Butter making process

Butter making process

1. Butter Making Process Fat Rich Dairy Products DT-213

2. Butter-FSSAI Definition Butter means the fatty product derived exclusively from milk of Cow and/or Buffalo or its products principally in the form of an emulsion of the type water-in-oil. The product may be with or without added common salt and starter cultures of harmless lactic acid and / or flavour producing bacteria. Table butter shall be obtained from pasteurized milk and/ or other milk products which have undergone adequate heat treatment to ensure microbial safety.

3. It shall be free from animal fat, vegetable oil and fat, mineral oil and added flavour. It shall have pleasant taste and flavour free from off flavour and rancidity. It may contain food additives permitted in these Regulations Provided that where butter is sold or offered for sale without any indication as to whether it is table or desi butter, the standards of table butter shall apply.

4. PFA Definition According to the PFA rules (1976), table creamery butter is the product obtained from cow or buffalo milk or a combination there of, or from cream or curd from cow or buffalo milk or a combination thereof with or without the addition of common salt and annatto or carotene as colouring matter. It should be free from other animal fats, wax, and mineral oils, vegetable oils and fats . No preservatives except common salt and no colouring matter except annatto and carotene may be added.

5. Butter must contain not less than 80 % by weight of milk fat, not more than 1.5 % by weight of curd, and not more than 3% by weight of common salt. Diacetyl may be added as a flavouring agent but if so used the total diacetyl content must not exceed 4 ppm . Calcium hydroxide, sodium carbonate, sodium polyphosphate may be added, but must not exceed the weight of butter as whole by more than 0.2 %.

6. Standards FSSAI, 2011

7. Total plate count 50,000/ g Coliform count 50/g E.Coli Absent/g Salmonella Absent / 25 g Staph. aureus 50/g Yeast and mold count 50/g Listeria monocytogenes Absent/g Microbiological standards for Pasteurized Butter

8. PFA Standards Constituents Table butter *Desi/cooking butter Milk at m/m 80% min. 76% min. Moisture m/m 16% max ------- Curd m/m 1.50% max ------- Common salt 3.0% max ------- Total plate count 5000/g max ------- Coliform count 5/g max ------- E.coli Absent in 1.0 g. ------- Salmonella Absent in 25.0 g. ------- Shigella Absent in 25.0 g. ------- Staphylococcus aureus Absent in 1.0 g. ------- Yeast & Mould Count 20/g max -------

9. BIS Standards Characteristic Table Butter White Butter Milk fat, percent by mass, Min 80.0 82.0 Moisture, percent by mass, Max 16.0 16.0 Acidity (as lactic acid), percent by mass, max. 0.15 0.06 Curd, percent by mass, Max. 1.0 1.5 Common salt, percent by mass, Max. 2.5 ---- Coliform count, per ml, Max 5 5 Total yeast and mould count, per ml, Max 20 20

10. CLASSIFICATION OF BUTTER Sour cream butter (made from ripened cream) having pH≤5.1 Mildly acidified butter (made from partially acidified or sweet cream) having pH in the range of 5.2 to 6.3 and Sweet cream butter (made from non acidified cream; this includes butter in which no bacterial culture have been worked in to enhance diacetyl content) having pH of ≥6.4.

11. BIS Classification Table Butter: the product made from pasteurized cream obtained from cow or buffalo milk or a combination thereof with or without ripening with the use of standard lactic culture, addition of common salt, annatto or carotene as colouring matter and diacetyl as flavouring agent. White Butter: the product made from pasteurized cream obtained from cow or buffalo milk or a combination thereof without ripening and without addition of any preservative including common salt, any added colouring matter or any added flavouring agent.

12. Cream ready for churning Butter manufacturing Standardization Pasteurization Cooling & ageing Ripening Milk receipts Cream for butter making Grading Weighing Sampling Testing Cream receipts Cream processing Cream Separation Neutralization

13. Loading of Churn Churning of cream Butter grain Butter milk Draining of butter-milk Butter grain Washing Initial working Addition of salt & moisture Final working Butter Packaging Colour addition Distribution Storage

14. Neutralization

15. Standardization of Cream Refers to the adjustment of fat to the desired level Done by adding calculated quantity of Skim milk or butter milk Desired level for butter making --- 35-40% High or low---- higher fat loss in buttermilk Reduction of fat with water--- interferes with ripening of cream & “flat” or “washed-off” flavor in butter

16. Pasteurization of Cream Heating cream to a temperature and holding it at that temperature for a definite time which ensures its safety for human consumption. Effects of Pasteurization of cream: Destroys all pathogenic organisms Destroys bacteria which can cause deterioration of cream during churning and ripening and Butter during storage Destroys enzymes (prevent oxidative rancidity) Eliminates some of the gaseous tainting substances Removes CO 2

17. Methods of pasteurization Holder method (Batch pasteurization)—74 C/ 30 min Continuous method (85 C/15 sec) Vacuum Pasteurization First section (88-93 C/11-6½ inches) Second section (72-81 C/ 20-15 inches) Last section (39 C/ 28 inches)

18. More severe heat treatment of cream should be avoided as higher the temperature, greater the migration of copper from milk serum to milk fat globules Milk fat becomes more prone to the oxidative rancidity reduce the shelf life of butter

19. Ripening of cream It refers to the process of fermentation of cream with the help of suitable starter culture. Main object--- to produce butter with a pleasing, pronounced flavour. Starter Culture: Mix. of both: acid producing organisms ( Streptococcus lactis , S. Cremoris ) Flavour producing organisms ( S. diacetylactis , Leuconostoc citrovorum and/or Leuc . Dextranicum )

20. Ripening of cream contd… 0.5-2.0% starter is used for ripening Incubated at 21 ° C till the desired acidity is reached. Usually, 1% starter is used and incubation period is 15-16 hrs Acidity of the starter should be 0.80-0.90% (pH of about 4.1 to 4.3) is most favourable.

21. Effect of cream ripening on Flavour of Butter The typical butter flavour is due to the presence of dicaetyl in combination with lactic acid , acetoin and intermediary products such as acetaldehyde . These substances are the products of fermentation brought about by the action of Lactic acid producing bacteria Citric acid fermenting bacteria

22. Distribution of Dicaetyl+Acetoin Relatively small proportion in butter Amount of Dicetyl : Fresh buttermilk > cream at churning > Butter Serum > fat content (of the same butter)

23. Effect on keeping quality of Butter Ripening of cream affects the K.Q. in two ways By its control on age deterioration due to bacterial causes By its influence on age deterioration due to chemical causes

24. Bacteriological effect Ripening assist in controlling bacterial deterioration in butter LAB and high acidity act antagonistically against flavour damaging organisms Preserve the fresh/ desired flavour Prolong the keeping quality of Butter Butter from sweet cream has Less keeping quality Flavour defects--- “Cheesy flavour”, “rancidity”, “putrid flavour” etc.

25. Chemical effect Ripening doesn’t improve the chemical stability of butter On the contrary, it shortens the life of salted butter. Flavour defects--- “Oily-metallic”, “fishy”, “ tallowy ” flavour . Salted butter made from sweet, unripened cream or from neutralized & pasteurized sour cream keeps better (from the standpoint of absence of flavour deterioration due to chemical causes)

26. Percent acid to which the cream should be ripened For fresh consumption salted butter , cream of moderate richness (30% fat) may safely be ripened to about 0.25-0.30% acid Salted butter for commercial cold storage- -- 0.21% or lower Unsalted butter--- cream may be ripened to any acidity without jeopardizing keeping quality

27. Addition of citric acid to cream for Ripening Major flavour and aroma producing substances ( diacetyl , acetoin , etc.) are the result of citric acid fermentation by the starter bacteria Addition of citric acid @ 0.2% to starter milk stimulates the production of these products And thus increases the desired flavour and aroma in the starter.

28. Cooling and Ageing of Cream When cream is cooled--- fat in the fat globules undergoes partial solidification Degree of solidification plays important role--- determines the firmness and standing-up properties of the body of butter Churning uncooled cream– high fat loss, weaker body butter Churning to abnormally low temp.--- more churning time, butter may not form at all.

29. High cooling temp .– shortens the churning period, high fat loss and butter with a relatively soft body Low cooling temp .– prolong the churning time, high fat loss, firm body butter Optimum temp . --- average rich cream (about 28-35% fat), churns in about 30 to 45 minutes Optimum temp. primarily depends on the composition of butter fat and thus vary with season Also affected by size of the fat globules and the richness of cream Cooling temp. In summer (7-9 C) In winter (10-13 C)

30. Churning Conversion of O/W (Cream) type of emulsion to W/O type (Butter) O/W type of emulsion in milk is stabilized by Surface tension Adsorption Electric charge It gets destabilized due to agitation and frothing (Theories of Churning)

31. Phase Reversal Theory Rahn’s Foam Theory King’s Theory Theories of Churning Black Portion = Milk Serum, White portion = Fat globules

32. Phase Reversal Theory Postulated by Fischer and Hooker According to this theory, churning is a process of Phase Reversal (from O/W to W/O) Stability of emulsion is related to the relative volumes of the fat and water (serum) It was postulated that agitation in the churning of cream causes coalescence and clumping of the fat globules Ratio of surface area to volume of the fat units becomes so small that the reduced SA can no longer contain all the buttermilk in stable form. The o/w emulsion suddenly breaks and butter grains are formed.

33. Rahn’s Foam Theory He postulated that churning would not be possible without foam formation. Fat globules concentrates on the surface of air bubble Air bubble collapse and fat globules clump together Fat globules on an air bubble air bubble collapse Fat globules clump together

34. King’s Theory He postulated that the mechanism of churning is midway between the theories of Phase Reversal and Foam. The film on the FG is partially removed in churning (either by foam formation combined with mechanical agitation or by vigorous agitation alone) Some residual fat is squeezed from the globules. Cause them to adhere together and gradually agglomerate

35. Summary of Churning Process The fat in cooled cream is present as clusters of globules (part of the fat in these globules is present in solid form) Churning breaks up the clusters and causes foam formation, globules concentrate on the bubble and thus are brought into close contact with one another. The movement of globules over one another and direct concussion between them causes wearing away of the emulsion protecting layer.

36. The globules adhere together to form larger and larger particles and eventually these particles become visible as Butter granules The fat in the granules is still mainly in globular form Working of butter causes the globules to move over one another Globules are broken by friction and pressure and due sliding and shearing effect of the working process. Finally there is enough liquid fat to enclose all the water droplets, undestroyed fat globules and the air bubbles.

37. Factors influencing churnability of cream and body of Butter These factors may be classified into two groups Initial character of the cream chemical composition of Butter fat Size of fat globules Richness of cream Viscosity of cream Conditions in the process of manufacture Churning temperature Fullness of churn Speed of churn Design of churn

38. Influence of chemical composition of butter fat Effect on body of the butter relates largely to the proportion of soft fats (low melting point fat) and hard fats (high melting points) This determines the degree of fat solidification in the cooled cream. Increase in the proportion of soft fats Shortens the churning period Diminishes the firmness of the butter Increases fat loss in buttermilk Decrease Prolongs the churning period

39. Effect of richness of cream High fat cream churns more rapidly than low fat cream Greater the concentration of fat globules--- they are more closer, more readily they aggregate, coalesce and form butter granules. Optimum fat percent 30-35% High and low fat –both cause higher fat loss in buttermilk

40. Effect of Viscosity of cream more viscous the cream---more churning time Sticky consistency of cream– diminishes the freedom of movement of the fat globules Lessens their opportunity of being brought together Retard coalescence

41. Effect of churning temperature Churning temperature determines the rapidity and exhaustiveness of churning Adjustment of temperature is effective way to correct the effect of many uncontrollable factors that cause wide fluctuation in the character of butter fat 7-9 C in summer 10-13 C in winter

42. Effect of Fullness of cream For maximum agitation, the cream must dash from side to side or from top to bottom Optimum load--- one third to one half full – provides maximum agitation Overloading diminishes the free space---- leads to increase in churning time

43. Effect of speed of churn Speed of the churn provides agitation So, the maximum speed of the churn is the speed that yields the maximum amount of agitation It is dependent on the ratio of centrifugal force and gravity force Centrifugal force should be less than gravitational force

44. Calculate max. speed when R=1 m

45. The Churning Process Preparing the Churn Filling the churn Churning the cream Draining the buttermilk and washing the butter Salting the butter Adjusting the moisture content Working the butter Unloading the churn

46. Preparing the Churn It should be thoroughly wetted before the cream is added It should be free from bacteria, for this the churn is filled about one-fifth with hot water and set rolling for ten to fifteen minutes Run out the hot water Fill the churn with cold water and rotate for 15 min

47. Churning the Cream When the cream is sufficiently filled, the filling port is closed and the churn is set rolling in top gear Pressure develops within the churn due to liberation of gases, thus after some rotations, the churn is stopped with its drain valve at the top, these valves are opened for some time to release the gases. The churn is again rolled in top gear After some time, free space in the churn is partially filled with froth After a further interval, froth breaks Presence of free buttermilk and butter granules becomes evident

48. The breaking stage is generally considered completed when the site glass becomes clear Sometimes, it is necessary to add break water (@ 15% of cream) at this stage (to control body of the butter by reducing temperature) It also prevents granules to join together and form large lumps Churn till the desired size butter granules are formed When the butter granules are formed, churn is stopped with the drain valves at the bottom The buttermilk is drained from the churn

49. Washing the butter Purpose To remove adhered buttermilk To correct defects in the firmness of butter Add wash water equal to the volume of the buttermilk drained Approx. 25% of the curd contained in the unwashed butter is removed by washing Temp.– approx. original temperature of the cream in the churn The wash water should be bacteriologically safe

50. Salting the Butter Purpose To improve its keeping quality To increase palatibility Calculating the amount of salt Determine the fat content of Buttermilk you know the fat content of cream This will give the fat present in the churn So, we can calculate the amount of Butter in the churn Multiply it with the desired salt percentage

51. Exercise Calculate salt to be added. The fat content of the cream (100Kg) used for churning was 35%. (consider fat content in the Buttermilk is negligible). Salt required in Butter is 2%.

52. Methods of Salting Dry Salting The dry salt is sprinkled evenly over the granular butter in the churn Satisfactory with butter of normal firmness Cause grittiness with abnormally weak butter Wet Salting Assist in forming rapid solution of salt And in avoiding the presence of undissolved salt crystals

53. Addition of make up water

54. Working the Butter Purpose To bring the butter granules together into a compact mass For convenient handling and packing To completely dissolve, uniformly distribute and properly incorporate the salt To incorporate the make up water During this process, remaining fat globules also break up and form a continuous phase

55. Amount of working required There should be no free moisture on a cross section cut from the Butter block by a sharp knife or a wire It is safer to overwork butter than to underwork Underworked butter may be leaky in body with large visible aggregates of water

56. Butter Colour Need Desirable properties Free from ingredients injurious to health Free from undesirable odors and flavors Strength should be such that only a small qty. is required Permanency of emulsion It must be oil soluble Types Mineral origin Vegetable origin

57. Vegetable Butter Color Derives the coloring component from plants Bulk of the vegetable color used today is made from the coloring substance extracted from the seed of the annatto plant ( Bixa Orellana ) Mineral Butter Color Derives the coloring component from harmless oil soluble coal tar dyes Dyes certifies by USDA are Yellow A B ( Benzeneazo - β - naphthlyamine Yellow O B (Ortho- Tolueneazo - β - naphthylamine )

58. Butter Defects Flavor and Aroma Due to off flavors in the cream Due to faulty methods in the manufacture After manufacture Body and texture color

59. Flavor defects due to faulty methods in manufacture Flat flavor Lacks the pronounced, pleasing flavor and aroma that is characteristic of butter of superior quality Causes: Fundamental cause is low content of volatile acidity, diacetyl and other products Churning the cream sweet and without the use of starter Profuse dilution of cream with water Excessive washing of butter Prevention : Proper ripening of cream Avoid dilution with water

60. HIGH ACID AND SOUR FLAVOR High acid----Characteristic of butter made from cream received in sour condition and that is not neutralized Causes: Churning over ripened cream Use of over ripe starter By use of high cream ripening temperature in the presence of starter that lacks flavor organisms and produces acid only Prevention: Use of starter containing proper balance of acid and flavor organisms Proper ripening (optimum temperature and time)

61. COOKED OR SCORCHED FLAVOR Characteristic of butter made from pasteurized cream. Caused by exposure of cream to high temperature Properly pasteurized cream- -- cooked flavor disappears before the butter reaches market If the temperature difference between heating medium and cream is too high ---- Scorched flavor More chances when high acid cream is neutralized by lime neutralizers Heating the cream by means of direct steam pasteurization under pressure (with live steam) minimizes the danger of cooked or scorched flavor even when pasteurizing at high temp.

62. NEUTRALIZER FLAVOR The tendency for this defect to appear and its intensity depends on the amount of neutralizer used This amount in turn depends on the initial acidity of the cream and the acidity to which cream is neutralized Lime Neutralizer – limy, bitter neutralizer flavour Soda Neutralizer --- Soapy flavor Causes : Reducing acidity of high acid cream to a very low level Adding the neutralizer in too concentrated form, not distributing it quickly and uniformly throughout the body of the cream or not giving the neutralizer sufficient time to complete the reaction in the cream Preventions: Double neutralisation Adopting proper way of adding neutralizer

63. Flavor defects that may develop after manufacture Surface taint, Limburger or Putrid Flavor The defect is called surface taint because it first appears at the surface. However, the defect is not confined to the surface, it rapidly involves the whole mass or package of the butter This defect is also called Limburger flavor suggesting the flavor and aroma of Limburger cheese Mostly found in butter made from unripened or sweet cream and light salt butter Causes: Protein decomposition by putrefactive bacteria ( Achromobacter putrefaciens , Pseudomonas flourescens and Bacillus flourescens liquefaciens ) Contamination of butter/ cream after pasteurization Prevention: Efficient pasteurization Sanitation between pasteurizer and churn Avoid contamination from churn No buttermilk should flow back to the churn at the time of draining as the buttermilk draining lines are rarely washed and it usually contains milk residues with putrefactive bacteria Ensure clean and sanitized water supply Precautions in packing butter

64. CHEDDAR AND ROQUEFORT FLAVORS Found mostly in light salted and unsalted butter Absent in butter held in commercial cold storage Cheddar cheese type flavor is caused by proteolysis and lipolysis by several species of bacteria Roquefort cheese flavor is usually associated with mold growth which involves both proteolysis and fat hydrolysis Trend of flavor change Flat flavor-----Stale flavor----Cheesy flavor of Cheddar type----Roquefort flavor and Rancidity Prevention : Good sanitation practices throughout the process Cream ripening with good starters

65. RANCID FLAVOR It is a common flavor defect of butter made from raw cream It resembles the pungent, rasping taste and odor of such volatile fatty acids as butyric, caproic and caprylic acids. It is caused by hydrolysis of fat which splits the butter into free fatty acids and glycerols This hydrolysis is brought about by the action of m.o . or enzymes or both Prevention : Proper pasteurization Efficient sanitation Clean water supply

66. TALLOWY FLAVOR The tallowy flavor of butter resembles the flavor and odor of mutton tallow In severe cases of tallowiness , butter also bleaches in colour It is caused by oxidation of the fat, involving the unsaturated fatty acids in butter such as oleic acid Oleic acid combined with free glycerol forms glycollic acid ester of oleic acid. This product is responsible for tallowy flavor Causes: Air, light and heat (air--- cause oxidation, light & heat accelerate it) Metals (oxides or salts) Absence of bacteria (utilizes oxygen in their metabolism and thus retard tallowiness ) Prevention: Use of air and light proof liners Metal surfaces should be properly tinned or SS should be used

67. FISHY FLAVOR Butter has a flavor and odor characteristic of a fish Trymethylamine is the product responsible for fishiness Causes: Feeds and area of feeding Activity of microorganism Mold Oidium lactis when grown in conjuction with S. lactis in cream, fishy flavor develops Certain yeasts and bacteria may also cause this defect Prevention: Keep CSA 0.35% or less Do not whip or over work butter Do not salt the butter excessively

68. Defects in Body & Texture Crumbly, Brittle Body Proportion of high and low melting point fat Winter butter-excessive hardness, crumbliness and stickiness of butter Prevention Avoid low cooling temperature and prolonged holding of cream at low temperature Chilling granular butter with cold wash water

69. Sticky Butter This refers to the butter that doesn't cut clean It sticks to the knife or Trier Prevention Same as for crumbly butter Churning immediately after cooling Wash the butter with wash water at a temp. of 3 to 4 o F below tha t of the buttermilk

70. Weak Body It lacks the desired firmness and standing up property Causes: Incomplete fat crystallization Faulty adjustment of cooling temperature of cream or holding time Low proportion of high m.p. glycerides

71. Greasy Texture Occurs when worked excessively while in soft condition Usually appears in the case of abnormally rich cream insufficiently cooled and churned and worked while too warm Prevention: Proper cooling of cream Chilling the butter granules thoroughly with very cold water before working

72. Leaky Texture Usually appears wet to the eyes When bored, it shows small droplets of moisture on the plug and the back of the trier looks wet Excessive shrinkage and weight loss in storage Causes: Incomplete and improper working Lack of fine dispersion of moisture in butter

73. Gummy Butter Butter when placed in mouth, does not melt readily, it sticks to the roof of the mouth and gives the impression of gumminess Cause: Presence of an excess amount of high melting glycerides Mealy Butter Most likely to occur in butter made from sour cream that is improperly neutralized with lime Insoluble calcium caseinate forms In subsequent pasteurization, these particles contract and harden giving the cream and butter, a disagreeable rough, grainy and mealy character

74. Defects in the Color of Butter Bleached color --- due to oxidation of fat Mottled Color Uneveness of color in the body of butter is shown in the form of streaks, waves and mottles Causes: The whitish, opaque dapples in mottled butter are due to localized sections of innumerable very minute water droplets Salting out action Uneven working of different portions of butter Prevention Keep worker rolls in good mechanical condition Don’t overload the workers/churn Completely dissolve the salt

75. Butter Overrun The difference between the weight of fat churned and the weight of butter made. In addition to butter fat, butter contains non-fatty constituents such as moisture, salt, curd and small amounts of lactose, acid and ash. Maximum overrun is 25%

76. The Churning operation Preparing the churn Straining the cream into the churn Addition of Butter Colour Operating the Churn Gas in the churn (slightly minimize agitation, leakage) Rise of temp. during churning (friction, heat of crystallization) When to stop the churn

77. margarine,   food product made principally from one or more vegetable or animal fats or oils in which is dispersed an aqueous portion containing milk products, either solid or fluid, salt, and such other ingredients as flavouring agents, yellow food pigments, emulsifiers, preservatives, vitamins A and D, and butter. It is used in cooking and as a spread. Nutritionally, margarine is primarily a source of calories. The French chemist H. Mège-Mouriès developed margarine in the late 1860s and was given recognition in Europe and a patent in the United States in 1873. His manufacturing method was simplified in the United ... (100 of 309 words)

78. Renovated Butter is a product made from butter that either has gone rancid, or that was impure. The purpose is to end up with a butter that is usable for human consumption. The butter is melted. The butterfat is collected from the resultant liquid and any foreign material filtered out. Air might be forced through it as well if needed to remove any undesirable odours. The butterfat is then mixed with water (usually at least 16%), some good milk, cream or skimmed-milk for flavour, then churned, and made back into butter, then packaged for sale. Strict conditions are attached to its sale everywhere. Typically, Renovated Butter has to be sold clearly labelled "Renovated Butter", and the word "renovated" has to be at least as big as the word "butter." In some places, sale to consumers is not permitted at all. History Notes for Renovated Butter Renovated Butter was particularly popular in America at the turn of the 1900s. It was a form of butter that could come closer to competing price-wise with margarine. At the turn of the 1900s, the largest producer of renovated butter was the "Illinois Creamery" (established 1896 in Elgin, Illinois), which had 30 workers (it was sold in 1906 to the "American Farm Products Company"). As margarine got cheaper Renovated Butter faded as a viable competitor altogether. Renovated Butters were generally not considered a person's first choice as a dairy spread. Some were the consistency of axle grease. It was included in soldiers' rations during the first world war. A lot of it came from Australia. Some soldiers said that it didn't taste of much; other said it was better than having nothing to spread on their bread at all. For a time, a good deal of Renovated Butter was sold by Americans to the UK. This eventually opened the door for sales of Canadian butter to the UK, because Renovated Butter gave all American butter a bad name. Copyright 2010 Practically Edible. All rights reserved and enforced.) Read more of this snippet here : http://www.practicallyedible.com/edible.nsf/pages/renovatedbutter#ixzz19ZgBlQQK ]]]]]]]][[]]]]]]]]]]]]]]]]]]]]]]]]]]]]]

79. 11/17/2012 NDRI, DT213 83 Continuous Butter Churn 3 main principles Churning or frothing: In this method butter grain is formed by aggregation of the fat globules under the action of air present in the cream. Eg: Fritz, Fritz Eisenreich process, Contimob (Simon Freres), Westfalia and Silkborg are based on this principle.

80. 11/17/2012 NDRI, DT213 84 2. Concentration and Phase reversal : In this method the concentrated cream will be subjected to combined effects of cooling and working, and bring about a direct conversion of cream to butter. Thus it bypasses the butter grain stage. Eg: Alfa process and maleshin(Russian) process . Contd….

81. 11/17/2012 NDRI, DT213 85 3. Emulsification: In this process, liquid butterfat and serum are emulsified and emulsion is cooled and worked to farm butter. Eg: Creamery Package and Gold’s Flow process.

82. 11/17/2012 NDRI, DT213 86 Fritz-Eisenreich Process Schematic Diagram of a continuous butter making machine

83. 11/17/2012 NDRI, DT213 87 In Fritz butter making machine, it contains only one churning cylinder and twin screw working device. This was only suitable for sweet cream of 40 – 50% fat. The second churning cylinder was developed by Eisenreich, which basically have second churning section, buttermilk discharge section and wash compartment. This allows churning of ripened cream as well. Contd….

84. 11/17/2012 NDRI, DT213 88 First churning section: Cylindrical in shape with cooling jacket Contains beater whose battens are at a distance of 2-3mm from the wall Beater rotates at a high speed (600 – 2800 rpm) which can be adjusted Cream containing 40 – 50% fat is passed to this section at a temperature of 7 – 10 C Butter granules are formed here within 3 – 5 sec. Contd….

85. 11/17/2012 NDRI, DT213 89 Cream is set into the rapid motion in the form of a thin film Fine cream froth is produced Through the breaking of these froth bubbles and through the action of the very vigorous mechanical action the cream is churned to butter granules and buttermilk. 30% fat cream can also be churned by increasing the unevenness of the inner surface (by inserting perforated cylinder) Mixture of butter granules and buttermilk is displaced from the cylinder by the incoming cream. Contd….

86. 11/17/2012 NDRI, DT213 90 Second churning section: Cylinder rotates at 10 – 25 rpm Cylinder is cooled and butter granules are able to form loose agglomerates Metal rods which rotate at the same rate loosen the mass and prevent the formation of lumps In the buttermilk discharge section major part of the buttermilk is drawn off through a wire mesh which covers the perforated cylinder Removal of buttermilk is almost complete and water is in very fine state of dispersion. Washing for butter granules can be done in wash compartment but it is hardly necessary. Contd….

87. 11/17/2012 NDRI, DT213 91 Twin Screw Working Device: Butter granules are collected by two contra rotating screws and worked intensively Buttermilk is pressed out Screws force the butter through a number of perforated plates arranged in series This treatment serves to produce a fine dispersion of water in the butter Process is assisted by mixing vanes which are placed between the plates and attached to the shaft Contd….

88. 11/17/2012 NDRI, DT213 92 Water or salt solution may be added through an opening immediately in front of the perforated plates to adjust moisture or salt Contd….

89. 11/17/2012 NDRI, DT213 93 CONTIMAB PROCESS

90. 11/17/2012 NDRI, DT213 94 Cream churns into butter granules in 1-2 sec churning cylinder rotates at 600 – 800rpm Two major working sections: wet and dry In WS-1, washing and cooling of butter granules and removal of butter milk along with working. In WS-2, further worked and reduces the moisture content to 13 to 14% Dosing section, where adjustment of salt and moist. Vacuum chamber, reduces the air content Contd….

91. 11/17/2012 NDRI, DT213 95 ALFA Process

92. 11/17/2012 NDRI, DT213 96 Cream of 30% fat is pasteurized at 90 C, degassed, cooled to 45 – 50 C and separated at this temperature in a cream separator to 82% fat The cream, which is still in the form of oil in water emulsion, but it is almost the composition of butter In this cream fat globules are so closely packed that their fat globule membranes are in contact with each other ALFA Process

93. 11/17/2012 NDRI, DT213 97 This cream is then passed through a two or three stage screw cooler where it is cooled to 8 – 13 C There the fat crystallizes and fat crystals perforate the fat globule membrane so that free fat escape This process is helped by rubbing together of the fat globules as they move in the cooler Thus phase inversion takes place and water-in-oil emulsion (butter) is formed. It contains all the fat globule membrane material, thus it has high phospholipids content and no buttermilk is produced in this process.