DETAILS OF MANUFACTURE OF Weighing:

BUTTER The cans of cream, which have been

accepted, are then weighed and weight
Receiving of milk or cream: recorded. Third grade cream is rejected.

This consists of the following: Testing:

a. Unloading Cream samples drawn are then tested

b. Grading for fat, solids-not-fat, acidity, etc.
c. Sampling
d. Weighing. Preheating of Milk:
e. Testing.
This is done if milk is used for
Unloading: separation to obtain cream and to
increase the efficiency of cream
The cans of cream brought to the separation.
creamery/butter-making factory are
unloaded on the receiving platform. Separation of Milk:

Grading: This is done by centrifugal method using

The purpose of grading is to pay for the
product on the basis of its quality.
Cream is graded by examining for smell,
taste, appearance, touch, acidity and
sediment test.
Cream grades are:
1st grade - sweet or slightly sour
2nd grade - sour, coagulated
3rd grade - markedly sour, fermented.
the centrifugal machine.
Neutralization of Cream:
This is the partial reduction of acidity of
the cream by addition of the calculated
amount of neutralizer.
Standardization of Cream:
This refers to the adjustment of the fat
level in cream to the desired
percentage, conforming to standard
requirements.

Pasteurisation:
Sampling:
Before sampling, cream in the can is Pasteurisation is done either in Batch
thoroughly mixed by a combined rotary Pasteurizer or in High Temperature
and vertical movement of the Short Time Pasteurizer. If pasteurisation
plunger/stirrer. Sampling is done for is done in the Batch Pasteurizer, the
testing purpose. time temperature combination is 71
degrees Centigrade for 20 minutes and
if done in HTST pasteurizer, the time
temperature combination is 95 to 100
degrees Centigrade for 15 to 16
seconds.
Cooling and Aging of Cream:
Cream is cooled by lowering its
temperature and aged by holding it at
this (low) temperature for few hours.
This is done to make churning possible.
Cream will not churn until the butterfat in
the fat globules has at least partially
solidified if not fat loss in buttermilk will
be excessive and butter obtained will
have an unsatisfactory and weak body.
Optimum temperature for cooling and
aging cream is preferably 5 - 10 degrees
Centigrade.
Ripening:
This refers to fermentation of cream with
the help of desirable starter culture.
Objective of ripening:
To produce butter with a pleasing,
pronounced characteristic flavour and
aroma.
Procedure:
Butter starter culture containing lactic
acid producers such as Str. lactis, Str.
cremoris together with aroma producers
such as Str. diacetilactis, Leuconostock
citovorum, Leu. dextranicum in correct
proportions is added to the
standardized, pasteurised and cooled
(20 - 22 degrees Centigrade) cream at
0.5 to 2 %. After being thoroughly
mixed, the cream is incubated at 21
degrees Centigrade for 15 - 16 hours.
Role of diacetyl:
The typical flavour of butter from ripened
cream is mainly the effect of diacetyl
and to a smaller extent, of acetic and
propionic acids. There is no diacetyl in
sweet cream. The flavour intensity in
butter depends on its diacetyl content,
as shown below:
Correlation of flavour intensity of butter
with its diacetyl content.
Diacetyl content Flavour
intensity in butter
None Flavourless
0.2 – 0.6 ppm Mild flavour
0.7 – 1.5 ppm Full flavour
Churning
Definition
Churning of cream consists of agitation
at a suitable temperature until the fat
globules adhere, forming larger and
larger masses, and until a relatively
complete separation of fat and serum
occurs.
Factors contributing towards stability of
fat-in-skim-milk emulsion.
The object of churning cream is to
produce butter. In milk or cream, the fat
exists in the form of an emulsion, i.e. a
continuous phase. The emulsion is fairly
stable. As long as it remains intact,
there is no formation of butter. The
factors contribution towards the stability
of this fat-in-skim-milk emulsion are, (1)
force of surface tension, (2)
Phenomenon of adsorption, (3) electric
charge on the fat globules and (4)
viscosity of cream.
(1) Force of surface tension: this causes
the fat globules in milk/cream to
retain their individuality and prevent
butter formation.
(2) Phenomenon of adsorption: the
surface layer of the fat globules
contains an adsorbed phospholipids-
protein complex, which resists de-
emulsification.
fats (such as tri-butyrin, olein, etc.)
where those with high melting points
are called “hard” fats (such as
stearin, palmitin, etc.) An increase in
the proportion of soft fats shorten the
churning period, diminishes the
firmness of butter and increases the
fat loses in butter milk and vice
versa. Fresh green succulent feeds
increase the proportion of hard fats.

(3) Electric charge: The fat globules
carry a negative charge and repel
each other. This prevents their
coalescence.
Factors influencing churnability of cream
and body of butter:
2. Size of fat globules Small fat
globules churn with difficulty, while
large ones churn readily. Therefore,
the higher the proportion of small-
sized fat globules, the longer the
churning time and the greater the fat
loss in butter milk and vice versa.

i. Chemical composition of fat 3. Viscosity of cream: The greater the

viscosity of cream, the greater the
ii. Size of fat globules churning period, and vice versa.

iii. Viscosity of cream 4. Temperature of cream at churning:

this is important for controlling the
iv. Temperature of cream at rapidity and exhaustiveness of
churning churning and the body of butter. The
optimum churning temperature
0
v. Fat percentage of cream ranges from 9 to 11 C. A higher
churning temperature causes a
vi. Acidity of cream shorter churning time, higher fat loss
and a weak body in butter (which is
vii. Load of cream difficult to wash and from which it is
difficult to remove curd particles
viii. Nature of agitation properly). A lower churning
temperature prolongs the churning
ix. Speed of churn period. The optimum churning
temperature will give an optimum
x. Pre-churning holding period churning period (30 – 60 minutes). A
butter of satisfactory firmness and
exhaustive churning.
1. Chemical composition of fat: Milk fat
is a mixture of numerous fats 5. Fat percentage of cream: Higher the
(glycerides) of widely varying melting fat percentage of cream, the lower
and solidifying points. Thus fats with the churning period and vice versa.
low melting points are known as soft
 The optimum fat level of cream for
churning.
6. Acidity of cream: according to
Hunziker, acidic cream churns more
rapidly and exhaustively than sweet
cream. However, McDowall believes
that the reverse is the case.
7. Load of churn: The optimum load of
churn which the churn can take
seems to be between one-half and
one-third its total capacity.
Overloading prolongs churning time,
while under loading reduces the
normal capacity of the churn.
8. Nature of agitation: This is influenced
by the size, type (design) and
revolution per minute of the churn
and affects the churning period.
9. Speed of the churn: Should be as
prescribed by the manufacturer,
since this maximises agitation and
shortens the churning period.
10. Pre-heating holding period: Refers to
cooling and ageing of cream.
CHURNING OPERATION:
Preparing the Churn:
A new churn (especially a wooden one)
requires careful pre-treatment before
use. An old (wooden) churn requires
proper sanitation and cooling to render it
clean.
Filling cream into the churn:
The cream should be strained to remove
lumps and objects. The amount then
filled should be between one half and
one third its total capacity or slightly
below the rated capacity.
Addition of butter colour:
This is done to maintain uniformity of
yellow colour. Amount of standard
colour added varies from 0 - 250 ml or
more per 100 kg of butter fat. The butter
colour should be preferably added to the
cream in the churn. Annatto or carotene
is the colour generally used in butter
making.
Operating the Churn.
After initially rotating the churn for 5 - 10
minutes, the liberated gas is removed
once or twice by opening the churn vent.
During the churning process there is
invariably rise in temperature from 1 - 3
0
C. Churning is accompanied by
foaming. Then comes the “breaking
stage,” when the cream breaks away
from the spy glass, which becomes
clear. At this stage the fat in the skim
milk emulsion breaks and very small
butter granules of the size of pin heads
make their appearance. After the
breaking stage, churning is continued
until the butter grains are of the desired
size (pea size in large churn).
Churning difficulties: The usual causes
are:
i. Excessive hardness of fat
ii. Small sized fat globules
iii. Excessively thin cream
iv. Over-loading of the churn
v. Excessively low churning
temperature of cream
vi. Abnormal cream (causing
excessive foaming)
Factors affecting fat loss in buttermilk:
i. Fat percentage of cream at
churning: The lower the fat
percentage of cream the lower
the fat percentage of buttermilk,
but the greater is the percent total
fat loss in buttermilk and vice
versa
ii) The size of fat globules: The
greater the proportion of small-
sized fat lobules (2 microns or
less) the greater the fat loss and
vice versa. The small globules
escape churning action and pass
on to the buttermilk
iii) Acidity of cream at churning:
According to Hunziker sour
cream causes a lower fat loss
than sweet cream but according
to McDowall, the reverse is true.
iv) Condition of cooling and ageing:
Insufficient cooling and ageing
(i.e. improper fat crystallization)
causes more fat loss and vice
versa.
Drainage of buttermilk:
When the cream has been churned the
churn is stopped in the proper position,
a drain plug fixed and the buttermilk
removed through a sieve.
Washing:
Purpose of Washing
i) To remove all loose buttermilk
adhering to butter grains so as to
reduce the curd content of butter,
thereby improving its keeping
quality.
ii) To correct defects in the firmness
of butter by proper adjustment of
wash water temperature
iii) To decrease the intensity of
certain off-flavours (in case of
poor quality cream), etc.
Procedure: After buttermilk has been
drained, chilled water is added to the
butter grains in the churn. The
temperature of chilled water is usually 1
– 2 0C lower than the temperature of
cream and equal to quantity of
buttermilk removed. After a few
revolutions the wash water is drained
out.
Salting:
Salting is done to improve keeping
quality, to enhance taste and to increase
over-run.
Amount and quality of salt: Usually
common salt is added at the rate of 2 to
2.5 percent of butterfat. The quality of
salt should be good and it should be
free from any extraneous matter and
germs. Excessive salt damages the
flavour of butter. The amount of salt
added to butter in a churn is calculated
as follows:
Problem: Fat in churn = 850 kg. Butter is
to contain 2.0% salt. How much salt
should be added to the churn (without
loss of salt during working)?
Solution: Butter is to contain 2.0% salt.
Assuming 80% fat in butter, the
requirement of salt per 100 kg fat =
2.0 x 100 = 2.5 kg
80
Hence the amount of salt to be added to
the churn
= 850 x 2.5 = 21.25 kg
100
Method of salting
1) Dry salting: Most common. Consists
of adding the desired amount of dry
salt (in instalments, if required) by
sprinkling it over the surface of the
butter during working.
2) Wet salting: The calculated amount
of salt is wetted in the least amount
of potable water and then sprinkled
over the butter during working.
Satisfactorily incorporates slat n the
butter.
3) Brine salting: The salt is added in the
form of a saturated solution of brine.
Practicable when only light salting is
required.
Working:
This refers to kneading of butter.
This is done to: -
1. Completely dissolve, uniformly
distribute and properly
incorporate the salt.
2. Expel buttermilk and to control
the moisture content of butter.
3. Bring the butter grains into
compact mass for convenient
handling and packaging.
Procedure: The working should be
continued until the butter has a compact
body, a closely-knit grain, a tough waxy
texture and an even distribution of salt
and moisture. There should be not free
moisture on the tier plug drawn from the
butter. Throughout the working process,
the temperature should be controlled.
Both over-working and under-working
are harmful and should be avoided; the
former damages the body and texture of
butter while the latter produces leaky
butter. Working increases the air-
content of butter. Normally worked
butter has an air-content of 0.5 to 10 ml
(average 4.0 ml) per 100 g of butter.
The air-content of butter is important
because it affects (i) the density of
butter, (ii) its microbial spoilage and (iii)
its oxidative spoilage
Moisture control: The legal limit for the
moisture content in butter in most
countries is 16%.
Packaging and Storage:
Removing Butter from Churn:
This is done either manually or by
gravity, or by mechanical means.
Types of Packs:
1. Bulk or Whole Sale:- in boxes, in
tubs, casks.
2. Retail Sale:- 1, 2, 4, 8, 16, 20, or 25,
50,100, 250, 500 gm packs; also
in collapsible (metal) tubs.
Objectives of Packaging:
1. To offer protection against
contamination and damage.
2. To protect the butter against loss Food and nutritive value of
in weight and Curd/Dahi.
degradation.(deterioration of It has been established that fermented
flavour) milk products including dahi increase in
food and nutritive value as compared to
3. To provide ease and safety to the original milk. The following points
transport. are cited in their favour:

4. To provide a convenient form of  Dahi is more palatable, and those

disposal. who usually do not like drinking milk
would consume it readily.
Uses of Butter.
 Dahi is more easily digested and
1. Direct consumption. assimilated than milk

2. In preparation of sauces.  Dahi seems to exert a possible

3. As a cooking medium.
4. In baking and confectionery
industries.
5. In the manufacture of ice cream,
butter oil, ghee, etc
Curd or Dahi.
Definition: According to the PFA Rules,
dahi or curd is the product obtained from
pasteurised or boiled milk by souring,
natural or otherwise, by a harmless
lactic acid or other bacterial culture.
Dahi may contain additional cane sugar.
It should have the same percentage of
fat and solids-not-fat as the milk from
which it is prepared.
therapeutic value in the stomach and
during intestinal disorders, possibly
due to its content of antibiotics.
Method of Production.
Traditional Method:
This invariably involves production on a
small scale, either in the consumer’s
household or in the sweet meat-
maker’s shop in urban areas. In the
household, the milk is boiled, cooled to
body temperature, inoculated with 0.5 -
1 per cent starter (previous day’s
curd/dahi or buttermilk) and then
allowed to set undisturbed overnight. In
cooler weather, the curd/dahi-setting
vessel is usually wrapped up with
woollen cloth to maintain warmth.