Butter making process

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

2. 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

3. 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

4. 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)

5. • 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

6. 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)

7. 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.

8. 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

9. 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)

10. 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

11. 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.

12. 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)

13. 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

14. 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.

15. 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.

16. • High cooling temp.– shortens the churning period, high
fat loss and butter with a relatively soft body
• Low cooling temp.– prolong the churning time, high fat
loss, firm body butter
• Optimum temp. --- average rich cream (about 28-35%
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)

17. 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)

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

19. 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.

20. 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

21. King’s Theory
• He postulated that the mechanism of churning is
midway between the theories of Phase Reversal and
Foam.
• The film on the FG is partially removed in churning
(either by foam formation combined with mechanical
agitation or by vigorous agitation alone)
• Some residual fat is squeezed from the globules.
• Cause them to adhere together and gradually
agglomerate

22. 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.

23. • 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.

24. 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

25. 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

26. 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 30-35%
• High and low fat –both cause higher fat loss in
buttermilk

27. 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

28. 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
• 7-9 0C in summer
• 10-13 0C in winter

29. 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

30. 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

31. Calculate max. speed when R=1 m

32. 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

33. 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

34. 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

35. • 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

36. 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

37. 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

38. 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%.

39. 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

40. Addition of make up water

41. 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

42. • 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

44. 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

45. 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)

46. 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

47. 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 and
Roquefort Flav
Rancid Flavor Tallowy Flavo
Fishy Flavor Woody Flavo
Body and Texture Color

49. 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

50. 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)
Sour flavor is usually the result of the presence of excessive
buttermilk. This is obviously due to insufficient washing

51. 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.

52. 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

53. OILY METALLIC FLAVOR
– Usually present in the fresh butter at the churn
– Modifying or controlling some factors can control this defect
• High acid cream
• High fat content in cream (more than 35%)
• High temp. of pasteurization
• Prolonged holding after pasteurization and cooling
• Contamination of cream with metallic salts
Prevention:
– Pasteurizing at temp. not too high
– If higher temperatures must be used, churn as soon as possible
– Avoid cream contact with bare surfaces of copper and other
metals

54. Flavor defects that may develop after
manufactureSurface 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

55. 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

56. 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

57. 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)
– Over neutralization
– Diacetyl
– 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
– Diacetyl max. 4 ppm
– Avoid over neutralization

58. 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

59. 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

61. 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

62. 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

63. 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

64. 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

65. 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 casein caseinate forms
 In subsequent pasteurization, these particles contract and
harden giving the cream and butter, a disagreeable rough,
grainy and mealy character

66. 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

67. 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%

68. 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