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Industrial Method of Ghee Making at Panchmahal Dairy, Godhra

Article · August 2006

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 Industrial Method of Ghee Making
at Panchmahal Dairy, Godhra
R.S. Patell R.K. Mathur2 Prateek Sharmas
S.A. Sheths and N.N. Patela

66 The quality of ghee made by the new method was studied with respect
to marketability. All were found to be at par with Agmark standards. The team
of sensory panelists also carried out the organoleptic evaluation and no difference
in comparison with earlier method of ghee manufacture was observed. 22

INTRODUCTION
6) hee occupies a very significant place in contains as high as 5 times CLAs as compared
(f --lnaian diet. The nutritional value of ghee is to original milk fat in milk. CLAs are also known
\f known since Vedic time in ancient India. to be antioxidants and are responsible for higher
Ghee is^ an indispensable part of religious and shelf life of ghee at ambient temperatures (Aneja
ceremonial functions. The major markets for and Murthi, 199O).
ghee are located in south Asian countries. Ghee
The quality of ghee is described in terms of
is also consumed in Australia, Arabian countries,
flavour, texture and colour. The consumers of ghee
USA, UK, Belgium, New Zealand, Netherlands and
always look for most desirable sensory attributes
many other African and Asian countries.
and freedom from suspended serum residues.
Traditionally in Indian households, ghee is They also want an assurance of purity, freshness
made first by converting milk into dahi, churning and wholesomeness.
it at room temperature to obtain makkhan or desi
Rajorhia (1980) reported that consrlmers'
butter, clarifying the desi butter accumulated preferences
over a period of time and conversion into ghee by
for ghee in India varies from region
to region. The findings have been given in Table 1.
boiling it continuously at temperature upto 110-
Ghee manufacturer should be able to use this
12O"C depending upon the regional flavour
information for commercial applications.
preferences. Making of ghee in the presence of
milk proteins yields high levels of conjugated Post WTO scenario presents a big challenge
iinoleic acids (CLA) which are known to be before the Indian dairy industry where
anticarcinogenic agents. Ghee rnade traditionally competition from overseas manufacturers in
1 Managing Director, The Panchmahal Distt. Coop MiIk Producers Union Ltd. Godhra-389 001.
E-mail: rsp@p anchmahalunion. coop
2 Managing Director, The Boroda Distt. Coop. MiIk Producers' Union Ltd.
s Dg. Generol Manager (Engineering), The Panchmahal Distt. Coop MiIk Producers Union Ltd.
a Manager (Engineering), The Panchmohal Distt. Coop MiIk Producers Ilnion Ltd.
s Research Scholar, D.T. Diuision IfDRI. Karnal

*e Indian Dairyman, 58,8,2006

 Table 1: Regional Preference fot Ghee Flavour and Texture
Slight acidic, mildly curdy
Fine to medium size grains (Yz to 3/+ th solid portion)
Mildly curdy (Strongly curdy in Saurashtra)
Coarse grains of 0.3 to O.6 mm size
Mildly to high cooked, aromatic. Higher level of free fatty (butyric) acid
(preference for special herb flavours in Tamil Nadu & Karnataka)
Medium sized grains (Tamil Nadu), Coarse grains (Andhra Pradesh and
Karnatakal
Flavour Slightly to definitenly cooked flavour
Medium grains (%ft liquid and 7+'h solid)

Source: (Rajorhia. 1980)

Table 2: A Comparison of Various Ghee Manufacturlng Methods

Fat recover5f/o 88-90 88-92 92 93 93

Aroma Strong nutty Pleasantly rich Mild & milkv Pleasantly rich Mild
Flavour Acidic Normal Cooked Normal Flat
Texture Packed coarse Slushy fine grain Mostly liquid with Fine grains Greasy
grain (cow) slight granulation
Packed fine
grain (buffalo)
Clarification Easy, economic, Easy, economic, Difficult slow, Easy and Easy and
using heat pre-stratification pre-stratification pre-stratification economic economic
possible possible not possible
Essential Butter Cream separator Cream separator Cream separator Scraped
equipments churn & butter churn & butter churn surface heat
exchanger
By-product Buttermilk and Skim milk, Skim milk. Skim milk, Skim milk,
produced Ghee Residue Buttermilk and Buttermilk and Buttermilk and Buttermilk and
Ghee Residue Ghee Residue Ghee Residue Ghee Residue
Adaptability Small scale Large scale Large scale Large scale Very large scale
Source: Rajorhia (1993) and Aneja et el (2002)

global market has become unavoidable. Although
Ghee is our indigenous product, besides meeting
the international standards, it should be
manufactured in a manner that is cost effective
with considerable savings in enerry and without
affecting the sensory and shelf life attributes.
For manufacture of ghee, there are many
methods, such as Desi (indigenous or traditional
method), Creamery-butter method, Direct cream
method. Pre-stratification method and Continuous
method (Rajorhia, 1993). Comparison of these
methods is given in Table 2.
Nearly, 90 per cent of tl:e ghee produced in
the country is made by traditional method.
IncreaS,ed awareness about enerry management
in past motivated the research works to develop
ener$/ efficient and continuous methods fot ghee
manufacture (Punjrath, 1-9741, which include
either an oil separator (Bhatia, 1978) to separate
serum and fat phase or use of scrapped surface
 Fig. 1: Layout of Ghee Manufacturiag System of
Panchmahal Dairy, Godhra

*"w,-
r
I

.7
I cli&r I

Cream &om
CST'/oF
t0-12 ocr__ -/ \
I I lil_l
Moisture<20.Jvo, |r-:_'_-:-_---1
5hh-hri" | | rsKrm
,. I lsarun
fr"1,.rirli.%, trcny t i;;;;--- il I

| *s*tsY"
|
| | l)u-ou"L I
llntaroo.c llsePeto'
I
tl I

1
Oher seltling tan*s
j Haiual slow cooling
bywell w*erto 50 C

To packaging sertion

heat exchangers (Abhichandani, et al, 1995). Both small holdup of raw material in the plant at any
the processes save ener$/ and yield a comparable given time and hence no chances of whole batch
product. getting spoiled (4) no spillage loss (5) simple, robust
CONTINUOUS METHOD OF GHEE MAKING and hygienic design {6) minimum strain on the
Dairy plants have tried to modify, scale_up and operator (7) facilitate clean in place (g) high
adopt the traditional batch process for commercial
degree of automation possible (9) no surface
production. Although large quantities of ghee are fouling and hence heat transfer coefficient can
be maintained throughout the run of the system
made by this process, there is a long felt need of
a continuous plant. One of the ways is to adopt (10) easy capacity control (i 1) no foaming problem,
the established process for producing butter oil cream can be handled conveniently and (12)
economic operation.
involving centrifugal separation of moisture
followed by final dehydration under vacuum. IMPROVED METHOD
OF GHEE MAKING
However, the product would lack typic al ghee DEVELOPED BY PANCHMAHAL
DAIRY
flavour. (Pandya and Sharma,2OO2) Under Total Quality Management programme at
As an alternate to such system, a scraped Panchmahal Dairy, Godhra, a Small Group
surface falling film heat exchanger along with Activity (SGA) team was constituted which worked
auxiliary equipment such as a melting vat and on the improvement in production of ghee making
mechanical clarifier has been developed to serve with a special focus on reducing fat and
as a continuous ghee making plant. SNF losses.
Various approaches made for continu ous ghee Firstly, data analysis was done to identify
making were directed to achieve the following the losses areas, which occurred in ghee
salient features in the process viz. (1) high heat manufacture on a big scale. A brainstorming
transfer coefficient and hence compact design session was conducted on saving the serum solids
(2) better control on quality of product (3) only since fermentation of milk was not carried out

.5 i', Indian Dairyman, 58,8,2006

Ghee from GST
at 38-4OoC

I 5K6 MA}'IUAL TIN FILLER

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and only sweet serum separated out of The procedure was finalized with the
stratification tank. inclusion of a serum separator and a spiro-heater
. It was decided that a modification in normal in the process. The details of which are shown
procedure has to be done to recover fat and SNF in the flow diagram and block diagram. (Fig. l,
from sweet serum. To collect fat and SNF from Fig. 2 and Fig. 3).
serum, a serum separator was installed for melted . At first, fresh raw milk is received at raw
fresh butter so that SNF can be directly used in
milk receiving dock (RMRD) of the main dairy
market milk for standardization and fat plant, chilled and stored. This milk is subjected
percentage in butter be increased and sent to to cream separation after necessary
filtration and
butter melting vat and primary Settling Tank warming to 55-60"C in regeneration section of
(PST) and thereafter to ghee kettle. pasteurizer. Resultant cream is pasteurized, in a

Fig. 3: Process Steps of A llew, Modified Method of Ghee Manufacture

Pasteurized Cream
I

Continuous gutteY Makiag Machine

I

white butter from cBM gz '/" h!, tuttermilk o.z o/ofat,?.s % sNF

Positive screw driving ontt roY white butter to spiro-heater

I

spiral heater jacket type hot -"t"rV.i""olatlon at 6o o c to melt butter

Melted butter tanks with agitatof"oa hot water circulation jacket

I
Y
Serum separator

{Butter (90-95 o/o fatl to butter vat} Serum {O.8 % fat, 8.O yo SNF) to milk
Process section for standardizitionl
V
Primary Settling Tank
V
Ghee boillng at 113" C
(For usual ghee manufacture)
I

V
Ghee Clarifying at 95 " C
(To remove fine ghee residuef
I

V
Natural coollng of ghee to 50 " C
!

v
Ghee Settling tanks
v
Retall packlng

,&#: Indian Dairyman, s8.8.2006

 high temperature short time (HTST) plant at 9O- The benefits obtained by adopting the new method
92"C for 15 seconds, chilled to 1O-12'C and stored commercially are listed as under:
in insulated, jacketed, cream storage tanks. This o
cream is then pumped to Continuous Butter
Stean saving: Due to implementation of hot
water circulation in spiral heater to melt white
Making machine (CBMM) wherein white butter butter at 60oC, 250-3OO per cent steam was
is obtained. Resultant buttermilk along with saved. Secondly, in ghee boiler, water to be
serum from serum separator is chilled in a plate evaporated reduced drastically as serum solids
chiller and diverted for use in standardization of were removed by serum separator and
fresh milk. percentage of fat in melted butter increased to
White butter is pumped via screw conveyor as high as 95 per cent.
to spiro-heater where it is melted by circulating o Increased. ghee production: Using traditional
hot water. Melted butter is conveyed to tanks method for making one batch of ghee making
provided with agitator and hot water circulation takes about 4-30 hours whereas by using this
jacket from where it is subjected to serum method it takes 1-30 hours. Thus the same
separation. Serum is separated, chilled in a plate ghee vessels can be used for more number of
chiller and pooled with sweet buttermilk for use batch making.
in milk standardization. Melted butter with low
moisture and high fat and serum solids is o Saving ln Fat and SNF: Serum separated from
collected in a butter melting vat from where it is fresh white butter having 0.8 per cent fat and
pumped to Primary Settling Tank (PST) and then 8.0 per cent SNF was used in milk processing
continuously to different Ghee kettles (boilers) for for standardization.
ghee manufacturing in a norma-l way during which o Reduced Load on ETP: Because of serum
residual moisture is evaporated at 113"C. separation, SNF in melted butter reduced; so
After some holding, ghee clarifrcation is done quantity of serum residue in the effluent also
at 95"C through a ghee clarifier to remove fine decreased to a great extent.
particles of residue. Clarified ghee is pumped to o Hygienic condition: As the circuit for heating
ghee settling tanks where ghee is cooled with through Plate heat exchanger and conveying
water circulation to 50'C. At this stage, a sample melted butter is totally closed and a continuous
is withdrawn for analysis with respect to chemical one, the hygienic condition in the glrce section
constants and physical attributes before allowing was dramatically improved.
it for packing into retail containers.
e Delight in working conditlon: There was visible
The ghee made by this process is fetching delight in the operators and workers of the
premium price in the market. Last year Ghee section because less scraping in ghee boilers
export was worth Rs. 50 million. was to be done due to less ghee residue. Ghee
ADVANTAGES OF MODIFIED METHOD OF filtration was a-lso fast and efficie,nt and. ghee
GHEE MANUFACTURE batch gets ready in half the time as compared
The quality of ghee made by this new method to earlier method. Work of Shop floor got reduced,
was studied with respect to marketability as section does not get that much soiled as
involving the tests like colour, flavour, texture earlier.
and other chemical constants. A11 were found to o Overall savings: As per this estimate, an annual
be at par with Agmark standards. The team of saving amounting to Rs.190 lakhs could be
sensory panelists also carried out the organoleptic obtained by way of saving in fat/SNF, steam,
evaluation and no difference in comparison with electricit5r, man-power, water, hygiene, house-
earlier method of ghee manufactuie was observed. keeping, etc. The saving was calculated by
Hence, it was decided to adopt the new considering 12000 kg. of ghee per day made in
manufacturing process. all 365 days of the year (Table 3).
 Table 3: Savings obtained by rnnovated Method per Tonne of Ghee

*"*'
ffi,:;.:,.';l
Steam consumption Rs.9O0 Rs. 300 Rs.600
SNF recovery Nit Rs. 750 Rs. 750
Fat loss Rs. 3000 Nil Rs. 3000
Total savings Rs. 4350
Savings per year/tonne Rs. 15.88 lakhs
Net Profit to the plant Rs. 190.56 lakhs
per annum (12 tonne per
day capacity)

o Ghee made by this process has no residue other
than ghee fat. Since last five years the
Panchmahal Dairy is making ghee using this Aneja, R. P., Mathur, B. N., Chandan, R. C. and
innovated process. Banergee, A.K. (2002).
o The average test parameters of ghee made by
this process were: Moisture 0.18 per cent, Free
fatty acids 0.16 per cent as oleic acid, Reichert
Meissl (RM) value 32, Polenske (p V) value 1.6,
Butylorefractometer (BR) reading at 4O"C is 41-
42 and Baudouin's test negative.
ACKNOWLEDGMENT
I dedicate this article to Prof. (Dr.) S.H. Vyas,
former Principal Scientist & Head Dairy
Technologz Division, Sheth M.C. College of Dairy
Science, Anand, Gujarat on his 85th Birth Day.
REFERENCES
Abhiclnndani.. H., Bector B.S. and Sarma S.C. (1gg1)
Continuous ghee making sgstem - design,
operation and performance. Indian J. Dairg
Sci. 48 (17): 6a6-650.
Aneja, R.P. and Murthi,T.N. (1990). Conjugated
linoleic acid contents of Indian curds and ghee.
IndianJ. Dairg Sci. 43 (2): 231-238.
TechnologA of Indian
Mitk Products. Dairg India Yearboo,k. (Eds.
Gupta P.R.). Neu: Delhi p3-33 and p1B3-190.
Bhatia T.C. (1978) Ghee making utith centifugattg
separated butterfat and serum. M.Sc. Thesis,
Kurukshetra Uniu e rsitg.
Pandga A.J. and Sharma, R.S. (2002) Ghee - its
Chemistrg, Technologg and Nutrition. An
Oueruieut. Paper presented at National Seminar
on "Role of Pure Ghee in Health and Nutrition
" dated 13-14 June 2002, page 1-14.
Punjrath J.S. (1974) New deuelopment in ghee
making. Indian Dairyman 26 (7): 2ZS-228.
Rajorhia, G. S. (1980) Aduances in the preseruation
of ghee and regional preferences for quatitg.
Indian Dairyman 32: 745-750.
Rajorhia, G. S. (1993) Ghee and Anhgdrous milk
fat. In Encgclopaedia of Food Science, Food,
Technologg and Nutition. VoL4. p 2186-2192
Pub. Academic Press, London.

$:',*r Indian Dairyman, 58,8,2006

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