Manufacture of Milk Products

Manufacturing process of Butter

Dr. Md. Abdus Shabur Talukder

PhD (Japan)
• Butter is made by churning one of the following products: cream, sour cream, or sour
milk.
• If you do not have enough milk from which to skim off the cream, the milk can be soured
and churned as a whole (provided that the fat content of the milk is rather high; above
4%).
• But sour cream is better to churn than sour milk. It is only possible to manufacture sweet
cream butter if the production and handling of the milk, cream and butter are
exceptionally hygienic and the cream has undergone after pasteurization a cold
treatment by storing it for at least 12 hours at temperatures below 10°C.
a) Heating and souring

• Heat the milk or cream to a temperature of 85°C.

• Let it cool down to 18°C as quickly as possible (use a
thermometer)
• using cold running water on the outside of the pan.
• Add 10 - 30 ml (about 1 - 2 tablespoons) of fresh fermented
sour milk or a starter culture to one litre of milk or cream and
stir.
• After about 24 hours at 16 to 18°C,
• the mixture will become thick and sour enough to be churned.
 b) Churning
•During churning the cream, sour cream or sour milk will be mixed intensively with
air.
•This process causes fat globules to flocculate (or stick together), producing
butter and buttermilk. The simplest way to make butter from small quantities of milk
is by using a bottle or a jar that can be covered with a well-closing lid or a simple
bowl with beaters. If large quantities of milk or cream are available, you should
consider acquiring a real churn.
•There are several types available. The churn tub is a simple method, which is often
used in the tropics. A cheap and practical domestic churn is a glass pot with a
paddle attached to a screw top.
•The paddle can be turned manually. This churn is difficult to clean. It is best to rinse
it with water before use, in order to prevent the butter from sticking to the sides.
•Churns should not be filled more than one third with soured
milk or sour cream. Churn with a regular up and down or
sideways movement. Stop churning when the butter particles
reach the size of rice grains or peas and the buttermilk looks
rather liquid. If, after 30 minutes, no grains have yet been
formed, you can change the temperature by adding a little
clean cold or warm water. The amount of added water should
never be more than 25% of the total amount of churned cream
or milk. The butter particles will float to the top of the buttermilk,
because
• Butter is lighter than buttermilk.

• This makes it easier to separate the two products by

pouring off the buttermilk through a coarse sieve.

Never add too much water, otherwise the buttermilk

will become too watery.

c) Washing
Washing of the butter grains is not necessary. However, if very
clean water is available, it can improve butter quality. Washing the
butter can be done in two ways:
1) Fill the churn 2/5 full with clean, cold water. Wash the butter by
churning it for about 3 minutes. This can be repeated, if
necessary. The idea is to remove part of the remaining buttermilk
from the butter particles. It is important to remove as much as
possible in order to produce butter that can be kept for a longer
period. After washing, the butter particles can be skimmed off or
the buttermilk can be drained.
2) If small quantities are available, the butter particles can be
washed using a sieve. Put the sieve on top of a bowl and pour the
mixture through it. Make sure that during churning the butter does
not become one big lump, otherwise it will be difficult to wash - in
d) Salting (if preferred)
Salting is not necessary for preservation; many
people, however, like the taste of salted butter.
The butter can be slightly salted (according to
taste) by kneading in about 10 grams of salt to
each kilogram of butter.
Mix the butter again the next day in order to
allow the salt grains to dissolve.
 e) Kneading
• Kneading the butter is important in order to get a nice, smooth
product.
• It helps to distribute the moisture and this improves quality
and shelf life, provided that kneading is done in a hygienic
way.
• Use a clean, well-rinsed kneading board.
• Knead the butter with the back of two wooden spoons until
drops of water and buttermilk are not perceivable any more
and the butter has a nice, smooth surface.
• Remove drops of buttermilk during this process.
• Instead of a wooden spoon, a wet roller or bottle can be used.
• If none of these are available, just use clean hands to knead.
 f) Storage
• Butter should be stored in a cool, dark place.
• Put it in a pot or wrap it up in greaseproof paper or aluminium
foil.
• After some time, one to two weeks, the surface of the butter
can be covered with moulds.
• This mould formation can be partially prevented by sprinkling
salt on the surface or by wrapping the butter air tight.
• Moulds only grow if oxygen is available. Butter can also be
frozen.
• However, after defrosting the butter will rather soon have an
off-taste.
• It is therefore a good idea to divide the 50 Preparation of
dairy products butter into smaller portions before freezing.
• Salted butter is less suitable for freezing.
 Manufacturing process of Ghee
• Heat the butter until water and fat form separate layers;
the fat will float on top. There are two ways to remove the
water:

a) It can be removed by further heating. The water

present will evaporate.
b) It is possible to remove the layer of fat with a spoon.
This fat should then be heated again. The scum, which will
form, has to be skimmed off regularly, preferably with a
skimmer.
The colour of ghee can vary from almost white to dark
brown.
A rancid flavour is acceptable, but if it tastes burnt it
should be discarded.
 Manufacturing Process of Dahi
•Good quality whole milk is selected for preparation of dahi.
•Milk is firstly heated to 30-400c for straining with clean muslin cloth.
•After then milk is heated to boiling point for reduction of volume up
to 20%.
•Then 10-15% sugar of the volume of milk is added.
•After reduction of volume milk is allowed to cool at 36-400c add
inoculated to suitable bacterial culture.
•The species of microbes used are Streptococcus lactis,St.
diacetilactis, St. cremoris, Lactobacillus acidophilus and L.
bulgaricus.
•After inoculation of bacterial culture it is mixed properly and milk is
incubated in the incubator at 36-400c.
• At this temperature normally curd formation takes 5-6 hours.
•Coagulation time increases with the increase of time.
•Finally the prepared dahi is kept in the refrigerator at 5-70c before
serving.
•N.B.: In case of sour dahi sugar is not added.
 Manufacturing process of Yoghurt
The general process of making yogurt includes
modifying the
• composition of and
• pasteurizing the milk;
• fermenting at warm temperatures;
• cooling it;
• and adding fruit, sugar, and other materials.
a) Modifying milk composition:
• When the milk arrives at the plant, its composition is modified before it is used to
make yogurt.
• This standardization process typically involves reducing the fat content and increasing
the total solids.
• The fat content is reduced by using a standardizing clarifier and a separator (a device
that relies upon centrifugation to separate fat from milk).
• From the clarifier, the milk is placed in a storage tank and tested for fat and solids
content.
• For yogurt manufacture, the solids content of the milk is increased to 16% with 1-5%
being fat and 11-14% being solids-not-fat (SNF).
• This is accomplished either by evaporating off some of the water, or adding
concentrated milk or milk powder.
• Increasing the solids content improves the nutritional value of the yogurt, makes it
easier to produce a firmer yogurt and improves the stability of the yogurt by reducing
the tendency for it to separate on storage.
• The milk substance is fermented until it becomes yogurt.
• Fruits and flavorings are added to the yogurt before packaging.
b) Pasteurization and homogenization
•After the solids composition is adjusted, stabilizers are added and the milk is
pasteurized.
•This step has many benefits.
•First, it will destroy all the microorganisms in the milk that may interfere with the
controlled fermentation process.
• Second, it will denature the whey proteins in the milk which will give the final
yogurt product better body and texture.
•Third, it will not greatly alter the flavor of the milk.
•Finally, it helps release the compounds in milk that will stimulate the growth of
the starter culture.
• Pasteurization can be a continuous-or batch-process.
• Both of these processes involve heating the milk to a relatively high temperature
and holding it there for a set amount of time.
• One specific method for batch process pasteurization is to heat a large, stainless
steel vat of milk to 185° F (85° C) and hold it there for at least 30 minutes.
• While the milk is being heat treated, it is also homogenized.
• Homogenization is a process in which the fat globules in milk are broken
up into smaller, more consistently dispersed particles.
• This produces a much smoother and creamier end product.
• In commercial yogurt making, homogenization has the benefits of giving a
uniform product, which will not separate.
• Homogenization is accomplished using a homogenizer or viscolizer.
• In this machine, the milk is forced through small openings at a high pressure and
fat globules are broken up due to shearing forces.
c) Fermentation
•When pasteurization and homogenization are complete, the milk is cooled to
between 109.4-114.8° F (43-46° C) and the fermentation culture is added in a
concentration of about 2%.
• It is held at this temperature for about three to four hours while the incubation
process takes place.
•During this time, the bacteria metabolizes certain compounds in the milk
producing the characteristic yogurt flavor.
•An important byproduct of this process is lactic acid. Depending on the type of
yogurt, the incubation process is done either in a large tank of several hundred
gallons or in the final individual containers.
•Stirred yogurt is fermented in bulk and then poured into the final selling
containers. Set yogurt, also known as French style, is allowed to ferment
right in the container it is sold in. In both instances, the lactic acid level is
used to determine when the yogurt is ready. The acid level is found by taking
a sample of the product and titrating it with sodium hydroxide. A value of at
least 0.9% acidity and a pH of about 4.4 are the current minimum standards
for yogurt manufacture. When the yogurt reaches the desired acid level, it is
cooled, modified as necessary and dispensed into containers (if applicable).
Manufacture of sweet meat
 Manufacturing process of Peda
•Milk is first taken in the karahi and heated to boiling point.

•After evaporation of 50% moisture required amount of sugar is

added.

•Then the mixture is heated on open fire with constant stirring

until almost all the moisture evaporated.

•Then the semi-dried mass is cooled to room temperature.

•Finally the semi-solid mass is given desired peda shape.

 Manufacturing process of Monda
• For monda preparation milk is firstly heated to boiling point.
• Then milk is cooled to 800c.
• Then fermented whey water is added until chhana
separates.
• As much as whey water is removed from chhana by
hanging it in a filter cloth and pressing the chhana with filter
cloth.
• Then the chhana is put in the karahi.
• The chhana is cooked on open fire with continuous stirring.
• Sugar is added and stirring is continued.
• Then some cardamom powder is added .
• When the chhana becomes a uniform paste, the karahi is
removed from the fire.
• The mass is cooled to room temperature.
• Finally the monda is given desired shape and wrawpped
 Manufacturing process of Rasogolla
•For rasogolla preparation milk is firstly heated to boiling point.
•Then milk is cooled to 800c.
•Then fermented whey water is added until chhana separates.
•As much as whey water is removed from chhana by hanging it in a
filter cloth and pressing the chhana with filter cloth.
•The chhana is then broken, flour is added and the mixture is kneaded
to prepare a mass.
•Small balls are made with fine finish.
•Concentrated sugar syrup is made (sugar:water = 1:1) and heated to
boiling.
•Then the balls of chhana are boiled in the sugar syrup for 25-30 mins
so the balls swell to double of its initial size.
•Finally the boiled balls are transferred to dilute sugar syrup
(sugar:water = 1:2) and cooled for 10-12 hours.
Manufacturing process of Rasomalai
•For rasomalai preparation required amount of milk is taken and the total
milk is divided into two parts – 3/5th is for rasogolla preparation and 2/5 th
is for malai preparation.
•For rasogolla preparation milk is firstly heated to boiling point.
•Then milk is cooled to 800c.
•Then fermented whey water is added until chhana separates.
•As much as whey water is removed from chhana by hanging it in a filter
cloth and pressing the chhana with filter cloth.
•The chhana is then broken, flour is added and the mixture is kneaded to
prepare a mass.
• Small balls are made with fine finish.
•Concentrated sugar syrup is made (sugar:water = 1:1) and heated to
boiling.
• Small balls are made with fine finish.
•Concentrated sugar syrup is made (sugar:water = 1:1) and heated
to boiling.
•Then the balls of chhana are boiled in the sugar syrup for 25-30
mins so the balls swell to double of its initial size.
•Then milk kept for malai preparation is taken in the saucepan with
some pieces of cardamom and is heated until the volume is
reduced to 50%. Rasogolla is heated in the hot malai for 5
minutes.
•Finally the rasomalai is cooled to room temperature for at least 6
hours.
 Manufacturing process of Kalojam
•For kalojam preparation milk is firstly heated to boiling point.
•Then milk is cooled to 800c.
•Then fermented whey water is added until chhana separates.
•As much as whey water is removed from chhana by hanging it
in a filter cloth and pressing the chhana with filter cloth.
•The chhana is then broken and necessary amount of flour,
soyabean oil, dalda, and baking soda is added.
•The mixture is then kneaded to prepare a mass and to made
slightly oval balls.
•Then the balls are fried in hot soyabean oil until the surface
becomes deep brown.
Manufacturing process of Cheese
•Cheese is made from milk, and that milk comes from animals as
diverse as cows, sheep, goats, horses, camels, water buffalo, and
reindeer.
•Most cheese makers expedite the curdling process with rennet, lactic
acid, or plant extracts, such as the vegetable rennet produced from
wild artichokes, fig leaves, safflower, or melon. In addition to milk and
curdling agents, cheeses may contain various ingredients added to
enhance flavor and color.
•The great cheeses of the world may acquire their flavor from the
specific bacterial molds with which they have been inoculated, an
example being the famous Penicillium roqueforti used to make
France's Roquefort and England's Stilton.
•Cheeses may also be salted or dyed, usually with annatto, an
orange coloring made from the pulp of a tropical tree, or carrot juice.
•They may be washed in brine or covered with ashes.
•Cheese makers who wish to avoid rennet may encourage the
bacterial growth necessary to curdling by a number of odd methods.
•Some cheeses possess this bacteria because they are made from
unpasteurized milk.
•Other cheeses, however, are reportedly made from milk in which
dung or old leather have been dunked; still others acquire their
bacteria from being buried in mud. The unusual texture and flavor of
processed cheese are obtained by combining several types of
natural cheese and adding salt, milk-fat, cream, whey, water,
vegetable oil, and other fillers.
•Processed cheese will also have preservatives,
emulsifiers, gums, gelatin, thickeners, and
sweeteners as ingredients.
•Most processed cheese and some natural cheeses
are flavored with such ingredients as paprika, pepper,
chives, onions, cumin, car-away seeds, jalapeño
peppers, hazelnuts, raisins, mushrooms, sage, and
bacon.
•Cheese can also be smoked to preserve it and give it
a distinctive flavor.
•Although cheese making is a linear process, it involves many
factors.
•Numerous varieties of cheese exist because ending the simple
preparation process at different points can produce different
cheeses, as can varying additives or procedures.
•Cheese making has long been considered a delicate process.
Attempts to duplicate the success of an old cheese factory have
been known to fail because conditions at a new factory do not
favor the growth of the proper bacteria.
 a) Preparing the milk
• Small cheese factories accept either morning milk (which is
richer), evening milk, or both.
• Because it is generally purchased from small dairies which
don't pasteurize, this milk contains the bacteria necessary to
produce lactic acid, one of the agents that triggers curdling.
• The cheese makers let the milk sit until enough lactic acid has
formed to begin producing the particular type of cheese
they're making. Depending on the type of cheese being
produced, the cheese makers may then heat the ripening
milk.
• This process differs slightly at large cheese factories, which
purchase pasteurized milk and must consequently add a
culture of bacteria to produce lactic acid
b) Separation of the curds from the whey
•The next step is to add animal or vegetable rennet to the
milk, furthering its separation into curds and whey.
•Once formed, the curds are cut both vertically and
horizontally with knives.
•In large factories, huge vats of curdled milk are cut vertically
using sharp, multi-bladed, wire knives reminiscent of oven
racks. The same machine then agitates the curds and slices
them horizontally. If the cutting is done manually, the curds
are cut both ways using a large, two-handled knife. Soft
cheeses are cut into big chunks, while hard cheeses are cut
into tiny chunks. (For cheddar, for instance, the space
between the knives is about one-twentieth of an inch [half a
centimeter].)
•After cutting, the curds may be heated to hasten the separation from the whey, but they
are more typically left alone.
•When separation is complete, the whey is drained. In a typical cheese-making
operation, the first step is preparing the milk. Although smaller factories purchase
unpasteurized milk that already has the bacteria present to produce lactic acid
(necessary for curdling), larger factories purchase pasteurized milk and must add
bacteria culture to produce the lactic acid.
•Next, the curds must be separated from the whey. Animal or vegetable rennet is
added, and then the curds are agitated and cut using large knives.
•As the whey separates, it is drained. The curds are then pressed into molds, if
necessary, to facilitate further moisture drainage, and aged for the proper amount of
time.
•Some cheeses are aged for a month, others for several years.
 c) Pressing the curds
•Moisture must then be removed from the curds, although the amount removed depends
on the type of cheese.
•For some types with high moisture contents, the whey-draining process removes
sufficient moisture.
•Other types require the curds to be cut, heated, and/or filtered to get rid of excess
moisture. To make cheddar cheese, for example, cheese makers cheddar, or finely chop,
the curd.
•To make hard, dry cheeses such as parmesan, cheese makers first cheddar and then
cook the curd.
•Regardless, if the curds are to be aged, they are then put into molds. Here, they are
pressed to give the proper shape and size. Soft cheeses such as cottage cheese are not
aged.
•To make hard, dry cheeses such as parmesan, cheese makers first
cheddar and then cook the curd. Regardless, if the curds are to be aged,
they are then put into molds. Here, they are pressed to give the proper
shape and size. Soft cheeses such as cottage cheese are not aged.
 d) Ageing the cheese
•At this stage the cheese may be inoculated with a flavoring mold, bathed in brine, or
wrapped in cloth or hay before being deposited in a place of the proper temperature and
humidity to age.
•Some cheeses are aged for a month, some for up to several years. Ageing sharpens
the flavor of the cheese; for example, cheddar aged more than two years is
appropriately labeled extra sharp.
 e) Wrapping natural cheese
•Some cheeses may develop a rind naturally, as
their surfaces dry. Other rinds may form the growth
of bacteria that has been sprayed on the surface of
the cheese.
•Still other cheeses are washed, and this process
encourages bacterial growth.
•In place of or in addition to rinds, cheeses can be
sealed in cloth or wax.
•For local eating, this may be all the packaging

that is necessary.

•However, large quantities of cheese are

packaged for sale in distant countries.

•Such cheeses may be heavily salted for

export (such as Roquefort) or sealed in

impermeable plastic or foil.

 f) Making and wrapping processed cheese
•Edible yet inferior cheeses can be saved and made into processed cheese.

•Cheeses such as Emmental (commonly called Swiss), Gruyere (similar to

Swiss), Colby, or cheddar are cut up and very finely ground.

•After this powder has been mixed with water to form a paste, other ingredients

such as salt, fillers, emulsifiers, preservatives, and flavorings are added.

•The mixture is then heated under controlled conditions. While still warm and

soft, the cheese paste is extruded into long ribbons that are sliced. The

small sheets of cheese are then put onto a plastic or foil sheet and wrapped

by a machine.
•Although peoples choice and taste are changing day by day the indigenous dairy
products are still very popular in Bangladesh.
• It is true that complicated machinery and sophisticated processing methods have
not been invented to make better dairy products, but traditional techniques of
manufacturing indigenous dairy products are still very popular.
•Very often our milk and dairy processors have to face severe problems specially in
case of availability of milk specially due to transportation problem.
•The market is not always within easy reach for delivering fresh raw milk and local
processors, if any exist, are constrained to take milk in excess of processing ability
as they may be plagued by problems like power failure or transport breakdown.
Producers, therefore, have adopted, over the generations, a variety of methods to
minimize the loss in value of fat and SNF (solids-not-fat) in liquid milk.
•The processors, similarly, adopt small-scale processing technology which is
adequate to process limited marketable surpluses of an area, often in the form
of a chiller or a bulk cooler, as independent units to cater to the local demand
for liquid milk or as feeders to bigger units of the area.
•As for small-scale processing, it is believed that `it is in fact possible to
manufacture the highest quality dairy foods with extremely simple tools and
means.
•It is also true that most dairy foods can be made with the help of relatively few
basic processes provided that the manufacturer has the necessary skills and
experiences.