Greek yoghurt, a popular dairy product, generates large amounts of acid whey as a by-product during manufacturing. Post-processing treatment of this stream presents one of the main concerns for the industry. The objective of this study was to manipulate initial milk total solids content (15, 20 or 23 g/100 g) by addition of milk protein concentrate, thus reducing whey expulsion. Such an adjustment was investigated from the technological standpoint including starter culture performance, chemical and physical properties of manufactured Greek yoghurt and generated acid whey. A comparison was made to commercially available products. Increasing protein content in regular yoghurt reduced the amount of acid whey during whey draining. This protein fortification also enhanced the Lb. bulgaricus growth rate and proteolytic activity. Best structural properties including higher gel strength and lower syneresis were observed in the Greek yoghurt produced with 20 g/100 g initial milk total solid compared to manufactured or commercially available products, while acid whey generation was lowered due to lower drainage requirement.

The feasibility of applying ultrafiltration (UF) to concentrate a yoghurt base prior to fermentation during Greek yoghurt manufacturing was studied as a way of minimising acid whey (AW) generation. Two Greek yoghurts were prepared by concentrating a milk base through UF to 13.8% and 17.5% (w/w) (GY‐2, GY‐3). Production of GY‐3 resulted in zero AW discharge, while the GY‐2 production discharged 78% lower AW compared to the control (GY‐1). GY‐2 exhibited a hard gel structure, low syneresis, maximum viscosity properties and a high protein and fat content. Applying both, UF and straining, resulted yoghurts with required structural attributes while substantially reducing the generation of AW.