2. The creamery package process is one of the
methods of continuous buttermaking from cream,
introduced during 1939-1945 world war.
Six basic physical changes take place when butter is made
in accordance with this method:
Concentration to cream of 80% fat content.
Reversal of fat phase from fat-in-serum to serum-in-fat.
Concentration from 80% to 98% fat.
Pasteurization and cooling 98% fat.
Composition control of the butter mix.
Controlled solidification and crystallization of the butter.
3. 1.CONCENTRATION TO CREAM OF 80% FAT
CONTENT
Either milk or sweet cream may be starting product.
Milk is first separated to yield 40% cream.
The 40% cream is heated in a plate type heat exchanger to
155-165°F and separated by a heavy cream separator to 70-
80%.
The concentrated cream from the centrifugal separator
enters a special balance tank and is ready for the next step.
4. 2.REVERSAL OF FAT PHASE FROM FAT-IN-
SERUM TO SERUM-IN-FAT
It is the step which provides a means of making a quality
product unavailable through any other process.
The concentrated cream is removed from the balance tank
by a centrifugal pump which provides a steady supply to the
Phase Reverser.
Phase Reverser is a machine similar in design to a
homogenizer.
Here, the cream is processed in such a way that the protein-
phospholipids complex surrounding the individual fat
globule is broken.
This frees the fat from globular form.
5. 3.CONCENTRATION FROM 80% TO 98%
FAT CONTENT
The concentrated oil and serum product enters the
gravity type separator slightly below center.
The oil-serum product at 165°F enters the serum
separator which removes the major portion of serum
to concentrate the fat to 98.5%-99%.
The fat is directed upward while the serum is directed
down and is discharged back into the balance tank for
40% cream.
This return serum is thus re-separated so that there is
no possible fat loss.
6. 4.PASTEURIZATION AND COOLING 98%
FAT
The 98.5% purity fat is directed to a plate type heat
exchanger in which it is heated to 190°F.
Then it is immediately cooled to 110°-120°F.
It is then directed to a battery of three composition
control tanks for standardization of components for
the desired butter.
7. COMPOSITION CONTROL
(STANDARDIZATION)OF THE BUTTER MIX
In this step the various components of
fat, moisture ,salt and curd are standardized.
A controlled portion of unbroken fat is introduced.
This is accomplished by segregation of a portion of
the 80% cream in the special balance tank which
receives cream from the heavy cream separator(step
one).
contd...
8. The desired quantity is metered by a positive pump
into the 98.5% fat as it enters the plate heat exchanger
for heating to190°F and subsequent cooling in step
four.
The quantities of water ,salt and color are then added
to produce the desired composition.
The standardized butter mix in the composition
control tanks is thoroughly agitated to ensure
extremely accurate control throughout the entire
quantity in the tank.
9. 6.CONTROLLED CRYSTALLIZATION AND
SOLIDIFICATION OF THE BUTTER.
The thoroughly agitated butter mix is removed from
the composition control tanks by means of a
centrifugal pump ,which supplies a steady pressure to
the high pressure pump feeding the chiller at pressure
up to 325 pounds.
The chiller is so designed that the butter mix is cooled
from standardizing temperatures of 110°F . to
approximately 40°F.
At this temperature it passes to the crystallizer. contd…
10. The crystallizer provides for the control of the
crystallizing structure during growth.
In passing through the machine the temperature of
the product is increased 10-11°F due to heat of
crystallization.
The final product is discharged at approximately 50°F.
