials to
products through the action of biocatalyst, enzyme microorganisms, and cell of animals or
plants. The raw material could be an organic compound as sugar or an inorganic chemical as
2 .
The advantages of using bioreactors in fermentation is, continuous operation, good
temperature control, easily temperature to two run, good control, simplicity of construction,
low operating (labour) co-stand the last is easy to clean. Furthermore, the disadvantages are
the need for shaft seals and bearings and size that limitation by motor size, shaft length and
weight.
System bioreactor is a vessel in which a chemical process is carried out which involves
organisms or biochemically active substances derived from such organisms. For the effective
20

bioreactor is to control, contain and positively influence the biological reaction must find the
suitable reactor parameters for the desired biological.
2.2 The chemical reactions involved
Probiotics provide chemical reactions that convert carbohydrate molecules into alcohols or
acids as they release energy through the chemical reaction, fermentation.
Lactic acid fermentation
Lactic acid fermentation is a biological process by which sugars such as glucose, fructose,
and sucrose, are converted into cellular energy and the metabolic by product lactate. It is an
anaerobic fermentation reaction that occurs in some bacteria and animal cells, such as muscle
cells. If oxygen is present in the cell, many organisms will bypass fermentation and undergo
cellular respiration; however, facultative anaerobic organisms will both ferment and undergo
respiration in the presence of oxygen. Lactate dehydrogenase catalyzes the interconversion of
pyruvate and lactate with concomitant interconversion of and + .

In homolactic fermentation, one molecule of glucose is ultimately converted to two

molecules of lactic acid. Heterolactic fermentation, in contrast, yields carbon dioxide and
ethanol in addition to lactic acid, in a process called the phosphoketolase pathway.

21

Chemical process
The process of lactic acid fermentation using glucose is summarized below. In homolactic
fermentation, one molecule of glucose is converted to two molecules of lactic acid:
6 12 6 2 3
In heterolactic fermentation, the reaction proceeds as follows, with one molecule of glucose
converted to one molecule of lactic acid, one molecule of ethanol, and one molecule of
carbon dioxide:
6 12 6 3 + 2 5 + 2
Before lactic acid fermentation can occur, the molecule of glucose must be split into two
molecules of pyruvate. This process is called glycolysis.
Glycolysis
To extract chemical energy from glucose, the glucose molecule must be split up into two
molecules of pyruvate. This process also generates two molecules of adenosine triphosphate
as an immediate energy yield and two molecules of .
6 12 6 + 2 + 2 + 2 +
2 3 + 2 + 2 + 2 2 + 2 +
In aerobic respiration, the pyruvate is further oxidized completely, generating additional
and NADH in the citric acid cycle and by oxidative phosphorylation. However, this can occur
only in the presence of oxygen. Oxygen is toxic to organisms that are obligate anaerobes, and
is not required by facultative anaerobic organisms. In the absence of oxygen, one of the
fermentation pathways occurs in order to regenerate + ; lactic acid fermentation is one of
these pathways.

22

Fermentation
Lactic acid fermentation is the simplest type of fermentation. In essence, it is a redox
reaction. In anaerobic conditions, the cells primary mechanism of production is
glycolysis. Glycolysis reduces that is, transfers electrons to + , forming .
However, there is only a limited supply of + available in a cell. For glycolysis to
continue, must be oxidized that is, have electrons taken away to regenerate the
+ . This is usually done through an electron transport chain in a process called oxidative
phosphorylation; however, this mechanism is not available without oxygen.
Instead, the donates its extra electrons to the pyruvate molecules formed during
glycolysis. Since the has lost electrons, + regenerates and is again available for
glycolysis. Lactic acid, for which this process is named, is formed by the reduction of
pyruvate.
In homolactic acid fermentation, both molecules of pyruvate are converted to lactate. In
heterolactic acid fermentation, one molecule of pyruvate is converted to lactate; the other is
converted to ethanol and carbon dioxide. Homolactic acid fermentation is unique in that it is
one of the only respiration processes that do not produce a gas as a byproduct

23

2.3 The overall production flow sheet and equipment

24

1. Mixing of Raw Ingredients

Live Lactobacillus casei Shirota strain is cultured in a 'seed tank' in our laboratory.
Skim milk powder is mixed with sugar, glucose and filtered, sterilised water to make a sweet
milky solution.
2. Sterilisation
The sweet, milky solution is sterilised at a high temperature for a short time, destroying any
bacteria that may be present. The solution is then transferred to a 6,500-litre culture tank via a
closed system of pipes and valves.
3. Culture Tank
The temperature of the tank is reduced to 37C and live Lactobacillus casei Shirota strain is
added. The solution is allowed to ferment for about one week until the number of
Lactobacillus casei bacteria reaches an ideal concentration.
4. Mixing and Storage Tank
The concentrate is transferred to a 12,000-litre mixing and storage tank. The tank is chilled to
around 2 C. Sterilised flavours, syrup solution, vitamins and calcium are added to the
concentrate. Prior to bottling, the concentrate is diluted with filtered, sterile water.
5. Injection Blow Moulding Machine
The plastic bottles are produced on site. The bottles are made from polystyrene.
6. Bottling and Packaging
The bottles are wrapped with individual bottle labels. Then, they are filled with Yakult,
capped with a foil lid, sealed and transferred along the conveyor belt to the packaging
25

facility. Single bottles of Yakult are sorted into groups of five and shrink-wrapped in
polypropylene film. Ten "5-packs" are grouped together and wrapped again in polyethylene
film and then heat shrunk, forming a 'carton' of 50 Yakult bottles.
7. Refrigeration Room
Finished products are kept refrigerated before delivery to stores.
8. Yakult Quality Assurance
Yakult maintains a comprehensive quality assurance program in order to ensure that our
product is of the highest quality. For this reason, samples are collected for laboratory analysis
throughout the production process to confirm that the quality assurance measures in place
have been effective.
Our testing involves more than 150 samples per production run, upon which a total of more
than 200 tests are conducted. These determine Lactobacillus casei numbers, check for
potential contaminants, microbiological quality, composition, acidity, physical attributes and
taste. In addition, each bottle is inspected for undesirable markings and incorrect printing.
Quality assurance measures are in place to maintain standards for personnel and factory
hygiene, equipment cleaning, processing methods and parameters, and product handling.
Yakult's quality assurance utilizes a system called "Hazard Analysis and Critical Control
Points" (HACCP). The principles of HACCP are internationally recognised as an excellent
method for assuring stringently high standards.
9. Waste Management
Cleaning - Yakult adheres to a comprehensive hygiene and sanitation program, following a
cleaning program that is predominantly governed by CIP (Cleaning in Place). Steam, an

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environmentally friendly cleaner, is used to sterilize the pipes and tanks. A single phase
chemical cleaner is used, reducing the numbers of chemicals introduced into the drains.
Chlorine based chemicals are not used.
Solid wastes - The amount of solid waste is relatively small.
Liquid wastes - Any liquid waste goes into a holding tank in our water treatment facility. The
acidity (pH) of the water is adjusted with acid or alkaline before being released into the
sewage system.

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2.4 The modes of operation

Process design
They follow Batch Production process with a continuous flow. No rework can be done i.e. if
there is any fault or malfunctioning of the mixture in between the process, the whole batch
has to be discarded.
Inauguration of the Hyogo Miki Plant
Yakults company have for many years been working to strengthen dairy product plant
functions for improving product quality and protecting the environment, and efforts in these
respects have entailed the introduction of HACCP (Hazard Analysis and Critical Control
Point) systems and the attainment of ISO9001 and ISO14001 certification.
In recent years, customers have been showing increasingly high levels of interest in safety
and peace of mind regarding food. The introduction of production equipment and product
inspection equipment that incorporates leading-edge technologies has been a crucial part of
efforts to respond to this trend by ensuring our capabilities for providing stable supplies of
even-higher-quality products. As part of its second-stage capital investment plan, Yakult
decided to end a 26-year hiatus of new plant construction with the creation of a plant
designed to meet five key goals
Goals of the Hyogo Miki Plant
(1) Pursue high levels of product quality in response to customers expectations
(2) Achieve high-productivity operations that strike an optimal balance between production
volumes and production capacities

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(3) Create facilities designed to enable the handling of new products and the installation of
new equipment
(4) Establish a plant that can undertake environmental protection measures and exist in
harmony with neighboring communities
(5) Establish a plant that enables customers to make study tours to view production facilities
and quality management systems

Food safety systems at the plant

To ensure its capabilities for consistently maintaining outstanding food safety standards on a
daily basis, the Hyogo Miki Plant uses an integrated system for all processes, from raw
materials procurement, sterilization, and fermentation through to blending, filling and
packaging, and shipment processes.
Zoning management methods employed in the plants production area entail the setting of
specific facility conditions and hygiene management methods required for guaranteeing the
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required hygene levels in each production room, and the maintenance of those conditions and
methods enables the plant to sustain stable hygienic environments. Employees must change
into prescribed work uniforms, wash and disinfect their hands, and pass through an air
shower before they can enter production rooms. The facility also features dedicated corridors
for use by plant study tour participants so that the paths of participants and employees do not
intersect.
To make sure that thorough quality assurance processes are implemented for each type of
product, automated inspection devices incorporating leading-edge technologies have been
installed in a way that enables diverse kinds of rigorous checks during production processes.
2.5 General costing of the production
Private and confidential

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2.6 The safety & health issues that should be taken care of
Ensuring reliable safety
In order to provide outstanding final products, it is essential the materials Yakults company
develop fully utilize the inherent properties of their ingredients, and so it is extremely vital
that they must be tested to ensure safety at each corresponding developmental stage. Yakults
company regard safety assurance as a vital role in our development research activities, and
equipped with enhanced testing facilities they conduct highly reliable safety tests that comply
with standards and regulations stipulated by the government of Japan, thereby ensuring the
highest level of safety measures.

Safety testing and evaluation for Probiotic microorganisms.

Safety testing and evaluation for developed food, pharmaceutical and cosmetics
products and their materials.

Development of new safety testing and evaluation systems

Yakults manufacture requires documented precautions and procedures to ensure the product
is not subject to any hazards that might compromise its safety hence the use of Hazard
Analysis and Critical Control Points (HACCP).
HACCP:

identifies potential risks at every point of manufacture

prevents and controls potential risks

implements corrective action

monitors all processes

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Our commitment to quality extends to transportation; ensuring the cold chain is uninterrupted
and the temperature in Yakults refrigerated vans and transport delivery vehicles is between
0-4C.
There are 7 steps Hazard Analysis and Critical Control Points (HACCP) Plan
1. Hazard Analysis and Risk Assessment
Develop flowchart for the manufacturing process.
2. Identification of critical control points
Identify potential hazards; these could be physical, chemical or biological.
3. Control standards for critical control points
Set measurable standards for each critical control point.
4. Monitoring of critical control points
Regular or scheduled monitoring of each critical control point.
5. Corrective action
Actions to be taken.
6. Record keeping system for HACCP program
Keep records of all monitoring as this shows that nothing has gone wrong, and it can also be
helpful if something does go wrong.
7. Review of HACCP program
Documentation gets audited by external auditors every year. Random checks can also occur.

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2.7 The ethic issue if applicable

In research ethics including research on probiotic three ethical principles have been
identified; respect for person, beneficence, and justice. The research proposal/ project trial
should be reviewed and approved by a properly constituted Ethics Committee. The consent of
the participant must be obtained before research is undertaken except in exceptional
circumstances described in the national statement.
Issues related to research participants
With respect to clinical of the product, the ethical principles which apply for the protection of
the trial participant should be observed. The main objective of this is to minimize harm to the
participant. To justify this a through literature survey should be done to note the possible
side-effect to weigh the risk-benefit ratio appropriately as many ethical guidelines consider
that harm to an individual should not be done at the expense of societys benefit.
Role of ethics committees
The ethics committees comprise medical, non-medical scientists, and non-scientists. The
scientists in the committee have the obligation to study the scientific contents of the proposal
carefully. The committee would approve a project only after review of the side-effect that are
highlighted in the proposal, based on which it would determine whether the harm to the
participant is minimal. Like other trials, emphasis has to be given on essentiality, risk-benefit
ratio, selection of participants, conduct of the study, privacy and confidentiality,
compensation, and protection of research participants, which are equally important for review
by the institutional ethics committees to safeguard the interests of these participants. If a
subject expert needs to be consulted, then such a person could be co-opted to give comments.
In multicentric trials, approval needs to be taken from the independent ethics committee
(IEC) of each trial site as it would not only take care of the details of the proposal in the
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context of the local culture, but will also be responsible for the conduct of the trial for which
it has given the approval. The IEC would have to review the proposal in the light of the
revised Ethical Guidelines for Biomedical Research on Human Participants brought out by
the ICMR in 2006.
These guidelines are intended for investigators, health policy-makers, member of ethical
review committees, and other who have to deal with ethical issues that rise in epidemiology.
They may also assist in the establishment of the standard for ethical review of
epidemiological studies.
3.0 Conclusion/summary
Summary
During the trip of Yakult. Our group, get a new learn about the good bacteria are need to our
body to make sure the bad bacteria will remove and changed with the new bacteria that
provides our body maintain health, for example, when we drink Yakult that have good
bacteria. It will give our skin more beautiful in and out of our body, for women who are very
obsess in beautiful skin, must take Yakult. Next, intestinal flora very important, because if the
nutrition were interference the proses peristalsis will also interference and became
constipation. The normal intestinal flora will make sure no more constipation. To get the
optimum intestinal flora good bacteria must supplier continuously or probiotics to get a
balanced diet. We also learn about the good bacteria can take to pregnant women for their
baby but cannot give to baby who are new born. Still health and who are take antibiotic,
encouraged to drink Yakult, why? Because antibiotics function is to kill bacteria in the body,
but it does not matter in antibiotics, bacteria good or evil all he could withdraw. Both Yakult
Ace and Yakult Ace Light contains low glycemic index content because when we consume,
the sugars break down slowly, releasing glucose gradually into the blood stream and will not
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cause a rapid rise in your blood sugar levels you like to drink Yakult, depending on the
individual, you will notice your stomach after drinking it will feel a little uncomfortable.
There will likely continue to defecate. This is because the bacterium in Yakult helps speed up
the digestive process. We also learn that within a day, 700,000 bottles of

Yakult can be

produced in this factory. Each bottle is then sent to the rest of Malaysia for sale. Among the
interesting facts about this product Yakult is just beginning to be in Malaysia in 2004. A bit
slow but also because the palatability and benefits derived from drinking it, Yakult health
drink now is among the most popular in Malaysia. Besides that, we also know about on how
produces of Yakult, ingredient inside that Yakult and it will gain our confidence when we
look ourselves on manufacturing method that also clean and the quality is in under control.
The weakness that we found in this trip is we are not be able to see the process of making
Yakult in details because of the rules of the factory is very strict.
Conclusion
The uses of probiotics and their applications have shown tremendous increase in the last two
decades. Probiotics can turn many health benefits to the human, animals, and plants.
Applications of probiotics hold many challenges. In addition to the viability and sensory
acceptance, it must be kept in mind that strain selection, processing, and inoculation of starter
cultures must be considered. Probiotics industry also faces challenges when claiming the
health benefits. It cannot be assumed that simply adding a given number of probiotic bacteria
to a food product will transfer health to the subject. Indeed, it has been shown that viability of
probiotics throughout the storage period in addition to the recovery levels in the
gastrointestinal tract are important factors. For this purpose, new studies must be carried out
to: test ingredients, explore more options of media that have not yet been industrially utilized,
reengineer products and processes, and show that lactose-intolerant and vegetarian consumers
demand new nourishing and palatable probiotic products.
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4.0 References
Yakults Malaysia website
http://www.yakult.com.my/index.aspx
Yakults Japan website
http://www.yakult.co.jp/english/index.html
Yakult Central Institute
http://institute.yakult.co.jp/index_en.php
Yakults Australia website
http://www.yakult.com.au/index.html
Yakult Social & Environmental Report 2013
https://www.ecosearch.jp/pdfdata/2013/349e_2013.pdf
Recent Application of Probiotics in Food and Agricultural Science
http://cdn.intechopen.com/pdfs/39607/InTechRecent_application_of_probiotics_in_food_and
_agricultural_science.pdf
Lactic acid fermentation
http://medicallabtechno.weebly.com/uploads/7/5/1/5/7515789/yogurt_production.pdf

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