The document describes the butter making process. It defines butter according to FSSAI and PFA and provides the standards for table butter. The process involves standardization, pasteurization, cooling, ripening, churning, washing, salting and packaging of butter. Ripening of cream with starter culture is important to develop flavor. Churning involves breaking the emulsion of cream into butter grains through agitation. Factors like fat composition, globule size, cream richness and viscosity influence churnability and body of butter.

1. Butter Making Process
Fat Rich Dairy Products
DT-213

2. Butter-FSSAI Definition
Butter means the fatty product derived exclusively from
milk of Cow and/or Buffalo or its products principally in
the form of an emulsion of the type water-in-oil.
The product may be with or without added common salt
and starter cultures of harmless lactic acid and / or
flavour producing bacteria.
Table butter shall be obtained from pasteurized milk
and/ or other milk products which have undergone
adequate heat treatment to ensure microbial safety.

3.  It shall be free from animal fat, vegetable oil and
fat, mineral oil and added flavour. It shall have
pleasant taste and flavour free from off flavour
and rancidity.
 It may contain food additives permitted in these
Regulations
 Provided that where butter is sold or offered for
sale without any indication as to whether it is
table or desi butter, the standards of table butter
shall apply.

4. PFA Definition
 According to the PFA rules (1976), table
creamery butter is the product obtained
from cow or buffalo milk or a combination
there of, or from cream or curd from cow or
buffalo milk or a combination thereof with or
without the addition of common salt and
annatto or carotene as colouring matter.
 It should be free from other animal fats,
wax, and mineral oils, vegetable oils and
fats. No preservatives except common salt
and no colouring matter except annatto and
carotene may be added.

5.  Butter must contain
– not less than 80 % by weight of milk fat,
– not more than 1.5 % by weight of curd,
– and not more than 3% by weight of common salt.
– Diacetyl may be added as a flavouring agent but if so
used the total diacetyl content must not exceed 4 ppm.
– Calcium hydroxide, sodium carbonate, sodium
polyphosphate may be added, but must not exceed
the weight of butter as whole by more than 0.2 %.

6.  Standards
–FSSAI, 2011

7. Microbiological standards for
Pasteurized Butter
Total plate count 50,000/ g
Coliform count 50/g
E.Coli Absent/g
Salmonella Absent / 25 g
Staph. aureus 50/g
Yeast and mold count 50/g
Listeria monocytogenes Absent/g

8. PFA Standards
Constituents Table butter *Desi/cooking butter
Milk at m/m 80% min. 76% min.
Moisture m/m 16% max -------
Curd m/m 1.50% max -------
Common salt 3.0% max -------
Total plate count 5000/g max -------
Coliform count 5/g max -------
E.coli Absent in 1.0 g. -------
Salmonella Absent in 25.0 g. -------
Shigella Absent in 25.0 g. -------
Staphylococcus aureus Absent in 1.0 g. -------
Yeast & Mould Count 20/g max -------

9. BIS Standards
Characteristic Table Butter White Butter
Milk fat, percent by mass, Min 80.0 82.0
Moisture, percent by mass, Max 16.0 16.0
Acidity (as lactic acid), percent by mass, max. 0.15 0.06
Curd, percent by mass, Max. 1.0 1.5
Common salt, percent by mass, Max. 2.5 ----
Coliform count, per ml, Max 5 5
Total yeast and mould count, per ml, Max 20 20

10. CLASSIFICATION OF BUTTER
 Sour cream butter (made from ripened
cream) having pH≤5.1
 Mildly acidified butter (made from partially
acidified or sweet cream) having pH in the
range of 5.2 to 6.3 and
 Sweet cream butter (made from non acidified
cream; this includes butter in which no
bacterial culture have been worked in to
enhance diacetyl content) having pH of ≥6.4.

11. BIS Classification
Table Butter: the product made from pasteurized cream
obtained from cow or buffalo milk or a combination
thereof with or without ripening with the use of
standard lactic culture, addition of common salt, annatto
or carotene as colouring matter and diacetyl as
flavouring agent.
White Butter: the product made from pasteurized
cream obtained from cow or buffalo milk or a
combination thereof without ripening and without
addition of any preservative including common salt, any
added colouring matter or any added flavouring agent.

12. Cream ready for churning
Butter manufacturing
Standardization
Pasteurization
Cooling & ageing
Ripening
Milk receipts
Cream for butter making
Grading
Weighing
Sampling
Testing
Cream receipts
Cream processing
Cream Separation Neutralization

13. Loading of Churn
Churning of cream
Butter grain Butter milk
Draining of butter-milk
Butter grain
Washing
Initial working
Addition of salt & moisture
Final working
Butter
Packaging
Colour addition
Distribution
Storage

14. Neutralization

15. Standardization of Cream
 Refers to the adjustment of fat to the
desired level
 Done by adding calculated quantity of
Skim milk or butter milk
 Desired level for butter making --- 35-
40%
 High or low---- higher fat loss in
buttermilk
 Reduction of fat with water---
◦ interferes with ripening of cream &
◦ “flat” or “washed-off” flavor in butter

16. Pasteurization of Cream
 Heating cream to a temperature and holding
it at that temperature for a definite time which
ensures its safety for human consumption.
 Effects of Pasteurization of cream:
◦ Destroys all pathogenic organisms
◦ Destroys bacteria which can cause deterioration
of cream during churning and ripening and Butter
during storage
◦ Destroys enzymes (prevent oxidative rancidity)
◦ Eliminates some of the gaseous tainting
substances
◦ Removes CO2

17. Methods of pasteurization
 Holder method (Batch
pasteurization)—740C/ 30 min
 Continuous method (850C/15 sec)
 Vacuum Pasteurization
◦ First section (88-930C/11-6½ inches)
◦ Second section (72-810C/ 20-15 inches)
◦ Last section (390C/ 28 inches)

18.  More severe heat treatment of cream
should be avoided as higher the
temperature, greater the migration of
copper from milk serum to milk fat
globules
 Milk fat becomes more prone to the
oxidative rancidity
 reduce the shelf life of butter

19. Ripening of cream
 It refers to the process of fermentation of
cream with the help of suitable starter
culture.
 Main object--- to produce butter with a
pleasing, pronounced flavour.
Starter Culture:
 Mix. of both:
◦ acid producing organisms (Streptococcus
lactis, S. Cremoris)
◦ Flavour producing organisms (S.
diacetylactis, Leuconostoc citrovorum and/or
Leuc. Dextranicum)

20. Ripening of cream contd…
 0.5-2.0% starter is used for ripening
 Incubated at 21°C till the desired acidity is
reached.
 Usually, 1% starter is used and incubation
period is 15-16 hrs
 Acidity of the starter should be 0.80-0.90%
(pH of about 4.1 to 4.3) is most
favourable.

21. Effect of cream ripening on
Flavour of Butter
 The typical butter flavour is due to the
presence of dicaetyl in combination
with lactic acid, acetoin and
intermediary products such as
acetaldehyde.
 These substances are the products of
fermentation brought about by the
action of
◦ Lactic acid producing bacteria
◦ Citric acid fermenting bacteria

22. Distribution of Dicaetyl+Acetoin
 Relatively small proportion in butter
 Amount of Dicetyl:
◦ Fresh buttermilk > cream at churning > Butter
◦ Serum > fat content (of the same butter)

23. Effect on keeping quality of
Butter
 Ripening of cream affects the K.Q. in two
ways
◦ By its control on age deterioration due to
bacterial causes
◦ By its influence on age deterioration due to
chemical causes

24. Bacteriological effect
• Ripening assist in controlling bacterial
deterioration in butter
• LAB and high acidity act antagonistically
against flavour damaging organisms
• Preserve the fresh/ desired flavour
• Prolong the keeping quality of Butter
• Butter from sweet cream has
• Less keeping quality
• Flavour defects--- “Cheesy flavour”, “rancidity”,
“putrid flavour” etc.

25. Chemical effect
Ripening doesn’t improve the chemical stability of
butter
On the contrary, it shortens the life of salted
butter.
Flavour defects--- “Oily-metallic”, “fishy”,
“tallowy” flavour .
Salted butter made from sweet, unripened cream
or from neutralized & pasteurized sour cream
keeps better (from the standpoint of absence of
flavour deterioration due to chemical causes)

26. Percent acid to which the cream should be
ripened
For fresh consumption salted butter, cream of moderate
richness (30% fat) may safely be ripened to about 0.25-
0.30% acid
Salted butter for commercial cold storage--- 0.21% or
lower
Unsalted butter--- cream may be ripened to any acidity
without jeopardizing keeping quality

27. Addition of citric acid to cream
for Ripening
 Major flavour and aroma producing
substances (diacetyl, acetoin, etc.) are
the result of citric acid fermentation by
the starter bacteria
 Addition of citric acid @ 0.2% to
starter milk stimulates the production
of these products
 And thus increases the desired flavour
and aroma in the starter.

28. Cooling and Ageing of Cream
When cream is cooled--- fat in the fat globules undergoes
partial solidification
Degree of solidification plays important role--- determines
the firmness and standing-up properties of the body of
butter
Churning uncooled cream– high fat loss, weaker body
butter
Churning to abnormally low temp.--- more churning time,
butter may not form at all.

29.  High cooling temperature– shortens the churning
period, high fat loss and butter with a relatively soft
body
 Low cooling temperature– prolong the churning time,
firm body butter, difficulty in churning
 Optimum temperature- average rich cream (about 35-
40a% fat), churns in about 30 to 45 minutes
 Optimum temp. primarily depends on the composition
of butter fat and thus vary with season
 Also affected by size of the fat globules and the
richness of cream
 Cooling temp.
In summer (7-90C)
In winter (10-130C)

30. ALNARP Process
To produce butter of uniform quality
 Cold-Warm- Cold Process
 Pasteurized cream is cooled to 8°C/ 2-3 h
 Cream is warmed to 20-21°C/ 4-5 h
 Cream is cooled to 14°C/ 8 h
This will result in less solid fat, larger fat
crystals and greater proportion of solid fat
inside the fat globules

31. Churning
Conversion of O/W (Cream) type of emulsion
to W/O type (Butter)
O/W type of emulsion in milk is stabilized by
 Surface tension
 Adsorption
 Electric charge
It gets destabilized due to agitation and
frothing (Theories of Churning)

32. Force of surface tension: this causes the fat
globules in milk/cream to retain their individuality
and prevent butter formation.
Phenomenon of adsorption: the surface layer of
the fat globules contains an adsorbed
phospholipidsprotein complex, which resists de-
emulsification.
Electric charge: The fat globules carry a negative
charge and repel each other. This prevents their
coalescence.

33. Theories of Churning
Phase Reversal Theory
Rahn’s Foam Theory
King’s Theory
Black Portion = Milk Serum, White portion = Fat globules

34. Phase Reversal Theory
 Postulated by Fischer and Hooker
 According to this theory, churning is a process of Phase
Reversal (from O/W to W/O)
 Stability of emulsion is related to the relative volumes of
the fat and water (serum)
 It was postulated that agitation in the churning of cream
causes coalescence and clumping of the fat globules
 Ratio of surface area to volume of the fat units becomes
so small that the reduced SA can no longer contain all
the buttermilk in stable form.
 The o/w emulsion suddenly breaks and butter grains are
formed.

35. Rahn’s Foam Theory
He postulated that churning would not be
possible without foam formation.
Fat globules concentrates on the surface of
air bubble
Air bubble collapse and fat globules clump
together
Fat globules on an air bubble
air bubble collapse
Fat globules clump together

36. King’s Theory
 He postulated that the mechanism of churning is midway
between the theories of Phase Reversal and Foam.
 At churning temperature, fat is present as clusters of fat
globules. And within each globule it is present partly in
solid and partly in liquid form.
 Agitation (churning) breaks up the clusters and causes
foam formation. The globules become concentrated to
some extent in the film around the air babble in the foam
and thus are brought into close contact of each other.

37. The direct concussion between globules causes a
gradual wearing away of the emulsion protecting
surface layer (of phospholipid protein complex).
The globules under pressure yields enough free liquid
fat during working to enclose water droplets, air
bubbles and intact fat globules.

38. Summary of Churning Process
 The fat in cooled cream is present as clusters of
globules (part of the fat in these globules is
present in solid form)
 Churning breaks up the clusters and causes
foam formation, globules concentrate on the
bubble and thus are brought into close contact
with one another.
 The movement of globules over one another
and direct concussion between them causes
wearing away of the emulsion protecting layer.

39.  The globules adhere together to form larger and
larger particles and eventually these particles
become visible as Butter granules
 The fat in the granules is still mainly in globular form
 Working of butter causes the globules to move over
one another
 Globules are broken by friction and pressure and
due sliding and shearing effect of the working
process.
 Finally there is enough liquid fat to enclose all the
water droplets, undestroyed fat globules and the air
bubbles.

40. Factors influencing churnability of cream
and body of Butter
These factors may be classified into two groups
Initial character of the cream
 chemical composition of Butter fat
 Size of fat globules
 Richness of cream
 Viscosity of cream
Conditions in the process of manufacture
 Churning temperature
 Fullness of churn
 Speed of churn
 Design of churn

41. Influence of chemical composition of butter fat
 Effect on body of the butter relates largely to the
proportion of soft fats (low melting point fat) and
hard fats (high melting points)
 This determines the degree of fat solidification in
the cooled cream.
 Increase in the proportion of soft fats
Shortens the churning period
Diminishes the firmness of the butter
Increases fat loss in buttermilk
 Decrease
Prolongs the churning period

42. Effect of richness of cream
 High fat cream churns more rapidly than low
fat cream
 Greater the concentration of fat globules---
they are more closer, more readily they
aggregate, coalesce and form butter granules.
 Optimum fat percent 35-40%
 High and low fat –both cause higher fat loss in
buttermilk

43. Effect of Viscosity of cream
More viscous the cream---more churning time
Sticky consistency of cream–
 Diminishes the freedom of movement of the
fat globules
 Lessens their opportunity of being brought
together
 Retard coalescence

44. Effect of churning temperature
Churning temperature determines the rapidity
and exhaustiveness of churning
Adjustment of temperature is effective way to
correct the effect of many uncontrollable
factors that cause wide fluctuation in the
character of butter fat
 Summer (7-9ºC)
 Winter (10-13ºC)

45. Effect of Fullness of cream
For maximum agitation, the cream must dash
from side to side or from top to bottom
Optimum load--- one third to one half full–
provides maximum agitation
Overloading diminishes the free space---- leads
to increase in churning time

46. Effect of speed of churn
Speed of the churn provides agitation
So, the maximum speed of the churn is the
speed that yields the maximum amount of
agitation
It is dependent on the ratio of centrifugal force
and gravity force
Centrifugal force should be less than
gravitational force

47. Calculate max. speed when R=1 m

48. The Churning Process
 Preparing the Churn
 Filling the churn
 Churning the cream
 Draining the buttermilk and washing
the butter
 Salting the butter
 Adjusting the moisture content
 Working the butter
 Unloading the churn

49. Preparing the Churn
 It should be thoroughly wetted before
the cream is added
 It should be free from bacteria, for this
the churn is filled about one-fifth with
hot water and set rolling for ten to
fifteen minutes
 Run out the hot water
 Fill the churn with cold water and
rotate for 15 min

50. Churning the Cream
 When the cream is sufficiently filled, the filling port is closed
and the churn is set rolling in top gear
 Pressure develops within the churn due to liberation of gases,
thus after some rotations, the churn is stopped with its drain
valve at the top, these valves are opened for some time to
release the gases.
 The churn is again rolled in top gear
 After some time, free space in the churn is partially filled with
froth
 After a further interval, froth breaks
 Presence of free buttermilk and butter granules becomes
evident

51.  The breaking stage is generally considered
completed when the site glass becomes clear
 Sometimes, it is necessary to add break
water (@ 15% of cream) at this stage (to
control body of the butter by reducing
temperature)
 It also prevents granules to join together and
form large lumps
 Churn till the desired size butter granules are
formed
 When the butter granules are formed, churn
is stopped with the drain valves at the bottom
 The buttermilk is drained from the churn

52. Washing the butter
 Purpose
– To remove adhered buttermilk
– To correct defects in the firmness of butter
 Add wash water equal to the volume of the
buttermilk drained
 Approx. 25% of the curd contained in the
unwashed butter is removed by washing
 Temp.– approx. original temperature of the
cream in the churn
 The wash water should be bacteriologically
safe

53. Salting the Butter
 Purpose
–To improve its keeping quality
–To increase palatibility
 Calculating the amount of salt
–Determine the fat content of Buttermilk
–you know the fat content of cream
–This will give the fat present in the churn
–So, we can calculate the amount of Butter
in the churn
–Multiply it with the desired salt percentage

54. Exercise
◦ Calculate salt to be added. The fat content of
the cream (100Kg) used for churning was
35%. (consider fat content in the Buttermilk is
negligible). Salt required in Butter is 2%.

55. Methods of Salting
 Dry Salting
–The dry salt is sprinkled evenly over the
granular butter in the churn
–Satisfactory with butter of normal firmness
–Cause grittiness with abnormally weak
butter
 Wet Salting
–Assist in forming rapid solution of salt
–And in avoiding the presence of
undissolved salt crystals

56. Addition of make up water

57. Working the Butter
 Purpose
–To bring the butter granules together into
a compact mass
–For convenient handling and packing
–To completely dissolve, uniformly
distribute and properly incorporate the salt
–To incorporate the make up water
 During this process, remaining fat
globules also break up and form a
continuous phase

58.  Amount of working required
–There should be no free moisture on a cross
section cut from the Butter block by a sharp
knife or a wire
–It is safer to overwork butter than to underwork
–Underworked butter may be leaky in body with
large visible aggregates of water

60. Butter Colour
 Need
 Desirable properties
– Free from ingredients injurious to health
– Free from undesirable odors and flavors
– Strength should be such that only a small qty. is
required
– Permanency of emulsion
– It must be oil soluble
 Types
– Mineral origin
– Vegetable origin

61. Vegetable Butter Color
• Derives the coloring component from plants
• Bulk of the vegetable color used today is made
from the coloring substance extracted from the
seed of the annatto plant (Bixa Orellana)
Mineral Butter Color
• Derives the coloring component from harmless
oil soluble coal tar dyes
• Dyes certifies by USDA are
• Yellow A B (Benzeneazo- β- naphthlyamine
• Yellow O B (Ortho- Tolueneazo- β-
naphthylamine)

62. Butter Defects
 Flavor and Aroma
–Due to off flavors in the cream
–Due to faulty methods in the manufacture
–After manufacture
 Body and texture
 color

63. Butter Defects
Flavor and Aroma
Due to off flavor in
cream
Feed and weed Cowy and Barny
Unclean or Utensil
flavor
Musty, Smothered
Flavor
Bitter flavor
Yeasty flavor and
odor
Cheesy Metallic Flavor
Due to faulty
methods in
manufacturing
Flat Flavor
High acid and Sour
Flavor
Cooked or
Scorched Flavor
Neutralizer Flavor
Oily or Oily Metallic
Flavor
After manufacture
Surface taint,
Limburger or Putrid
Flavor
Cheddar an
Roquefort Fla
Rancid Flavor Tallowy Flavo
Fishy Flavor Woody Flavo
Body and Texture Color

65. Flavor defects due to faulty methods in manufacture
Flat flavor
– Lacks the pronounced, pleasing flavor and aroma
that is characteristic of butter of superior quality
Causes:
Fundamental cause is low content of volatile
acidity, diacetyl and other products
Churning the cream sweet and without the use of
starter
Profuse dilution of cream with water
Excessive washing of butter
Prevention:
 Proper ripening of cream
 Avoid dilution with water

66. HIGH ACID AND SOUR FLAVOR
High acid----Characteristic of butter made from cream
received in sour condition and that is not neutralized
Causes:
 Churning over ripened cream
 Use of over ripe starter
 By use of high cream ripening temperature in the
presence of starter that lacks flavor organisms and
produces acid only
Prevention:
 Use of starter containing proper balance of acid and
flavor organisms
 Proper ripening (optimum temperature and time)

67. COOKED OR SCORCHED FLAVOR
– Characteristic of butter made from pasteurized cream.
– Caused by exposure of cream to high temperature
Properly pasteurized cream--- cooked flavor disappears before the
butter reaches market
If the temperature difference between heating medium and cream is
too high---- Scorched flavor
– More chances when high acid cream is neutralized by lime
neutralizers
– Heating the cream by means of direct steam pasteurization under
pressure (with live steam) minimizes the danger of cooked or
scorched flavor even when pasteurizing at high temp.

68. NEUTRALIZER FLAVOR
– The tendency for this defect to appear and its intensity depends
on the amount of neutralizer used
– This amount in turn depends on the initial acidity of the cream and
the acidity to which cream is neutralized
Lime Neutralizer– limy, bitter neutralizer flavour
Soda Neutralizer--- Soapy flavor
Causes:
– Reducing acidity of high acid cream to a very low level
– Adding the neutralizer in too concentrated form, not distributing it
quickly and uniformly throughout the body of the cream or not
giving the neutralizer sufficient time to complete the reaction in
the cream
Preventions:
– Double neutralisation
– Adopting proper way of adding neutralizer

69. Flavor defects that may develop after manufacture
Surface taint, Limburger or Putrid Flavor
– The defect is called surface taint because it first appears at the surface.
However, the defect is not confined to the surface, it rapidly involves the whole
mass or package of the butter
– This defect is also called Limburger flavor suggesting the flavor and aroma of
Limburger cheese
– Mostly found in butter made from unripened or sweet cream and light salt butter
Causes:
– Protein decomposition by putrefactive bacteria ( Achromobacter putrefaciens,
Pseudomonas flourescens and Bacillus flourescens liquefaciens)
– Contamination of butter/ cream after pasteurization
Prevention:
– Efficient pasteurization
– Sanitation between pasteurizer and churn
– Avoid contamination from churn
– No buttermilk should flow back to the churn at the time of draining as the
buttermilk draining lines are rarely washed and it usually contains milk
residues with putrefactive bacteria
– Ensure clean and sanitized water supply
– Precautions in packing butter

70. CHEDDAR AND ROQUEFORT FLAVORS
– Found mostly in light salted and unsalted butter
– Absent in butter held in commercial cold storage
– Cheddar cheese type flavor is caused by proteolysis and lipolysis by several species of
bacteria
– Roquefort cheese flavor is usually associated with mold growth which involves both proteolysis
and fat hydrolysis
Trend of flavor change
Flat flavor-----Stale flavor----Cheesy flavor of Cheddar type----Roquefort flavor and Rancidity
Prevention:
– Good sanitation practices throughout the process
– Cream ripening with good starters

71. RANCID FLAVOR
– It is a common flavor defect of butter made from raw cream
– It resembles the pungent, rasping taste and odor of such volatile fatty
acids as butyric, caproic and caprylic acids.
– It is caused by hydrolysis of fat which splits the butter into free fatty
acids and glycerols
– This hydrolysis is brought about by the action of m.o. or enzymes or
both
Prevention:
– Proper pasteurization
– Efficient sanitation
– Clean water supply

72. TALLOWY FLAVOR
– The tallowy flavor of butter resembles the flavor and odor of mutton tallow
– In severe cases of tallowiness, butter also bleaches in colour
– It is caused by oxidation of the fat, involving the unsaturated fatty acids in butter
such as oleic acid
– Oleic acid combined with free glycerol forms glycollic acid ester of oleic acid.
This product is responsible for tallowy flavor
Causes:
– Air, light and heat (air--- cause oxidation, light & heat accelerate it)
– Metals (oxides or salts)
– Absence of bacteria (utilizes oxygen in their metabolism and thus retard
tallowiness)
Prevention:
– Use of air and light proof liners
– Metal surfaces should be properly tinned or SS should be used

73. FISHY FLAVOR
– Butter has a flavor and odor characteristic of a fish
– Trymethylamine is the product responsible for fishiness
Causes:
– Feeds and area of feeding
– Activity of microorganism
– Mold Oidium lactis when grown in conjuction with S. lactis in
cream, fishy flavor develops
– Certain yeasts and bacteria may also cause this defect
Prevention:
– Keep CSA 0.35% or less
– Do not whip or over work butter
– Do not salt the butter excessively

74. Defects in Body & Texture
Crumbly, Brittle Body
 Proportion of high and low melting point fat
 Winter butter-excessive hardness, crumbliness and
stickiness of butter
Prevention
 Avoid low cooling temperature and prolonged holding of
cream at low temperature
 Chilling granular butter with cold wash water

75. Sticky Butter
 This refers to the butter that doesn't cut clean
 It sticks to the knife or Trier
Prevention
 Same as for crumbly butter
 Churning immediately after cooling
 Wash the butter with wash water at a temp. of 3
to 4o F below that of the buttermilk

76. Weak Body
 It lacks the desired firmness and standing
up property
Causes:
 Incomplete fat crystallization
 Faulty adjustment of cooling temperature of
cream or holding time
 Low proportion of high m.p. glycerides

77. Greasy Texture
 Occurs when worked excessively while in soft
condition
 Usually appears in the case of abnormally rich
cream insufficiently cooled and churned and
worked while too warm
Prevention:
 Proper cooling of cream
 Chilling the butter granules thoroughly with very cold
water before working

78. Leaky Texture
 Usually appears wet to the eyes
 When bored, it shows small droplets of moisture
on the plug and the back of the trier looks wet
 Excessive shrinkage and weight loss in storage
Causes:
 Incomplete and improper working
 Lack of fine dispersion of moisture in butter

79. Gummy Butter
 Butter when placed in mouth, does not melt readily, it
sticks to the roof of the mouth and gives the impression
of gumminess
Cause:
 Presence of an excess amount of high melting glycerides
Mealy Butter
 Most likely to occur in butter made from sour cream that
is improperly neutralized with lime
 Insoluble calcium caseinate forms
 In subsequent pasteurization, these particles contract and
harden giving the cream and butter, a disagreeable rough,
grainy and mealy character

80. Defects in the Color of Butter
Bleached color --- due to oxidation of fat
Mottled Color
 Uneveness of color in the body of butter is shown in the
form of streaks, waves and mottles
Causes:
 The whitish, opaque dapples in mottled butter are due to
localized sections of innumerable very minute water
droplets
 Salting out action
 Uneven working of different portions of butter
Prevention
 Keep worker rolls in good mechanical condition
 Don’t overload the workers/churn
 Completely dissolve the salt

81. Butter Overrun
 The difference between the weight of fat churned
and the weight of butter made.
 In addition to butter fat, butter contains non-fatty
constituents such as moisture, salt, curd and small
amounts of lactose, acid and ash.
 Maximum overrun is 25%

82. The Churning operation
 Preparing the churn
 Straining the cream into the churn
 Addition of Butter Colour
 Operating the Churn
–Gas in the churn (slightly minimize agitation,
leakage)
–Rise of temp. during churning (friction, heat of
crystallization)
–When to stop the churn

84.  margarine, food product made principally from
one or more vegetable or animal fats or oils in
which is dispersed an aqueous portion containing
milk products, either solid or fluid, salt, and such
other ingredients as flavouring agents, yellow food
pigments, emulsifiers, preservatives, vitamins A
and D, and butter. It is used in cooking and as a
spread. Nutritionally, margarine is primarily a
source of calories.
 The French chemist H. Mège-Mouriès developed
margarine in the late 1860s and was given
recognition in Europe and a patent in the United
States in 1873. His manufacturing method was
simplified in the United ... (100 of 309 words)

85.  Renovated Butter is a product made from butter that either has gone rancid, or that was impure. The
purpose is to end up with a butter that is usable for human consumption.
 The butter is melted. The butterfat is collected from the resultant liquid and any foreign material filtered
out. Air might be forced through it as well if needed to remove any undesirable odours.
The butterfat is then mixed with water (usually at least 16%), some good milk, cream or skimmed-milk for
flavour, then churned, and made back into butter, then packaged for sale.
 Strict conditions are attached to its sale everywhere. Typically, Renovated Butter has to be sold clearly
labelled "Renovated Butter", and the word "renovated" has to be at least as big as the word "butter." In
some places, sale to consumers is not permitted at all.
 History Notes for Renovated Butter
 Renovated Butter was particularly popular in America at the turn of the 1900s. It was a form of butter that
could come closer to competing price-wise with margarine. At the turn of the 1900s, the largest producer
of renovated butter was the "Illinois Creamery" (established 1896 in Elgin, Illinois), which had 30 workers
(it was sold in 1906 to the "American Farm Products Company"). As margarine got cheaper Renovated
Butter faded as a viable competitor altogether.
 Renovated Butters were generally not considered a person's first choice as a dairy spread. Some were
the consistency of axle grease. It was included in soldiers' rations during the first world war. A lot of it
came from Australia. Some soldiers said that it didn't taste of much; other said it was better than having
nothing to spread on their bread at all. For a time, a good deal of Renovated Butter was sold by
Americans to the UK. This eventually opened the door for sales of Canadian butter to the UK, because
Renovated Butter gave all American butter a bad name.
 Copyright 2010 Practically Edible. All rights reserved and enforced.) Read more of this snippet here :
http://www.practicallyedible.com/edible.nsf/pages/renovatedbutter#ixzz19ZgBlQQK
 ]]]]]]]][[]]]]]]]]]]]]]]]]]]]]]]]]]]]]]

86. Continuous Butter Churn
 3 main principles
1. Churning or frothing: In this method
butter grain is formed by aggregation
of the fat globules under the action of
air present in the cream.
Eg: Fritz, Fritz Eisenreich process,
Contimob (Simon Freres), Westfalia
and Silkborg are based on this
principle.
8/19/2022 NDRI, DT213 86

87. Contd….
2. Concentration and Phase reversal:
In this method the concentrated cream
will be subjected to combined effects of
cooling and working, and bring about a
direct conversion of cream to butter.
Thus it bypasses the butter grain stage.
Eg: Alfa process and maleshin(Russian)
process.
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88. 3. Emulsification: In this process, liquid
butterfat and serum are emulsified and
emulsion is cooled and worked to farm
butter.
Eg: Creamery Package and Gold’s Flow
process.
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89. Fritz-Eisenreich Process
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Schematic Diagram of a continuous butter making machine

90. Contd….
 In Fritz butter making machine, it contains
only one churning cylinder and twin screw
working device. This was only suitable for
sweet cream of 40 – 50% fat.
 The second churning cylinder was
developed by Eisenreich, which basically
have second churning section, buttermilk
discharge section and wash compartment.
This allows churning of ripened cream as
well.
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91. Contd….
 First churning section:
◦ Cylindrical in shape with cooling jacket
◦ Contains beater whose battens are at a
distance of 2-3mm from the wall
◦ Beater rotates at a high speed (600 – 2800
rpm) which can be adjusted
◦ Cream containing 40 – 50% fat is passed to
this section at a temperature of 7 – 100C
◦ Butter granules are formed here within 3 – 5
sec.
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92. Contd….
◦ Cream is set into the rapid motion in the form of a
thin film
◦ Fine cream froth is produced
◦ Through the breaking of these froth bubbles and
through the action of the very vigorous mechanical
action the cream is churned to butter granules and
buttermilk.
◦ 30% fat cream can also be churned by increasing
the unevenness of the inner surface (by inserting
perforated cylinder)
◦ Mixture of butter granules and buttermilk is
displaced from the cylinder by the incoming
cream.
8/19/2022 NDRI, DT213 92

93. Contd….
 Second churning section:
◦ Cylinder rotates at 10 – 25 rpm
◦ Cylinder is cooled and butter granules are able to
form loose agglomerates
◦ Metal rods which rotate at the same rate loosen the
mass and prevent the formation of lumps
◦ In the buttermilk discharge section major part of the
buttermilk is drawn off through a wire mesh which
covers the perforated cylinder
◦ Removal of buttermilk is almost complete and water
is in very fine state of dispersion.
◦ Washing for butter granules can be done in wash
compartment but it is hardly necessary.
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94. Contd….
 Twin Screw Working Device:
◦ Butter granules are collected by two contra
rotating screws and worked intensively
◦ Buttermilk is pressed out
◦ Screws force the butter through a number of
perforated plates arranged in series
◦ This treatment serves to produce a fine
dispersion of water in the butter
◦ Process is assisted by mixing vanes which are
placed between the plates and attached to the
shaft
8/19/2022 NDRI, DT213 94

95. Contd….
◦ Water or salt solution may be added through
an opening immediately in front of the
perforated plates to adjust moisture or salt
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96. CONTIMAB PROCESS
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97. Contd….
 Cream churns into butter granules in 1-2 sec
 churning cylinder rotates at 600 – 800rpm
 Two major working sections: wet and dry
 In WS-1, washing and cooling of butter
granules and removal of butter milk along with
working.
 In WS-2, further worked and reduces the
moisture content to 13 to 14%
 Dosing section, where adjustment of salt and
moist.
 Vacuum chamber, reduces the air content
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98. ALFA Process
Balance Tank
Pasteurization 80 -
900C /15 -10s
Cooling 45 – 500C
Cream separator
Mixing tank
(Salt/colour addition)
Screw Cooler/
Transmutator
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99. ALFA Process
 Cream of 30% fat is pasteurized at 900C,
degassed, cooled to 45 – 500C and
separated at this temperature in a cream
separator to 82% fat
 The cream, which is still in the form of oil in
water emulsion, but it is almost the
composition of butter
 In this cream fat globules are so closely
packed that their fat globule membranes
are in contact with each other
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100.  This cream is then passed through a two or
three stage screw cooler where it is cooled to
8 – 130C
 There the fat crystallizes and fat crystals
perforate the fat globule membrane so that
free fat escape
 This process is helped by rubbing together of
the fat globules as they move in the cooler
 Thus phase inversion takes place and water-
in-oil emulsion (butter) is formed.
 It contains all the fat globule membrane
material, thus it has high phospholipids
content and no buttermilk is produced in this
process.
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