Technological line for the production of butter.

Characteristics of products, raw materials and semi-finished products. Butter is a food product produced from cow's milk, consisting mainly of milk fat and having a specific taste, smell and plastic consistency inherent to it. In addition to fat, butter contains water, proteins, milk sugar, phosphatides, vitamins, minerals, etc.

Low melting point (27 ... 34 ° С) and solidification (18 ... 23 ° С) of milk fat promotes its transition in the digestive tract to the most convenient liquid state for assimilation (assimilation of milk fat - 91.0%, dry matter - 94.1 %). The nutritional value of butter is increased by the phospholipids it contains, especially lecithin, which gets into the butter together with the shells of fat globules.

Butter is the richest in fat-soluble provitamin A, from which the human body synthesizes vitamin A. Due to the high concentration of provitamin A (carotene), butter turns yellow.

The structure, quality, stability of the oil during storage is influenced by the uniformity of distribution and the size of water droplets, the size of air bubbles, etc.

The assortment of butter (animal cow) butter is determined by the type of feedstock, processing conditions and the composition of the finished product. Cream butter is made from fresh pasteurized cream, while sour cream butter is made from pasteurized fermented cream. According to the method of processing raw materials, a distinction is made between butter obtained by churning medium-fat cream or converting high-fat cream.

In our country, the following types of butter are produced: butter, containing 82.5% fat; amateur (78%); peasant (72.5%) and sandwich (61.5%). The oil can be unsalted or salted. Vologda butter (82.5% fat) is also produced from cream processed at a high temperature (105 ... 110 ° C) so that the product has a specific taste and smell.

Each type of oil has its own unique taste and aroma. Butter is divided into two grades: the highest and the first. In terms of taste, nutritional value and digestibility, butter is the best fat intended mainly for consumption in its natural form. In taste and smell, butter goes well with many food products and is widely used for making sandwiches and culinary spices.

The range of animal oils also includes ghee obtained by separating plasma from free fat in molten raw butter. Ghee contains up to 99% fat and about 1% moisture. The rest of the substances (a small part of proteins, organic acids, water-soluble vitamins and minerals) are separated together with the plasma. Ghee is used for frying semi-finished culinary products.

Features of production and consumption of finished products. the production of butter belongs to the group of physical and biochemical technologies for the formation of a product from a persistent fat emulsion of milk fat - cream. The main processes are the concentration of the fat phase of the cream, the destruction of the emulsion and the formation of the product structure with the desired properties. There are two methods of butter production: whipping cream of medium fat content (30 ... 40%) and conversion of high-fat cream (up to 80 ... 82%).

In the production of butter by the churning method, the concentration of the fat phase is achieved by separating the milk and the subsequent destruction of the milk fat emulsion with the formation of butter grains and a liquid fraction - buttermilk. Oil grain is a concentrated suspension-emulsion consisting of dilapidated aggregates of fat globules. The grain is formed as a result of the aggregation (fusion) of the fat globules contained in the cream under intensive mixing conditions. The texture of the finished product is formed by removing excess moisture by pressing, and sometimes by working (adding) the missing amount of water and dispersing it. Moisture regulation is carried out during oil processing. The crystallization of milk fat glycerides is completed during the physical maturation of the cream prior to mechanical processing of the butter.

When butter is obtained by the method of converting high-fat cream, the fat phase of milk is concentrated by separation. High fat cream is a highly concentrated emulsion of milk fat in plasma. High-fat cream production is reduced to mechanical separation of cream in a centrifugal separator field into high-fat cream and cream plasma - buttermilk. Moisture normalization of high-fat cream is carried out before the start of thermomechanical processing. The breakdown of the cream fat emulsion and the crystallization of milk fat glycerides occurs mainly during thermomechanical processing. At the final stage of the process, due to mechanical action, the product acquires a fine-crystalline structure and a plastic consistency.

Stages of the technological process. The production of butter by whipping cream consists of the following stages and basic operations:

- acceptance of milk and cream, sorting by quality and measuring the amount of milk and cream taken;

- heating and separation of milk;

- heating and ripening of cream;

- pasteurization, deodorization and cooling of cream;

- whipping cream and separating buttermilk;

- oil grain washing and water separation;

- oil evacuation;

- salting butter;

- mechanical processing: normalization and distribution of moisture, plasticization and formation of an oil layer;

- packing oil into consumer and shipping containers.

Characteristics of equipment complexes. The line for the production of butter begins with a complex of equipment for receiving and storing milk, which includes pumps, containers, receiving tanks and scales.

The line includes a set of equipment for heating and separating milk, consisting of plate pasteurization and cooling units and separators-cream separators.

The next is a set of equipment for the heat treatment of cream and its ripening, which includes a plate heat exchanger, a pasteurization and cooling unit, a vacuum deodorization unit and tanks for storing and ripening cream.

The leading one is a set of equipment for whipping cream, washing, salting and mechanical processing of butter, representing batch and continuous butter makers.

The final set of equipment includes machines for packing butter into boxes or consumer containers.

In fig. 2.20. shows the machine-hardware diagram of the butter line by the method of whipping cream (traditional).

The device and principle of operation of the line. Milk received using pumps 1 goes to the container 2 , heated in a plate pasteurization and cooling unit 3 and separated in a cream separator 4 .

The received milk is separated at a temperature of 35 ... 40 ° C to obtain cream with the desired mass fraction of fat. For the production of butter by the churning method, cream with a mass fraction of fat 36 ... 50% is used in continuous butter makers. When producing butter by churning in batch butter makers, medium fat cream with a fat mass fraction of 32..37% is used.

Skimmed milk after separation is sent to unit 3 for pasteurization and cooling, and then for processing or for returning to consignors.

The cream taken from the separator compartments is weighed on a scale 5 and through the receiving bath 6 are sent for heating to a plate heat exchanger 7 .

Cream from the separator and separator compartments goes to the tank 8 for intermediate storage, from where they are sent to a plate pasteurization and cooling unit 9 , where it is heated to a pasteurization temperature of 85 ... 90 ° C, and then cooled to a ripening temperature of 2 ... 8 ° C.

Pasteurized cream is supplied (if necessary) to the vacuum deodorization unit 11 equipped with a vacuum pump 10 ... After uninstalling in the installation 11 foreign smells and tastes, the cream is pumped into the cream-maturing apparatus 12 ... In it, with the slow development of lactic acid microflora, there is a change in the physicochemical properties of cream, which provide favorable conditions for butter formation.

Cream after ripening with a screw pump 13 sent either to a batch butter maker 14 , or to a continuous butter maker 17 where the whipping of cream, washing of oil grains, salting and processing of butter are carried out.

Cream for batch butter 14 supplied by a metering pump 13 and knock down to obtain oil grains with a size of 3 ... 5 mm. After that, buttermilk is released, the oil grain is washed and the oil is salted with dry salt or brine.

Rice. 2.20. Machine-hardware diagram of the butter production line

Then the oil is mechanically processed to separate moisture and form a layer of oil. To improve the consistency and distribution of moisture, the oil is processed in a homogenizer-plasticizer 15 ... The finished oil is discharged into a filling machine 16 .

To a continuous buttermaker 17 cream from a creamer 12 pumped by a metering pump 13 through the surge tank. Oil producer 17 consists of successively placed components: a beater with a cylindrical cooling body and a paddle mixer, and a screw texturer.

In the beater, the process of processing the cream is carried out under vigorous stirring conditions. As a result of churning, an oil grain is formed, which, after exiting the churner, is separated from the buttermilk.

In the texturer, the first processing of the oil grain, and then the oil layer, consists in pressing out moisture: removing the excess, and sometimes working in the missing amount of water and dispersing it. The texturer consists of three auger chambers (the first is for processing butter and separating the buttermilk into a tank 18 , the second - for washing oil grains and separating water into the tank 19 , the third is a vacuum chamber for evacuating oil), a salting unit with a dosing device 20 and a block for machining oil. The moisture content in the oil is regulated by the addition of the missing amount of water with a dosing pump 21 .

Finished oil by conveyor 22 goes to the filling machine 23 for packing in the form of briquettes in parchment packs.

The counters are littered with butter ... And this is suspicious! According to the calculations of specialists, in order to produce the amount shown by the reports of our enterprises, it is necessary to produce four times more milk than it is actually produced. Output? Three quarters of butter is closer to margarine in composition. How to tell a fake from real butter?

Butter is a special product. In order to get one kilogram of butter, up to 1.6 kilograms of cream is required, which, in turn, is made from 20-25 liters of natural cow's milk. Most doctors and nutritionists, despite the fat and high cholesterol content, consider butter to be an essential food for every person. Of course, if you use it in reasonable amounts.

The minimum daily allowance for a healthy person is 10 grams of butter, but in some cases (exhaustion, dry skin, vitamin deficiency), it can be consumed up to 30 grams. Butter contains fatty acids, proteins, carbohydrates, vitamins A, D, E, PP, B vitamins, iron, calcium, potassium, magnesium, phosphorus, sodium, copper, manganese, zinc. Vitamin E is essential for the beauty and health of skin, hair and nails, and the strength of our muscles. Vitamin A maintains normal vision, is responsible for the health of the skin and mucous membranes. Healthy bones and teeth are impossible without vitamin D. All of these vitamins are fat-soluble, and the body absorbs them best with the help of natural fats. And cholesterol in certain doses is vital for humans, since it is a structural component of cell membranes.

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Light, or, as they are also called, combined, oils in their composition are closer to margarine. They contain combined fats - such butter is made not from pure cream, but from a mixture of vegetable and milk fats. It used to be that light oil was thought to be healthier because it contains less cholesterol. However, now scientists are inclined to believe that it is better to simply reduce the portions of consumed butter than to eat an unnatural product. Studies have shown that the hydrogenated fats found in fake oils increase your risk of diabetes and weaken your immune system.

But what exactly are we used to buying in the store? The average cost of milk taken by the dairy plant from the population is 15 rubles. As mentioned above, to produce a kilogram of milk butter, you need at least 20-25 liters. Accordingly, if only natural milk is used in the production of butter, the cost of a kilogram of butter will be at least 300-375 rubles. It is necessary to add to the cost price the cost of delivery, packaging, shop mark-up ... As a result, a 200-gram pack of real butter will cost at least 80-100 rubles. Seeing on the counter a package of butter for 40 rubles, you can make a logical conclusion that it consists of natural cream less than half.

What else besides the price should make you wary?

Read the packaging

You will have to strain your eyes to distinguish a combo product from real butter. Manufacturers are used to indicating the composition in small print on the side or back of the package. Often this information is completely hidden in the folds of paper. If you are not even able to read the composition of the product, it is better to refuse it. In theory, a decent manufacturer has nothing to hide.

Aroma and color

Before you buy oil, smell it. Artificial flavors cannot completely recreate the smell of real butter. A high-quality product has a clean, characteristic odor without impurities. If you are buying oil by weight, ask the seller to cut a piece and show you the cut. Real butter is dense, shiny or slightly shiny, dry at the cut (although the appearance of single droplets of moisture is allowed).

Butter is one of the most consumed foodstuffs and buttermaking occupies a large niche in the dairy industry. Butter production as a business: technology, equipment and profitability calculation for aspiring entrepreneurs.

Classification

Butter is made from milk fat and may contain flavoring and aromatic additives. Various raw materials are used for manufacturing:

• cream skimmed from cow's milk;
• cream skimmed from buffalo milk;
• cream from curd whey;
• a mixture of milk fat with milk plasma;
• a mixture of baked milk and milk plasma.

In Russia, the production of different types of butter is carried out in accordance with GOST R 52969-2008 "Butter" and GOST R 52970-2008 "Butter with fillers":

1. Traditional - salty and unsalted, sweet cream and sour cream, 82.5% fat. The liquid content in sweet and sour - up to 16%, in salty - up to 15.
2. Amateur - salty and unsalted, sweet cream and sour cream, 80% fat. The liquid content in sweet and sour - up to 18%, in salty - up to 17%.
3. Peasant - salted and unsalted, sweet cream and sour cream, 72.5% fat. The liquid content in sweet and sour - up to 25%, in salty - up to 24%.
4. Sandwich - unsalted, sweet cream and sour cream, 62.5% fat. The liquid content is up to 35%.
5. Tea - unsalted, sweet cream and sour cream, 50% fat. The liquid content is up to 45.5%.
6. Chocolate - 62% fat.
7. Honey - 52% and 57% fat.
8. Dessert - 62% fat with additions of coffee, cocoa, chicory, fruits, berries.
9. Snack bar - 55% and 62% fat with the addition of vegetables and herbs.
10. Delicacy - 55% and 62% fat with seafood, fish, meat and mushrooms.

In addition, they produce:

• ghee, 99% fat;
• milk fat, 99.8% fat.

Butter is valuable because it contains milk protein, vitamins, minerals, and increases the digestibility of other food products. Oil is smeared on bread, added to cereals, vegetables, confectionery, used for frying and heating dishes.

Manufacturing technology

The butter production technique includes two approaches:

1. Cream is churned in batch and continuous butter machines. For this, heated milk is separated, normalized, purified and deodorized. Then the cream is hot pasteurized, cooled for several hours and whipped in a butter maker. The buttermilk obtained in the process is drained, and the oil grains in the same unit are washed with cold water 2 times. Then add salt and form a large piece of butter, which is cut into standard sticks. This method is time consuming and not used in large production facilities.
2. High fat cream is converted according to the Meleshin method. The cream is pasteurized in the same way as in the first case, then it is normalized. Further, in the process of aging, the oil becomes more fragrant and acquires a pronounced taste. The cream is whipped in a butter maker for 2.5 - 3 minutes, then salt and carotene are added. The oil crystallizes, is packaged and stored for up to 5 days in the cold.

This method is used in the Russian Federation at large factories.

To make butter with different flavors, the necessary ingredients are added at the normalization stage - cocoa, honey, fruit, vanillin, carotene and others. Then the mass is heated for 20 minutes and the butter maker is started.

Step by step, the technological process of making butter looks like this:

• Milk supply to the creamery. It is carried out in sealed and sterile from the inside tanks or tanks.
• Quality control. It is carried out both visually and in the laboratory.
• Storage of raw materials. Milk can be stored for about 6 hours at + 8 ° C, up to 24 hours at + 4 ° C.
• Purification of raw materials using filters.
• Separation with heating to 39 ° C, as a result of which cream is released from the milk - a fatty substance similar to cream.
• Cream pasteurization is carried out for 15-20 minutes at 85-90 ° С in summer and at 92-95 ° С in winter. This destroys harmful bacteria that cause spoilage of the product.

The main difference between these two methods of butter production technology lies in the applied temperature regime. Churning of cream after pasteurization occurs at temperatures of 5-20 ° C. With the method of converting high-fat cream, the process proceeds at 60-95 ° C until the moment of sudden cooling and hardening of glycerides.

To ensure the safety of the oil at the plant before shipment to consumers, it is necessary to create conditions in special chambers with sub-zero temperatures, good insulation, ventilation and humidity up to 80%. The shelf life depends on the type of oil and the material of the package.

Traditional, peasant, amateur is stored in parchment paper for up to 10 days, in foil - up to 20 days, in polymer material - up to 15 days, in metal packaging - up to 90 days. Butter with fillers is saved for no more than 3 days.

Free download here as a sample.

Equipment

The necessary equipment for the production of butter at the mini-factory consists of the following equipment:

1. Centrifugal and rotary pumps.
2. Scales.
3. Reception bath.
4. Cooler.
5. Tanks for cream, milk and buttermilk.
6. Heat exchanger.
7. Separator.
8. Pasteurizer.
9. Deodorizer.
10. Sourdough.
11. Homogenizer.
12. Churns of batch and continuous action.
13. Filling machines.
14. Machine for stacking packs of oil.
15. Box sealing machine.

A finished production line costs from 2 to 20 million rubles.

Video: butter production.

Profitability

To determine the profitability of an oil business, you need to consider all the costs of doing business, both initial and recurring. And also calculate the estimated income.

The production technology is such that 1 kg of butter 82% is obtained from 18 liters of milk 5% or from 24 liters of milk 3%. To reduce the cost, you can use vegetable fats, but this will negatively affect the quality of the product.

Planning the volume of oil production per month is 1 ton in packs of 250 grams. To start production, it is necessary to include in the calculation the purchase of 18,000 liters of milk with a fat content of 5%, 10 kg of fine salt "Extra", packaging material, boxes for storing and transporting oil, disinfectants.

To locate a mini-plant, you need to rent a room with an area of ​​about 150 sq. m., which will house a technological production line, a warehouse for raw materials, a warehouse for finished products, utility rooms.

The release of food products, in addition to the mandatory registration of a business entity, is subject to certification, inspection by the bodies of Rospotrebnadzor and SES. Product samples are submitted to the laboratory for quality analysis.

Employees of the mini-plant must have health books and undergo safety instructions. For the operation of the workshop, 3 workers, 1 technologist, 1 specialist in the purchase of raw materials and sales of products, 1 accountant are enough.

The initial investment for the launch of the project includes:

Fixed monthly production costs are:

Gross proceeds from sales per month at an oil price of 600 rubles / kg will amount to 600,000 rubles, profit - 100,000 rubles, investments in production will pay off in 2.5 years, business profitability - 16%.

You can organize sales through grocery stores, markets, conclude contracts for wholesale supplies with confectionery enterprises. To create a memorable brand, original packaging is developed, a trade mark is registered. A more economical option to ensure stable sales is to supply products to large retail chains under their own brands.

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Butter is a food product that will always be in demand among consumers. Therefore, its production can bring great profits. Equipment for the production of oil must meet certain requirements and carry out all the processes prescribed by the technology of work.

There are several types of oil, which differ from each other in quality composition, taste, fat content and other characteristics. However, they are very similar in appearance. In the production of butter, you can organize the production of the following varieties:

• melted. Contains about 99% fat and less than 0.7% moisture;
• Vologda. Fat concentration reaches 82.5%, moisture - 16%;
• amateur. Fat content of the product is 78%, moisture content is 20%;
• peasant. Fat content - 72.5%, moisture - 25%;
• sandwich. Fat concentration - 61.5%, moisture - 35%;
• chocolate. Fat content - 62%, moisture - 16%, sugar - more than 18%, cocoa - 2.5%.

What raw materials are needed to organize production

Regardless of the chosen methods of butter production, it is necessary to provide the workshops with quality raw materials. The taste and smell, as well as the shelf life of the finished product, will depend on this.

Quality control of raw materials should be carried out by qualified specialists at the stage of their arrival at the warehouse. Whenever possible, it is best to enter into contracts with local farmers who will supply the right products in the right quantities.

Cow's milk is considered to be the main raw material for butter production. If it is planned to release other types of products, it is necessary to additionally purchase honey, cocoa powder, nuts, etc. Many manufacturers use artificial components (stabilizers, flavor enhancers, colorants) to improve the basic quality characteristics of the finished product.

When buying milk, you should give preference to a product with a high fat content. If cream is used as a raw material, the following should be considered:

• 1st grade cream. They have a homogeneous consistency; lumps and flakes do not form during boiling;
• raw materials of the 2nd grade. The presence of oil clots with a mild taste is allowed.

When producing butter, it should be borne in mind that to obtain 1 kg of a finished product with 82% fat content, it is necessary to use 17 liters of milk of 5% fat or 23 liters of 3% fat. Vegetable fats can be added to its composition, which will reduce the price of the product, but will negatively affect its taste and quality.

Equipment used to organize production

Oil production is impossible without special equipment. Its quantity and capacity depend on the volume of products that are planned to be produced and the selected technology. Usually a mini-workshop for the production of oil is equipped with the following equipment:

• pasteurizer. It is used for heat treatment of raw materials, which makes it possible to destroy all harmful microorganisms in its composition;
• separator. Separates milk and cream, which takes place in several stages;
• vacuum type deodorizer. The equipment is used to remove extraneous tastes and odors from raw materials;
• normalizing baths or containers. They are used to bring the product to the required fat content;
• cylindrical or lamellar oil maker. It is used to obtain a finished product from prepared raw materials;
• homogenizers-plasticizers. Such equipment gives the creamy mass a uniform consistency;
• pump;
• automatic filling machine. The equipment puts the finished product into packaging.

Production technology

To obtain butter, two technological schemes are used - whipping cream and transforming them. In each case, the raw materials undergo the same preparation using the same equipment. The raw materials collected from suppliers are discharged into a receiving tank. Milk is heated, followed by separation.

With the help of special equipment, cream with a fat content of 35–45% is pasteurized, which destroys all pathogenic microflora. Subsequently, the raw material is deodorized. It is in this form that the cream is sent for further processing, using the selected technology and equipment.

The cream, pasteurized with the help of special equipment, is cooled and kept for some time at an air temperature of 2–8 ° С. This is necessary for the "ripening" of the product, which makes it suitable for further processing. The lower the ambient temperature, the faster this process will take place.

After this preparation, the cream is transferred to the butter mills. They are special wooden or metal containers that can rotate. As a result of the impacts produced, an oil grain is formed. It is a crystallized fat found in dairy products. After the formation of the oil grain, the whipping of the cream is stopped.

This process takes one hour on average. The rotation speed of the snare drums must be at least 30 rpm. The resulting grain is sent to the next stages of processing, and the buttermilk is discharged. In the future, the process of oil formation is carried out according to the following technology:

1. The resulting product is washed using special equipment (once or twice).
2. Calcined salt is added to the oil, which increases its shelf life.
3. With the help of special equipment equipped with squeezing rollers, a layer of uniform thickness is formed from the oil mass.
4. The finished product is packaged, packaged and sent to the consumer.
5. In the production of sour cream butter, after pasteurization, the milk is fermented.

The method of processing cream, which involves churning it with the use of special equipment, has many disadvantages. It is economically unprofitable to use it in the production of a large volume of products.

This method of butter production is based on thermomechanical processing of the butter mass. After preparing the milk, a high-fat cream is obtained. They are sent to a butter maker, where a mass with a characteristic structure comes out. Its consistency is significantly different from that which is obtained as a result of churning.

To complete the manufacturing process of a given product, it must go through a maturation process. For this, the prepared mass is allowed to stand at + 12–16 ° С for several days. After such an exposure, the finished product will not melt at normal room temperature. If the oil quickly loses its characteristics and loses its shape, then the manufacturer has violated the production technology.

To obtain a creamy yellow mass, a dye called carotene is added to the prepared raw materials. Its amount in the finished product should not exceed 0.1%. In the normalization process, which is carried out in special equipment, other additives are added to the raw materials - honey, cocoa, syrups, vanillin.

The advantage of this method of processing raw milk is considered to be its cost-effectiveness and speed. It is advisable to use it in the manufacture of large volumes of goods of various types.