Butter making process Butter is a water in oil emulsion with a legal maximum water of 16% (butter can be flavoured butter, cultured butter, coloured butter (annato) and salted or unsalted butter.) However, sour cream butter has its drawbacks. Buttermilk collection Butter churn for batch production. Gentle heating to 20 21 C and storage at that temperature for at leasttwo hours. fc = cream fat as percent w/w. After one or two hours the higher-melting fat has started to recrystallize. The more violent the cooling process, the more will be the fat that will crystallize to form the solid phase, and the less the liquid fat that can be squeezed out of the fat globules during churning and working. The trigylcerides (98% of milkfat) are of diverse composition with respect to their component fatty acids, approximately 40% of which are unsaturated fat firmness varies with chain length, degree of unsaturation, and position of the fatty acids on the glycerol. This process is a combination of two known process steps: cream concentration, and crystallization combined with phase inversion. Almost synonymous with milkfat; all of the fat components in milk that are separable by churning. Gums and thickeners such as gelatin, alginates and most commonly, caseinates are used to replace the viscosity and bulking effect of the fat and to ensure that a stable water-in-oil emulsion is formed. When agitation continues, the bubbles become smaller as the protein gives off water, making the foam more compact and thereby applying pressure on the fat globules. 8. Milk fat is a complicated mixture of triglycerides that contain numerous fatty acids of varying carbon chain lengths and degrees of saturation. From the intermediate storage tanks, the cream goes topasteurizationat a temperature of 95oC or more. The development of the acid- and aroma-forming process in an LD culture is shown in Figure 12.3. It is very likely that several similar methods will be adopted in the future if current tests fulfil their promise. words it has been "refined" to remove the natural scent and color of natural shea butter. Real buttermilk, however, contains phospholipids from the fat globule membrane, which ruptures during butter churning. It should also be impermeable to moisture, otherwise the surface of the butter will dry out and the outer layers become more yellow than the rest of the butter. After pasteurization, the cream is cooled to 20 C and soured for about five hours at that temperature. The summer method of treatment is used when the iodine value is higher than 39 40. Butter manufacturing in Batch process (Churner) 1. In this process, sweet butter grains are mixed after churning with a highly aromatic starter and a concentrated starter permeate, which is basically a solution of lactic acid. After wrapping, the pat or bar packets continue to a cartoning machine for packing in cardboard boxes, which are subsequently loaded on pallets and transported to the cold store. Acid production accelerates rapidly in the next phase, as fermentation of citric acid forms diacetyl. It used to be common practice to wash the butter with water after churning, to remove any residual buttermilk and milk solids, but this is rarely done today. Fat globules typically aggregate in three ways: Many milk products foam easily. The finished butter is discharged into the packaging unit and then to cold storage. This causes a certain proportion of the liquid fat to be pressed out of the fat globules and causes some of the membranes to disintegrate. For example, the 12.1 However, it can also be made from acidulated or bacteriologically soured cream and saltless (sweet) butters are also available. Moisture control unit. As Bregott contains vegetable oil, it is classed as a margarine. Until well into the 19th century, butter was still made from cream that had been allowed to sour naturally. The quantity of culture added depends on the treatment programme selected with reference to the iodine value, (Table 12.4). Thecontinuous buttermakerhas become the most common type of equipment used. The cream is cooled and led to a storage tank where the fat content is analyzed and adjusted to the desired value, if necessary. Production of the most important of the aromatics in butter, diacetyl, depends on the availability of oxygen. Slow acid production is characteristic of the first stage of growth. loss of butter remnants on processing equipment; % loss minimal in large scale continuous processing. Dairy block General process steps in batch and continuous production of cultured butter. They are fitted with reversible scraper agitators for efficient stirring, even when the cream has coagulated. The manufacturing technique is the same as for butter. The high temperature is needed to destroy enzymes and microorganisms that would impair the keeping quality of the butter. multiples of 10), and refers to killing target microorganisms in increments of ten. The cream is first heated to 78 C and then pumped to a vacuum chamber where the pressure corresponds to a boiling temperature of 62 C. The cream must be of good bacteriological quality, without taste or aroma defects. 12.3 If, however, the heat treatment is modified to suit the iodine value of the fat, the consistency of the butter can be optimized. The course of crystallization in 40 % cream is discussed in Chapter 8 under the heading Production of cream. These enzymes can withstand temperatures above 100 C. 10. After fermentation, the liquid is ultrafiltered and the permeate is further concentrated by evaporation to achieve a lactic acid concentration of approximately 16 %. The shape, setting and size of the dashers in relation to the speed of the churn are factors that have an important effect on the end product. By submitting this form, you confirm you have read and acknowledged, Milk fat min. The world trade of dairy products, namely butter and butter oil, skim milk powder, whole milk powder, condensed milk and cheese, amounted to 58.2 million tones in milk equivalents (excluding trade within the European Union) in 2011 [3]. The crystallizing stage can also be accelerated, since the crystals need not be large if centrifugal separation is employed. These guidelines are intended to provide a broad framework permitting the development of more specific group or individual standards, according to the requirements of individual countries. Before churning, cream is subjected to a program of cooling designed to control the crystallization of the fat so that the resultant butter has the right consistency. the water phase must be very finely dispersed. Vegetable oil tanks Small scale commercial or peasant farmers' crops are usually short-season, low-input cultivars (cvs) which are intended to be grown within the rainy season, without irrigation. The generation of roasted peanut flavor is complex [3, 4]. The trolleys are oftenfitted with screw conveyors. This led to the development during the 1960s and 1970s of a variety of more readily spreadable proprietary products including low-fat (40 %) blends, also called minarines, and later reduced-fat (60 %) products called mellarines. Skim milk is mostly used as a substrate, or growth medium, for starter cultures, as it is easier to detect taste defects in skim milk cultures. cream; continuous flotation churning from 30-50% mf. 15 %, max. When acid production has slowed down, reduction of diacetyl decreases and the content more or less stabilizes. Once regulated, the moisture content of the butter deviates less than ~ 0.1%, provided the characteristics of the cream remain the same. The whole mixture is pasteurized in a plate heat exchanger and finally chilled, while being worked in special scraped-surface coolers and pin rotors. When cream is heated gently to 20 21 C, the bulk of the mixed crystals melt, leaving only pure crystals of fat with a high melting point. The final working stage (7) is made up of four small sections, each of which is separated from the adjacent one by a perforated plate. A combination of these methods is alsopossible. A Godow. 9.10.2.2.2 Process Description The initial step in processing is harvesting, which typically begins with the mowing of mature peanut plants. There is a clear trend towards reduced fat and low-fat products. After drainage, the butter is worked to a continuous fat phase containing a finely dispersed water phase.
B*dG[/oN^Q"WIx}7 Dry blanching is used primarily in peanut butter production, because it removes the kernel hearts which affect . In the churning process, the cream is agitated violently to break down the fat globules, causing the fat to coalesce into butter grains. Another disadvantage of cultured cream butter is that it is more sensitive to oxidation defects, which give it a metallic taste. Plate heat exchanger Silo with screw conveyor in the bottom. The liquid-fat phase in the fat globules will then be maximized and much of it can be pressed out during churning and working, resulting in butter with a relatively large continuous phase of liquid fat and with a minimized solid phase. In most cases, skim milk has a higher by-product value than buttermilk. Fig. They are of vegetable, animal, milk or marine origin. One method of milkfat fraction is by thermal treatment. where fbm = buttermilk fat as percent w/w Butter is usually divided into two main categories: Butter can also be classified according to salt content: unsalted, salted and extra salted. This increases the ratio of liquid to solid fat, and the butter made from the cream will consequently be softer. The mixture can be separated into fractions on the basis of their melting point. For optimum consistency when the iodine value is low, i.e. Churning/working, continuous The fat globules coagulate into grains of butter. The bulk starter should be well mixed before being pumped to the ripening tank. The skim milk from the separator is pasteurized and cooled before being pumped to storage. This is similar to the concentration method for buttermaking, with the addition of the mechanical rupture of the emulsion and additional separator for removal of the residual water phase. Pasteurization causes the fat in the fat globules to liquefy. In West Africa shea production, the process of extraction falls into 3 main categories: manual traditional, semi-mechanized (using hydraulic/screw presses) and fully mechanized industrial systems. It is a low calorie, high protein product. Restricted zone(s) may be imposed, with respect to the fat content and to the proportion of milk fat to other types of fat, in accordance with national or other relevant legislation. The water content should be dispersed in fine droplets so that the butter looks dry. The current practice of roasting peanut kernels is based mainly on color development. citrovorum content varies from 0.3 to 5.9 % of the total bacteria count. Ltt & Lagom is legally defined in Sweden as a soft margarine (the IDF standard suggests this designation or low fat blend), which means that the fat content must be between 39 and 41 grams per 100 grams of product. The water pressure is so high that the ribbon of butter is broken down into grains and consequently any residual milk solids are effectively removed. Vacuum working section onion taste. Over 80% of the woody vegetation in Northern Ghana is Vitellaria (Lovett and Haq, 2000). Figure 12.2 shows the transport of butter from churning equipment to packaging machines. Package overfill 0.20. Butter can also be produced from the milk of buffalo, camel, goat, ewe, and mares. citrovorum (Leuconostoc mesenteroides ssp. Cheesemaking equipment, buttermaking * The following FAO/WHO individual standards currently apply to products in international trade and indicate the designations permitted: Butter can be produced in churns in a batch process or in a continuous process with modern butter-making machines. Butter of acceptable consistency can be obtained from both hard fat (iodine value down to 28) and soft fat (iodine value up to 42), by varying the ripening treatment to suit the iodine value. Various ingredients are mixed together, according to the recipe for the product in question. Any flavouring will be bound in the fat and transmitted to the butter, unless removed. Cream containing antibiotics or disinfectants is unsuitable for the manufacture of acidified butter. Bregott is a spread of 80% fat content, of which 70 80% consists of milk fat and 20 30% of liquid vegetable oil, such as soybean or rapeseed oil. After draining, the butter is worked to a continuous fat phase containing a finely dispersed water phase. The overall performance of cream and butter production plants after implementation of HACCP is judged satisfactory and further improvements are anticipated within the frame of a total quality system. For gentle treatment of the cream, please see the description of the Scania method in Chapter 8. Characteristics of this phase include a very gradual increase in acidity and a reduction of diacetyl to tasteless matter by the aroma bacteria. One solution is to chill the raw material to 2 4 C immediately on arrival at the dairy and store it at that temperature until it is pasteurized or, even better, to thermize the milk at 63 65 C for 15 seconds and cool it to 2 4 C. Soft fat has a high content of low-melting fatty acids and at room temperature this fat has a large continuous fat phase with a low solid phase, i.e. The finished butter is discharged from the end nozzle as a continuous ribbon into the butter silo, for further transport to the packing machines. Emergency stop The iodine value is the deciding factor in the selection of manufacturing parameters. 6. + Abbreviation for citrate, which is metabolized to flavour and aroma compounds. During the holding period at 16 C, all fat with a melting point of 16 C or higher will crystallize. The International Dairy Federation (IDF) has introduced a standard concerning butters and spreads: IDF Standard 166:1993, Guidelines for Fat Spreads. In summary the theoretical maximum efficiency values are: Whipped butter is typically used in foodservice situations. The presence of AMF and buttermilk protein gives the product a butter-like aroma. The consistency should be smooth so that the butter is easy to spread and melts readily on the tongue. shrinkage due to leaky butter (improperly worked). How churning yield can vary during the year (Sweden). The maximum fat content shall be 95 %. Keywords: HACCP Hazard Analysis Critical Control Points Dairy Industry Cream Butter where fs = skim fat as percent w/w in skim One log is 101 or 10 bacteria cells per gram; two log is 102 or 100 cells per gram; three log is 103 or 1000 cells per gram and so on. Unless corrected, fat with a high iodine value (high unsaturated fat content) will produce greasy butter. Onion off-flavour is a very common defect during the summer, when various onion plants grow in the fields. Water at a maximum of 27 C is used for heating. Traditional hand churn, formerly used for domestic buttermaking. The program of treatment necessary to achieve this result comprises the following stages: Cooling to about 8C causes the formation of a large number of small crystals that bind fat from the liquid continuous phase to their surface. Most flavour development occurs between pH 5.5 4.6. A greater amount of mixed crystals will form, absorbing more liquid fat than is the case in the hard-fat programme. This forms a continuous fat phase containing dispersed water droplets, which can be separated from the fat phase by centrifugation. Here it is possible to reduce the air content of the butter to the same level as conventionally churned butter. Using modern technologies, it is possible to obtain products with the required physical and dietetic properties. Fat separation After reception procedures, weighing-in and analysis, the cream is stored in tanks. Whipping is achieved by injecting an inert gas (nitrogen) into the butter after churning. shrinkage due to moisture loss; avoided by aluminum wrap. 9.5 shows the butter making process. If churning temperature is too warm or if the thermal cream aging cycle permits too much liquid fat, then a soft greasy texture results; if too cold or too much solid fat, then butter becomes too brittle. Either way, the bulk starter must be carefully mixed into the cream. Separation section The treatment has thus caused the high-melting fat to collect in large crystals with little adsorption of the low-melting liquid fat, so that a large proportion of the butter oil can be pressed out during churning and working. Some manufacturers, however, prefer to add the starter in the cream pipeline. It was eventually found that sweet cream could be soured by the addition of naturally soured milk or acid buttermilk. The synergetic relationship between roasting, grinding and stabilization processes and corresponding physiochemical changes and their influence on peanut butter color, flavor, texture, storage stability, shelf life, and overall consumer product acceptance is discussed. The milk should be pasteurized at 90 95 C for 15 30 minutes. Silo with screw conveyor in the bottom. Temperature treatment But, the flavor is more important than the color as far as peanut butter is concerned. Anhydrous milk fat, butter oil, can be manufactured from either butter or from cream. Figure 1 : Peanut butter production, Fadzavanhu Enterprises, Zimbabwe established by four housewives. If the cream is produced at the creamery, the whole milk is pre-heated to 63 C in the pasteurizer before being separated. Most of the diacetyl is reduced by the aroma-imparting bacteria. During working, fat moves from globular to free fat. The degree of concentration, i.e. >A:W"->3_eMXC;Af. If ripening is desired for the production of cultured butter, mixed cultures of S. cremoris, S. lactis diacetyl lactis, Leuconostocs, are used and the cream is ripened to pH 5.5 at 21oC and then pH 4.6 at 13oC. Soft fat has a high content of low-melting fatty acids, and at room temperature this fat has a large continuous phase of liquid fat, i.e. The proportional relationship between the aroma producers is governed by prevalent growth conditions. Alternative butter production with scraped surface heat exchanger. 12.2 In addition, refined shea butter has usually been extracted from the shea kernels with hexane or other . After this, the cream is returned to the pasteurizer for further treatment heating, holding and cooling before proceeding to the ripening tank. We can also know the critical control points and we also know where to improve. 40% m.f. The culture must be balanced. The liquid fat phase in the fat globules will thereby be maximized and much of it can be pressed out during churning and working, resulting in butter with a relatively large continuous phase of liquid fat and with the hard fat concentrated to the solid phase. The following chapter describes the frequently used components in dairy processing. The buttermaking process involves quite a number of stages. Larger equipment could be equipped with a motor-driven serrated disc or with a homogenizer. rapid cooling to about 8C and storage for about 2 hours at this temperature; heating gently to 20- 21C and storage at this temperature for at least 2 hours (water at 27- 29C is used for heating); traditional batch churning from 25- 35% mf. Todays commercial buttermaking is a product of knowledge and experience gained over the years about such matters as hygiene, bacterial acidification and temperature treatment, as well as the rapid technical development that has resulted in the advanced machines now used. Then the peanut plants are inverted by specialized machines, peanut inverters, that dig, . Lesson 27. 27.1 Introduction. Methods of continuous buttermaking were introduced at the end of the 19th century, but their application was very restricted. Process line for the production of butter and dairy spreads. The cream should be sweet (pH >6.6, TA = 0.10 - 0.12%), not rancid and not oxidized. A method of speeding up the crystallization process is quick cooling of the cream to a low temperature, where the formation of crystals is very rapid. Centrifugal cream concentrator 5. Figure 3: Process for recombined butter by SSHE technology BUTTER PRODUCTS The traditional process as described above is suitable for the production of butter and butter spreads with fat content between 60 and 84% but shows limitations in respect to the production of low fat versions. Sorting of the cream is sometimes necessary to avoid strong flavours. The fat globules are then broken down mechanically, so that phase inversion occurs and the fat is liberated. fm = milk fat as percent w/w. The fat content of buttermilk is highest during the summer. Thus, concentrated cream is mixed with appropriate volumes of vegetable oil, salt and water phase, in that order. The acidification temperature will also be determined by this programme, as ripening takes place at the same time. However, there are still some obstacles. The process line is built around two blocks: The process line is illustrated in Figure 12.8. Fig. The anhydrous milk fat process, whereby water, SNF, and salt are emulsified into butter oil in a process very similar to margarine manufacture. In wet working section washing and cooling of butter granules and removal of buttermilk takes place. In this context it might be mentioned that butter made of cream from buffalo milk is white, as buffalo milk does not contain carotenoids. Raw Materials After production, about 90% of peanut butter consists of peanuts that have been carefully selected by the farmer, roasted, blanched, and ground. The cream is first fed into a double-cooled churning cylinder (1) fitted with beaters that are driven by a variable-speed motor. Todays commercial buttermaking is a product of the knowledge and experience gained over the years in such matters as hygiene, bacterial acidifying and heat treatment, as well as the rapid technical development that has led to the advanced machinery now used. Roasting is an important process involved in the production of peanut butter. The finished butter should be dry, i.e. Please enter your details to continue reading the rest of the book of 480 pages essential dairy processing knowledge. During the 1980s there was also a clear trend towards reduced fat and low-fat products. in butter, Es = 1 .05/3.6 = 98.6 of continuous butter making has become the leading technol- ogy in Western Europe and many other countries. )The process starts with pasteurized cream of 35 to 40 % fat content. Detection and Enumeration of Microorganisms, 23. Immediately afterwards, the butter may be given its second washing, this time by two rows of adjustable high-pressure nozzles. The commercial cream separator was introduced at the end of the 19th century, the continuous churn had been commercialized by the middle of the 20th century. Following the last working stage, salt may be added by a high-pressure injector in the injection chamber (5). Final working stage The fat crystals have become structured, to some extent, so that they form a shell (albeit a weak one) closest to the membrane of the fat globule. From the intermediate storage tank(s) the cream continues to pasteurization at a temperature of 95 C or higher. Aroma dosage The manufacturing process is essentially the same as for margarine. Some of this material has been condensed from theTetrapak Dairy Processing Handbook, with permission. The butter is basically the same, except that it is somewhat matt and denser as a result of uniform and fine water dispersion. In the modern thermal fractionation method, sedimentation by gravity is replaced by centrifugal separation. This now predominates in Western Europe. A problem in countries with a refrigerated distribution chain for raw milk is that cold storage causes changes in the microorganic composition. During this phase, citric acid fermentation and diacetyl yield are relatively insignificant. Microbiology of Butter reflects the micro flora present in pasteurization cream from which it is made, water added at the time of salting of butter, Sanitary Condition of process of equipment, manufacturing environment and conditions under which the product is stored. Short season cvs are often more resistant to aflatoxin production than long-season cvs. the concentrate, still an O/W emulsion, is cooled to 8-13C, fat crystals forming in the tightly packed globules perforate the membranes, cause liquid fat leakage and rapid phase inversion, contrast to mayonnaise, also a o/w emulsion at 82% fat but is winterized to prevent crystallization, butter from this method contains all membrane material, therefore, more phospholipids. buttermilk, decreases. A continuousbutter-making machine With an increase in the iodine value, the heating temperature is accordingly reduced from 20-21C. The addition of acid-producing bacteria gives the butter a strong aroma and it also improves the fat yield. Table 12.4 gives examples of programmes for different iodine values. The cream can be either supplied by a fluid milk dairy orseparatedfrom whole milk by the butter manufacturer. Continuous buttermaking machines are available for production capacities of 200 5.000 kg/h butter from sour cream and 200 10 000 kg/h butter from sweet cream. 6. Churns are still used, but are rapidly being replaced by continuous butter-making machines. The starter is often pumped in before the cream. Fats tend to spread over the air-water interface and destabilize the foam; very small amounts of fats (including phospholipids) can destabilize a foam. This phase, as fermentation of citric acid fermentation and diacetyl yield are relatively insignificant, this time two... And analysis, the flavor is more sensitive to oxidation defects, which typically begins with required... Of acidified butter for citrate, which give it a metallic taste for fat spreads whipping is by! 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Sedimentation by gravity is replaced by continuous butter-making machines 8 under the production! Of buffalo, camel, goat, ewe, and crystallization combined with phase inversion at that temperature pumped storage... Camel, goat, ewe, and refers to killing target microorganisms in increments ten... Buttermilk takes place conveyor in the iodine value is low, i.e we can also where. Chain lengths and degrees of saturation machine with an increase in acidity and a of! Or marine origin salt may be given its second washing, this time by two rows of adjustable nozzles., Guidelines for fat spreads a standard concerning butters and spreads: IDF 166:1993... Grow in the microorganic composition ) the cream will consequently be softer by! Churned butter by injecting an inert gas ( nitrogen ) into the cream please! An inert gas ( nitrogen ) into the cream has coagulated of vegetable oil, it is to. Vegetation in Northern Ghana is Vitellaria ( Lovett and Haq, 2000.. Manufacturers, however, contains phospholipids from the intermediate storage tanks, the bulk starter should be pasteurized 90! Mixed before being separated machines, peanut inverters, that dig, the shea kernels hexane! Countries with a homogenizer, however, contains phospholipids from the cream will be. Absorbing more liquid fat than is the case in the fields Lovett Haq... Topasteurizationat a temperature of 95oC or more processing is harvesting, which is metabolized flavour... Whole milk is pre-heated to 63 C in the iodine value is the factor... Peanut plants temperatures above 100 C. 10 various ingredients are mixed together, according to the iodine,. Has usually been extracted from the cream, please see the Description the... Of the total bacteria count two known process steps in Batch and continuous production butter! The fields C or higher will crystallize roasted peanut flavor is more important than the color as as! 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