Associate Professor

Deptt. of Dairy Sc. & Tech. (Fromerly A.H. & Dairying)

R.K. (P.G) College

 Shamli, U.P., India 

Butter - When milk or cream is gently agitated the fat particle aggregate to from granules which on bulking from a consistent mass is known as butter.

Actually butter is a conversion of cream fat from fat in water emulsion to water in fat emulsion from during churning process.

Composition - Butter Contain 80-83% fat, 15.5-16.0 moisture, 0-3% Salt and 1 to 1.5 curd.

Method - Normally too methods are in practices for the manufacturing of butter.

1.     Indigenous Method - Butter made by this method called as Makhan, It contain high level of water and lactic and where it processes fat lower than its legal standard. Firstly Dahi is made from milk, then it is transferred to a wide mouthed earthen pot and churnd with the help of wooden hurner. During churing process small quantity of cold water in summer season and warm water in winter season is admixed so that dahi is diluated and desired temperature is achieved. The process makes fat globules stick together to form butter in granules and butter milk gets separated, then Makhan is started rising to the top and floats on the surface. Now the Makhan is collected by hands and is storage in another pot.

The Makhan Contain 18-20% moisture, 70-80%. fat, 1.0-15 Curd and 0.15 to 0.20%. lactic acid.

2.     Creamery/Scientific Method

Details of Butter manufacture

1. Receiving Mick & cream - Milk and cream received should be at 5'c or below and free from extraneous materials and off flavours.

a. Grading - Milk- sensory grading is generally supplemented with sediment, M.BR and acidity test.

Cream- Cream is graded based on appearance, flavour, smell testy and acidity test. cream is graded as follow.

1^st Grade- sweet or slightly sour acidity <0.20%

2^nd  Grade - Sour and coagulated acidity 0.2 to 0.6%

3^rd  Grade- Markedly (acidity > 0.6%) or fermented.

b. Weighing - Weighing Machine are: Plate form balance and spring balance.

c. Sampling - Before sampling, the cream in the can is thoroughly mixed by a combined rotary and vertical movement of the plunger.

d. Testing- The sample of milk or cream are tested for fat, solids-not- fat, acidity etc. using standard test.

2.    Neutralization of cream- The standardization of acidity as desired level is known as neutralization" or ‘‘partial reduction in its acidity’’. if butter for long storage cream should contain 0.06-0.08% acidity and if the butter  for early consumption after manufacturing cream, should contain 0.25 to a 0.30%, acidity.

Objectives:

(a)   To reduce the acidity in cream to a point (0.14 to 0.16%)

(b)   To check fat losses in butter milk.

(c)    To enhance the aroma and flavours in the butter .

(d)   To improve the keeping quality of butter.

Type of Neutralizers- Soda- Na₂Co₃, NaHCO₃, NaoH

Lime - Cao, Ca(oH)₂ Mg (OH)₂, CaCo₃

Neutralizers Factor (N-F) - The amount of an alkali required to neutralize one kg of lactic is called N.F.

N.F. Lime Cao 0.311, Ca(OH)₂  0.411, Mg(OH)₂ 0.322, CaCO3 0.55

Soda- Na₂Co₃ 0.59, NaHCO_3, 0.93 NaOH 0.44.

Double neutralization with lime and soda - The sequence as are 1.  First used lime neutralizer to bring the cream acidity down to 0.3-0.4%

2. Next use soda neutralizes to bring the cream acidity down to the  denied level.

3. Standardization- For making butter cream Containing 35 to 40%. fat is used.

4. Pasteurization - The butter manufactured from pasteurized Cream increases its self life dues due to destroy the  pathogenic and undesirable micro flora in cream and inactive the enzyme present.

Pasteurization method –  pasteurization consist three method.

a.     Low Temperature Long Time (LT.LT)  Method-  Cream heated at 74°C for 30 minute and then Met the cooled at 20-22°

b.    High Temperature short time (HTST)- cream heated at 85’C  for 15 seconds  and then cooled  at 20-22’C.

c.     Vacreation - In His method direct steam is injected to heat the cream to a suitable temperature after pasteurization the cream is cooled at 20°C temperature. During vacreation sourness and all volatile off-flavor of cream are expelled out through vapors.

5.  Ripening of Cream - Develop acidity (fermentation) in cream with the use of desirable starter culture is referred to as  Ripening of cream. The purpose of ripening of cream before churning are to prepare butter with a desirable pleasing flavous and aroma and to reduces the fat looses in butter milk during churning. Starter culture is added @ 0.5 to 2% at 22°C temperature until the acidity develops 0.2 to 0.4%  Starter culture Contain two types of bacteria:

a.      Lactic acid producing (Str. lactic and Str. cremoris)

b.    Aroma producing - (Str. diacetilactis, Leuc. citrovorum and Leuc. dextranicum)

These aroma producing bacteria produce Diacetyl and Acetyl Methyl carbinol which are directly responsible for typical flavour.

6. Cooling and Ageing - Fat present in both solid and liquid state in the form of fat globules in cream. During pasteurization process the solid form of fat is melted to liquid fat and thus the proportion of liquid fat increases cream containing more liquid fat does not churm properly hence it is essential to cool the cream at 20-22°C and store it at chilling. temperature at 5-10°℃ for sometime so that partial resolidification of the melted fat takes place. To produce butter gains the cream has been properly cooled and aged at 5-10°C for 2 to 4 hours preferably 15-16 hours.

7.  Preparation of Churn for loading with cream

Churning -  Charming Before the start of the Churning operation the butter churn it should be properly washed with clean water than with hot 2% soda solution using brush and finally with hot water at 71°c The optimum load of cream with the Churn can take seems to be between one half and one-third its total capacity of churn.

8. Addition of colour - Before churning the butter colour (4-8 drop per kg of cream) is added to cream and door of the churn is closed.

Vegetable colour - Annatto made by annatto seeds heated in oil for several hours.

Mineral Colour – Coal tar dyes are mixed with oil, boiled and filtered Yellow A.B, Yellow O.B.

9.  Churning of cream - The churning containing at certain temperature is cooled and is revolved gently and then provided light stocks. When mirror becomes clear the butter has been prepared and this point is referred ‘’Breaking stage’’. At breaking stage fat separates from the skim milk in the form of small butter granules of pin-head size. It is some time necessary to add break water at this stage to reduce the temperature of the churn contents. and thereby control the body of the butter. The amount and temperature of break water depend upon the temperature, reduction required. After the breaking stage, the churning is continued until the butter grains are of the desired size which is Pea size in 1/8 to 1/4" diameter in large churns.

10. Washing - When spy-glass of the churn becomes clear or transparent butter churn is stopped and butter milk is removed from the churn using a butter sieve. Now the butter is washed twice using water having temperature 2-3 °C less than the temperature of butter milk. After addition & wash water the churn is again rotated few revolution and then the water is drained out. Collect the butter granules with the help of butter scoop and put on the cleaned butter worker for next operation.

11. Salting of butter. The salt should be good quality with while coarse grain.it should be from any extraneous insoluble matter and also chemically pure.

 "The addition of common salt (sodium chloride) to butter is referred to as salting of butter'

Objectives-

a.     To improve the keeping quality (Microbiologically and chemically).

b.    To enhance taste and flavour and offers Consumer desireness with satisfaction.

c.     To increase over run of butter.

Common salt is added into butter at the rate of 2 to 2.5% of amount of fat in butter for churning. In country. according to FSSR (2011) maximum permissible limit of common salt in butter is 3 percent.

Method of salting

Dry salting - Most common method Estimated, amount of salt is sprinkled our the surface of butter during working wet salting - common salt is dissolved in the least amount of portable water and then it is sprinkled over the butter during working process.

Brine salting - In this method, the salt is added on the form of saturated brine solution, hence can be used only where lightly salted butter is to be required.

12. Working of butter

 This refers to the kneading process of butter in which butter grains are formed into a compact. mass for convenient handling and packaging.

Objectives

a.     To completely dissolve and distribute the salt evenly.

b.     To expel as much of the butter milk and moisture as possible.

c.      To archive butter into proper firm shape for packaging.

The working process continued until the butter attains. a compact body should be a tough wary texture with closely- Knit granules, and an uniformarly  distribution & salt and moisture content.

During the working process, the temperature should be controlled. Over working damages the body and texture while under working produces leaky butter, working incress the air Content of butter. The normal air content is 0.5 to 10 ml (an average 4.0ml) per 100 gm. of butter. It is important because its affects the density of butter and its microbial and oxidative spoilage.

13. Packaging

Objective – These includes

a.     To protect butter against contamination with yeast, mould, and bacteria.

b.    To protect the butter against of degradation resulting development of off flavor.

c.      To escape loss in weight during storage of butter (due to evaporation process)

d.    To resist corrosion and de-lamination.

e.     To provide a convenient form of disposal and increases sale.

f.     To identify the product and appeal to the consumer.

g.    To protect against mechanical damage.

Properties of packaging materials

a.     It should be moisture and grease proof.

b.    It should have good strength and impervious to light.

Packaging materials include:

a.     Parchment or butter paper.

b.    Wax coated paper.

c.     Cellophane

d.    Aluminum foil laminates.

e.     Cardboard boxer

f.     Tin-plate cans.

Techniques of packaging

a.     Machine molding and wrapping.

b.    Mechanical moulding patting and wrapping.

14. Storage

 Butter is stored at -23°c to -29°C

Butter Defects- The common defects in butter, their causes are given below.

1.     Aroma and flavour defects-  

a.     Flat- Caused by unripened cream neutralizing to too low acidity and also excessive, washing of the butter.

b.    Bitter - Caused by growth of proteolytic’ bacteria in cream, lipase activity during cream separation and it take of butter - weeds by milch animals.

c.     Cooked- Due over heating of cream during pasteurization process.

d.     Fishy- Butter with high acidity is stored in presence of copper. and iron, in commercial cold storage.

e.     Yeasty - Using old yeasty cream for churning.

f.     Sour- use of cream with high acid or improper neutralization.

g.     Feedy/Weedy - Feeding of milk tainting fodder or weeds. to much animal within three hours before milking.

h.     Rancid- Causing flat hydrolysis with lipase action in milk of cream under poor storage Conditions.

Body & Texture

a.     Weak-caused by insufficient cooling and ageing of Cream and churning at too high temperature.

b.     Sticky over working of crumbly butter.

c.      Greasy over working and excessively high temperature wash Water.

d.     Leaky - Under working of butter, Excessively high churning temperature of cream and use high temperature of wash water, Incorrect cooling and ageing of cream.

e.     Gummy-High proportion of high melting points fat use.

f.     Gritty- Incorrect salting, undissolved coarse salt butter.

g.    Crumbly- Under Working of butter, seasonal change. In fat composition, sudden chilling of butter soon after production.

Colour defect-

a.   Bleached butter-due to oxidation of fat.

b.  Mottled- Due to inadequate washing of butter grains, Inadequate working of butter.

c.   Dull/Pale - Due to over working of butter.

d.  Streaky - Uneven working.

References

1.      Jauhar I.J (1989) Market Milk and Milk Product Singhal Book Depot. Baraut (Baghpat).

2.     Ahmed Tufail (1990). Dairy Plant Engineering Management Kitab Mahal, Allahbad.

3.     Achya, k, Rangappa. K.S.(1984) The Chemistry and manufacture of indian dairy products 2^nd  Editions.

4.     Sangwan KPS (2008) Dairy Science & Technology Kalyani Publishes.

5.     Aneja, RP, Mathur, B.N. Benerjee A.K, and Chandan, R.C (2002) Technology of indian Milk products A Dairy india Pub, Delhi.

6.     Jawhar I.J  and Gupta Ram ji (2021) Food Processing and safetey issue, Rama Publishing House. Meerut.

7.      Jadish Prasad - Animal Husbandry and Dairying (2011) Kalyani Publishers.