Butter Manufacturing Process

Cooling and ageing of cream

After pasteurization, cream is cooled by lowering its temperature and aged it by holding at that
low temperature for a few hours. Cooling and ageing help to partially solidify (crystallize) the
butter in the fat globules, if it is not done properly, fat loss in the butter milk will be high and the
butter obtained will have an unsatisfactory body. Ageing temperature is usually from 5 to 100c
ageing time from at least 2 to 4 hours to 15 to 16 hours depending on temperature cooling cream
to abnormally low temperature and holding it at that temperature renders the fat globules to become
firm, which coalesce with each other during churning and making the churning process more
difficult. On the other hand, high cooling and ageing temperature of cream shorten the churning
period but more fat losses occur with butter milk

Ripening of cream

Ripening is the process of fermentation of cream with the help of desirable starter culture under
specified condition.

The main objectives of ripening are:

1. To produce desirable flavor and aroma in butter

2. To destabilize the nature of milk protein for easy separation of fat
3. For improving the churning efficiency.

Procedure:

Ripening process is also called as souring of cream. For this purpose, desired type of bacterial
culture containing lactic acid producers and flavor producers are added at the rate of 5 to 10% of
the total weight of the cream depending on temperature and incubation period. A common practice
is to add culture when the temperature of the cream is about 20 to 210 C and the time of incubation
is about 15 to 16 hours. Acid producing bacteria in the culture are Streptococcus lactis, S.
cremoris, S. Diacetilactis etc. and flavor producing bacteria are Leuconostoc citrovorum, L.
paracitrovorum and L. dextranicum.

The incubation period may be reduced depending on the rate of acid production. An acidity level
of up to 30 to 40% and PH of about 5 to 5.2 will be the accepted level. Too high level of acid is
detrimental to the keeping quality of butter. When the desired acidity is reached, further
development is checked by cooling. It must be borne in mind that the principal purpose of a starter
in cream is to impart a desirable flavor and aroma, rather than development of high acidity. Certain
amount of acidity is required for enhancing the flavor producing activity and also to denaturation
of casein for easy separation of milk fat during churning.
Formation of the typical butter favor, known as diacetyl is takes place during fermentation. At a
pH 5.0 to 5.2, lactic acid displace citric acid from its salts, and the released free citric acid, in the
presence of lactose is converted into diacetyl and acetone diacetyl can also be produced by
oxidation of its precursor called acetyl methyl carbonate as follow:

CH3 CHOH. COCH3 +O2 ----------- CH3 COCOCH3+H2O

Acityl methylcarbinal diacetyl

Maintaning the optimum pH (<5.2) and addition of 0.15% citric acid to the cream enhance the
diacety formation.

❖ The level of diacetyl in sour cream butter is 0.5-2.0 mg/kg of butter.

❖ Diacetyl is also called biacetyl.
❖ No starter is added for the manufacture of “sweet cream butter”.

Effect of Cream ripening on butter

Effect on Flavor and Aroma

The mildly acid and pronounced nutty flavor that is characteristic of the pleasing flavor of good
butter is usually accompanied by a high, attractive aroma. The typical butter flavor is due to the
presence of diacetyl in combination with lactic acid, carbon dioxide, acetoin and intermediary
products such as acetaldehyde, and probably other aromatic products as yet not definitely
determined. These substances are the products of fermentation, brought about by the associative
action of lactic acid-producing bacteria and citric acid-fermenting bacteria.

Factors which Influence the Diacetyl + Acetoin Content of Butter

Cream ripened with a normal starter shows a varying ratio of diacetyl to acetoin. In the case of
20% cream, a ripening temperature of 17˚C. (62.6˚F) yields the largest amount of diacetyl. With
increasing fat content the amount of diacetyl + acetoin increases. Cream testing 40% fat yields
higher diacetyl content in the butter than 20% cream, or whole milk. The diacetyl content of butter
to affect its flavor as follows:

Amount of Diacetyl Flavor

Absence of diacetyl Flavorless
0.2 to 0.6 ppm diacetyl Mild flavor
0.7 to 1.5 ppm diacetyl Full flavor
Bacteriological effect

The ripening of cream improves the keeping quality of butter as far as keeping quality is dependent
on freedom from age deterioration due to biological causes. Cream ripening assists in controlling
bacterial deterioration in butter. In butter made from ripened cream there is a great prevalence of
lactic acid bacteria and a relatively high acidity and probably an abundance of lactate salts. These
agencies are antagonistic to the great majority of flavor-damaging organisms that may be present
in the butter, thus retarding their action, preserving the fresh or desired flavor, and prolonging the
keeping quality of the butter.

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 to 0.30% acid. For salted butter of commercial cold storage, it has been found
preferable not to ripen the cream and to churn it at an acidity of about 0.21% acid or lower. In case
of unsalted butter, the cream may be ripened to any acidity without threatening keeping quality.

Churning of Cream:

Churning is the process of agitation of cream under specified conditions to remove the water
from cream and adhering of fat globules for manufacturing butter. The apparatus used for
churning process is known as “churn”.

The main objectives of churning are-

1. To remove water from cream

2. To adhere fat globules for making large globules.
3. For complete separation of fat and serum.

Procedure of churning:

Before using the churn, it should be washed thoroughly with hot water. If the churn is new or is
used at frequent intervals or it is made of wood, it should be soaked thoroughly by filling with hot
water at least 24 hours before the time of using and rinsing it with cold water just prior to
adding the cream.

The churn is filled from one third to half with cream. The temperature of the cream should be
around 120C in summer and 150C in winter season. Usually, the cream is allowed to run through
a strainer/filter when it enters the churn to assist in breaking the lumps of cream and to remove
any particles of curd. The churn then is operated for a few revolutions and then is stopped, to
release the air pressure by opening the small stopper provided for that purpose. This pressure may
be due to the escape of gases in the cream and also due to expansion of the air in the churn caused
by the absorption of moisture. The churn is then operated until the butter granules become the size
of a pea or a kernel of corn.
As churning proceeds, the cream undergoes some changes, it appears granular, small granules of
butter become more clearly defined. They adhere together and become the size of a pea or a kernel
of corn, the butter milk is clearly noticed. Separation of fat and butter is completed at this point.
This point is known as breaking point. The butter milk is then allowed to rain from churn. When
this is complete, a small quantity of water at the same temperature as the butter milk may be poured
over the butter granules until it is observed to be almost clear as it flows from the gate of the churn.
The gate of then closed and the churn is filled with water of desirable temperature for washing
purpose. The amount of water added is equal to that of the amount of butter milk which has been
drained off. After a few revolution of the churn, the water is drained off and the butter is then ready
for further work.

Fig. Different types of butter churns

Factors influencing churning:

There are some factors which can influence the efficiency of churning. The important factors are
as follows:

1. Temperature of cream
2. Composition of milk fat
3. Influence of size of fat globules
4. Acidity of cream
5. Viscosity of cream
6. Richness of cream
7. Fullness of churn
8. Speed of churn
Temperature of cream:

Temperature is an important factor which can influence the efficiency of churning. The colder the
cream, the longer the period required for complete churning of cream. If the cream is too cold, it
creates difficulty in churning. On the other hand, if it is too warm, the churning period will reduce
but the butter obtained will be soft in texture and high loss of fat occurs. Under factory condition,
typical churning temperature during summer season is about 90c and in winter it is approximately
12 to 130c. Under optimum temperature, the churning period of sweet cream is from 40 to 60
minutes.

❖ Note: when normal churning is completed, the temperature of butter and butter milk is
usually 2 to 40c higher than the temperature of cream which was at the beginning. The rise
in the temperature is due to following reasons-
1. Some heat is absorbed from the churn itself as because the temperature of the room
where churning is done is usually higher than of the temperature of cream in the churn.
2. Due to the friction within churn

Composition of milk fat:

Softness and hardness of milk fat depends on the type of fatty acids present. If milk fat contains
more butyric and oleic acid, then it becomes soft but when proportion of stearic acid and, palmatic
acid etc increases, the fat becomes hard. Soft fat churns quickly but the texture of butter becomes
weak. On the other hand, hard fat takes more churning time and the texture of butter becomes
harder. The soft and hard condition of fat could be overcome by adjusting the churning temperature
and also by adjusting the temperature if water used during washing of butter.

Size of fat globules:

It was observed that cream containing small size fat- globules churns with difficulty, while large
one’s churns quickly. Therefore, the higher the proportion of small sized fat globules, the longer
the churning time and greater the fat loss in butter milk and vice versa.

Acidity of cream:

Acidity of cream can influence the churning time. Sweet cream takes more time for churning then
that of the sour cream. The easier churning of the sour cream is due to the changed physical
condition of cream as a result of the presence of acid in such type of acid media; the cream
precipitated and gathered into masses of varies sizes offers less resistance to the contact of the fat
globules than when the casein is in the normal colloidal solution.
Viscosity of cream:

If the cream is more viscous it adheres on the wall of the churn and creates problem in churning
viscous cream also contain more air insides and for this reason milk fat could not come together
rapidly until air is escaped from cream. As a result, churning time is delayed.

Richness of cream:

The higher the fat percentage of cream, the lower the churning period 20% of less fat the churning
time will be more and fat loss will be high. Similarly, cream contains 40% or above fat, a fat loss
often occurs because of unchurned cream adhering to the walls. It was observed that cream
containing 30 to 35% fat (average 33%), is best for churning, as because this time cream saves
churning time and also loss of fat during churning.

Fullness of churn:

Overloading of churn with cream increases churning time while underloading reduces churning
time. Practically it was found that if a cream at a certain churning temperature requires 50 to 60
minutes for complete churning when it is ½ full, the same cream at the same temperature of
churning will require 4 to 6 hours to complete churning when it is 2/3 to ¾ the full. For better
performance churn should be loaded with ½ to 1/3 of its volume with cream.

Speed of the churn:

The amount of agitation given in a churn depends on the speed of the churn. It was observed that
maximum agitation given in a churn shortens the churning time the speed should be given on the
basis of manufacturer’s instruction. It should be remembered that if the churn be too fast, the force
of gravity is overcome by centrifugal force and the cream follows the motion of the churn,
receiving little or no agitation and thus, churning is delayed.

❖ Difficult churning: Sometimes it becomes very difficult to complete the churning

operation smoothly. The following are the causes of difficult churning –
a. Over loading of the churn.
b. Excessively low churning temperature of cream.
c. Excessive hardness of fat.
d. Excessively high percentage of fat in cream.
e. Excessively thin cream.
f. Very small sized fat globules of cream.
g. Abnormal cream (excessive foaming due to bacterial/ enzymatic action)

❖ Fat losses during churning:

The following are the factors responsible for fat losses in butter milk –
 Size of far globules:

Greater the amount of small sized (2 micron or less) fat globules, the higher will be fat loss.

Richness of cream:

Too low or too high percentage of fat in cream increase fat loss in butter milk.

Acidity of cream:

Fat losses from sweet cream are more than sour cream.

Softness or hardness of fat:

Usually, the softer the fat, the more the fat loss and vice-versa.

Cooling and aging cream:

Insufficient cooling and aging of cream increases fat loss in butter milk.

Churning condition:

Under loading, overloading and under churning etc. increases fat loss in cream

Washing of butter:

After drainage of butter milk from the churn, the next stage is the washing of butter. The main
purposes of washing are as follows-

❖ To remove all loose butter milk adhering to butter grains.

❖ To adjust the softness or hardness of butter (Texture) by adjusting the temperature of wash
water.
❖ To reduce the intensity of certain off flavors, if present in cream.

Procedure of washing:

After removing butter milk, the churn is filled with fresh, clean and safe water to a point
approximately the same as that originally reached by the cream during loading the churn or, the
amount of water added for washing will be equal to the amount of butter milk drained out from
churn. The temperature of the water should be approximately the same as that of the butter milk,
If the texture of butter is satisfactory. When the butter is soft, then the temperature of water should
be little lower (1 to 20c) than that of the butter milk in order to, harden the butter somewhat during
working. After a few revolutions of the churn the water is drained off and the butter then is ready
for further processing.
Addition of butter colour:

If milk fat contains less carotene, then the colour become whitish which is the characteristic of
buffalo milk fat. Sometimes animals are deprived of green roughage which are rich in carotene.
Due to this reason colour of fat also become whitish. If butter is prepared from whitish cream, the
color of the butter will also white. But market demand is golden yellowish in colour. For this
reason, in order to produce uniform colored butter color, need to add with cream. This work is
done during churning process.

The amount of the color added depends on several factors such as type of color, intensity off-color
in butter etc. Usually the amount varies from 0-250ml/100 kg of butter. The coloring materials
used should be harmless.

The butter colour most commonly used in either vegetable origin or mineral origin. The
vegetable color used is a pigment from the seeds of Annato ( Bixa arellana), which does not
supply carotene but a related pigment. On the other hand, mineral colors are one of the series of
coal- tar dyes e.g yellow AB (Benzene Azo-β –naphthyl-amine), yellow OB ( ortho Tolune Azo-
β- naphthyl- amine)etc.

Both vegetable and coal-tar colors are prepared in natural oil which unites with the milk fat and
for this reason the buttermilk does not show, to any appreciable extend, the presence of colour.

Salting of butter:

Salting means addition of salt in butter. The main objectives of salting are as follows-----

1. To increase teats of butter

2. To improve keeping quality
3. To increase overrun in butter.

Procedure of salting:

Usually common salt is added at the rate of 2 to 3/5% of butter fat the quality of salt should be
pure (99.5- 99.8% NaCI), with fine granules and free from other foreign materials. The calculated
amount of salt can be added in butter in dry or liquid from. For liquid condition, the salt is dissolved
with small amount of water, in both conditions (dry/ liquid) the salt is sprinkled on the butter either
in churn or outside the churn during working of butter. If the salt is to be added in churn it should
be done after at the end of churning operation when all the buttermilk has been drained out. Then
few revolutions in the churn is given before taking out butter from the churn.

Problem: Fat in churn is 850 kg. Butter is to contain 2.0% salt. How much salt should be added to
the churn?
Working of butter:

Working of butter means the kneading of it. This is an important step of butter making. The
main objectives of working are----

1. To bring the fat granules into a compact mass

2. To distribute the salt evenly
3. To expel the surplus butter milk
4. To adjust the water percent in butter and
5. To give the shape of butter

Procedure of working:

During working attempts should be made to give proper composition and shape of butter. For this
purpose, the operator determines the water and fat content of butter during working. If butter
contains more moisture, then is adjusted by further working. If the butter contains less water or if
butter becomes drier due to over expel butter milk, then small amount of water is added, to adjust
the water percentage in butter. Excessive over work or under work should be avoided; otherwise,
it will damage the body of butter. When the working is completed, no free moisture should be
visible on butter and the texture of butter will be smooth, attractive and glossy.

Packaging of butter:

After working completed next step is the packaging of butter. The main objectives of
packaging are:

1. To offer protection against contamination and damage.

2. To protect butter against loss in weight and degradation (deterioration of flavor)
3. To provide ease and safety of transport
4. To provide a convenient from of disposal
5. To identify the contents and increase sales appearance.

Storage of butter:

Usually, the temperature of commercial cold storage for butter ranges from -230C to -210C. Sweet
cream butter made from good quality cream can be stored months under storage condition but the
butter from acid cream has shorter storage period than sweet cream butter. During storage
condition, butter shrinkage due to the evaporation of moisture from the butter. In order to maintain
weight during sealing an extra allowance pack is usually given during packaging.

The shrinkage of butter depends on condition of moisture in butter size of pat, temperature of
storage, relative humidity of storage air, and period of storage.
Overrun in butter

Overrun may be defined as the increase in the amount of butter made from a given amount of fat

It is always expressed as a %

The overrun in butter is due to the presence of moisture, salt and curd particles. As the minimum
legal fat content of butter is 80%, the maximum amount of butter that can be obtained from 100
kg of milk fat is

100*100/80=125kg.

This is an overrun of (125-100)25% but practically it does not happen. It was observed that, under
ideal condition an overrun of 23.5% is usually obtained

The overrun in butter is mainly influenced by the following factor:

1. Inaccuracy in weight or fat test of cream of butter

2. Fat losses in skim milk or butter milk due to faulty operation
3. Unavoidable fluctuations in the fat content of butter.
4. Weight allowance during packaging
5. Handling losses

Overrun in butter may be calculated by using the following formula% OR=B-F/F*100

Where,

OR= overrun in butter (expressed as percentage)

B= Butter made in (kg)

F= fat in churn (kg)

Calculation of yield of butter:

Yield of butter from a given lot of cream can be calculated by using the following formula

Y= F*100+%OR/100

Where, Y = yield of butter (kg)

F = fat content of cream (kg)

%OR = percent overrun in butter