Coursework: Technique and technology for the production of butter. Oil classification, methods and technological schemes of production

The technological process of butter production includes the concentration of milk fat, the destruction of the fat emulsion and the formation of a product structure with desired properties.

There are two production methods butter: churning cream (traditional) and converting high-fat cream.

In the production of butter by the method of churning, the concentration of the fat phase is achieved by separating milk and subsequent destruction of the milk fat emulsion when churning the resulting cream. Moisture control is carried out during oil processing. The crystallization of milk fat glycerides is completed during physical maturation before the mechanical processing of the butter.

Upon receipt of butter by the method of converting high-fat cream, the concentration of the fatty phase of milk is carried out by separation. Normalization of high-fat cream by moisture is carried out before the start of thermomechanical processing. The breakdown of the cream fat emulsion and the crystallization of the milk fat glycerides occurs mainly during the thermomechanical treatment.

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 method of churning in butter-manufacturers of continuous action, cream with a mass fraction of fat of 36 ..; 50% is used. When producing butter by the method of churning in batch butter makers and by the method of converting high-fat cream, cream of medium fat content with a mass fraction of fat of 32 ... 37% is used.

When choosing a heat treatment mode, the quality of the cream and the type of oil produced are taken into account. When producing Vologda butter, only cream of the first grade is used, and heat treatment is carried out at a temperature of 105 ... 110 ° C so that the product has a specific taste and smell.

To correct defects, the cream is deodorized or replaced with cream plasma. Cream deodorization is usually combined with heat treatment.

Stages of the technological process. The production of butter by the method of churning cream consists of the following stages:

Reception and storage of milk;

Heating and separation of milk;

Heat treatment of cream and their maturation;

Whipping cream, washing, salting, mechanical processing of butter;

Packing and storage of oil.

The production of butter by the process of converting high-fat cream includes the following steps:

Reception and storage of milk;

Heating and separation;

Heat treatment of cream;

Cream separation (obtaining high-fat cream);

Normalization and thermomechanical processing of high-fat cream;

Packing and storage of oil.

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

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

The next is a complex of equipment for the heat treatment of cream and its maturation, which includes plate heat exchangers and pasteurization-cooling units and tanks for cream maturation.

The leading one is a complex of equipment for churning cream, washing, salting and mechanical processing of butter, representing batch and continuous butter producers.

The final set of equipment includes a machine for packing oil into boxes or an automatic machine for packing into small containers.

The figure shows one of the variants of the machine-hardware scheme of the butter production line by the method of churning cream (traditional).

Rice. Machine-hardware scheme of the oil production line by the churning method

The device and principle of operation of the line. The received milk is sent to the tank 2 with the help of pumps 1, heated in the plate pasteurization-cooling unit 3 and separated in the separator-cream separator 4.

The received cream from the separator compartments is weighed on the scales 6 and through the receiving funnel 7 is sent for heating to the plate heat exchanger 8.

The cream from the separator and separator compartments enters the container 5 for intermediate storage, from where it is sent to the plate pasteurization and cooling plant 9 for cream with a dispenser 10. After pasteurization, deodorization and cooling, the cream enters the container 11, where it is kept for physical maturation.

Skimmed milk after separation is sent for pasteurization, and then for processing or for return to deliverers.

The cream after physical maturation with a screw pump 12 is sent either to a batch butter maker 13 or to a continuous butter maker 16, where cream is churned, butter grains are washed, salted and butter is processed.

The cream is fed into the batch butter maker 13 under vacuum or with the help of pumps and is churned until a butter grain of 3...5 mm in size is obtained. After that, the buttermilk is released, the oil grain is washed, and the oil is salted with dry salt or brine.

The oil is then mechanically treated to separate moisture and form an oil layer. To improve the consistency and distribution of moisture, the oil is processed in a homogenizer-plasticizer. The finished oil is unloaded into the machine 14 for packing the oil into boxes 15.

The main working bodies of the continuous oil separator 76 are the beater and the oil collector. The oil grain selector consists of three screw chambers (the first is for processing oil and separating buttermilk into tank 7 7, the second is for washing oil grain and separating water into tank 18, the third is a vacuum chamber for evacuating oil), a salting unit with dosing device 19 and a block for mechanical processing of oil. The moisture content in the oil is regulated by adding the missing amount of water to the dosing pump 20. The finished oil is sent to the machine 22 by the conveyor 21 for packing in packs.

Butter is a product that is constantly present in the refrigerators of most Russians. Polls show that a butter and cheese sandwich is a favorite breakfast for both children and adults. Butter emphasizes or, on the contrary, softens the taste: for example, a sandwich with red caviar is simply unthinkable without butter.

Few people know that this product has an ancient history: for the first time, butter was obtained in India about 3000 years ago. But the Italians became the first developers of the industrial method for the production of butter. It was they who, at the beginning of the 19th century, launched the first mechanical units, with the help of which a high-fat product was produced, which became the prototype of butter in its modern conception. In the middle of the 19th century, butter was also successfully produced in Russia, churning it from fresh or fermented cream, and Vologda butter rightfully became the pride of domestic butter makers.

The quality of a product cannot depend on only one parameter: everything is important in the butter production process: the quality of raw materials, the method of manufacture, and strict adherence to the parameters of the technological process. Each of these factors largely determines the quality characteristics of the finished oil.

For the production of butter, both first and second grade milk can be used. Yes, do not be surprised: since the time of Bulgakov (“sturgeon can only be the first freshness”), little has changed. In European countries, the concept of “second-class milk” is absent at all, while in Russia, milk, which has obvious defects in taste and texture, is used very actively for the production of butter, which, oddly enough, is allowed by GOST.

Butter production is a complex multi-stage technological process, the ultimate goal of which is the concentration and isolation of milk fat. On an industrial scale, butter is produced in two ways: by mechanical churning of cream with a fat content of 35-40% or by converting high-fat cream with a fat content of 70-85%. When churning cream, a higher quality butter is obtained, which has better organoleptic and structural characteristics, but this method, alas, is inefficient. That is why for more than half a century, 90% of butter has been produced by converting high-fat cream.

Receiving milk and separating it are stages that are the same for all methods of butter production. After separation, cream containing from 35 to 45% fat is subjected to pasteurization, during which extraneous microflora is killed and deodorization is carried out (removal of extraneous "feed" flavors). The subsequent technological steps differ significantly depending on how butter is produced.

Whipping cream method

Before you place the cream in the butter drums, they must be cooled and kept at a temperature of 2 to 8 ° C. During this time, the cream ripens, its viscosity increases, microscopic fat globules agglomerate, which subsequently become centers of fat crystallization. The lower the temperature, the faster the cream "ripens", and mechanical stirring allows you to further speed up the process.

Whipping cream is carried out in butter makers, which are rotating metal cylinders or wooden barrels. Under the action of mechanical shocks, an oil grain is born, consisting of crystallized particles of milk fat. After the buttermilk begins to splatter, the churning process stops and the butter grain is washed once or twice. To increase the stability of the oil during storage, it is salted with extra calcined salt. Further, the oil mass is passed through the squeezing rollers, after which a dense homogeneous layer is formed, ready for packing, packaging and storage. It should be noted that the production of butter from sour cream is possible only by churning.

High fat cream conversion

The principle of the method is based on the conversion of an oil-in-water emulsion (cream) into a water-in-oil emulsion (butter) using thermomechanical treatment. At the first stage, high-fat cream with a fat content of 72.5% or 82.5% is obtained, which, passing through the butter former, acquire a structure characteristic of butter. Without delving into the wilds of the theoretical foundations of fat crystallization, we can say that the oil obtained in this way has a completely different structure than that produced by churning cream. Before the final readiness, it must go through the stage of maturation - holding for several days at a temperature of 12-16 ° C in order to complete the crystallization process. Probably, many paid attention that sometimes butter "spreads" at room temperature - this is a consequence of a violation of the temperature regime at the stage of cream transformation or butter maturation. The nutritional value at the same time, it does not decrease at all, and the consistency defect is not a rejection sign.

Regardless of how butter is produced, its structure must be uniform and dense. At a temperature of 12-14°C, the oil should not crumble; on the cut, the appearance of the smallest drops of water is allowed.

In accordance with GOST, several varieties of butter are produced in Russia (from fresh or fermented cream, with different fat content, salted or unsalted). Each consumer can choose the product that best suits their own food preferences.

Since oil is an everyday product for many people, it is therefore important what is butter production technology. Butter is a rather valuable product where milk fat is concentrated. It must necessarily satisfy certain requirements that relate to taste, product structure, consistency, and durability.

First of all, the quality of the butter produced depends on the quality of the raw materials used, where the butter production technology, compliance with all necessary sanitary regimes and its storage conditions are also of great importance.

Production technology regarding the manufacture of butter:

The first method involves the conversion of high-fat cream.
The second method is to churn cream, where the allowable percentage of fat should be 30-35 percent.

The second method is used in the production of small volumes of traditional butter among urban dairies.

Butter is made by the conversion method, which is used in all other types, which also includes varieties with fillers of any volume.

Technology for the production and release of butter using the churning method.

At the entrance, the product presents: MJ cream with 35 percent.

At the output, the product is: MJ butter, where the percentage of fat content can be in the range of 61-82.5 percent.

Butter production - main operations

Any factory for the production of butter implies a production process that is based on the following steps:

1. Milk intake.
2. Next comes the separation whole milk after which the cream is obtained.
3. Normalization of the resulting cream for fat. Removal of possible odors and tastes.
4. Pasteurization of cream at a temperature of 85 degrees without exposure.
5. This is followed by low-temperature preparation of cream.
6. Whipping cream.

The production of butter involves the use of various structures on which the process of churning cream takes place, butter grains are washed, salting, and mechanical processing of butter is also carried out. For the implementation of these processes is used equipment that is necessary for the production of various butter.

As for the cream, before they enter the butter maker, they are filtered. The churn is filled with 50 percent cream of its total volume. The duration of whipping takes from forty to sixty minutes. The churning process ends after an oil grain of 3-5 mm in size is obtained.

7. Washing the oil grain.

Thanks to this process, butter has a greater shelf life. So, in the process of washing, the remains of buttermilk, which acts as a nutrient medium for many microorganisms, are removed. Wash water must be of potable quality.

8. Salting oil.

The production of butter includes a process such as salting the butter, due to which the butter has a high storage stability. The boiled salt is sifted and also calcined.

9. Mechanical processing of oil grains.

This procedure is carried out in order to combine disparate grains into a single layer of oil. Rollers or screws are used for mechanical processing of oil in oil producers.

10. Packaging of the product is carried out in parchment, corrugated boxes, as well as in cached foil.

Thermostating implies a certain process, where the production of butter in the first days (up to 5 days), after the butter is produced, it must be kept at temperatures up to 15 degrees. This is done in order to create favorable conditions for the final process of crystallization of milk fat itself, in order to improve the structure and physical properties oils.

In the process of making butter, the technology of butter production must be maintained.

Butter is one of the most consumed food products, and butter making occupies a large niche in the dairy industry. Butter production as a business: technology, equipment and profitability calculation for start-up entrepreneurs.

Classification

Butter is made from milk fat and may contain flavoring and aromatic additives. For the manufacture of various raw materials are used:

• cream skimmed from cow's milk;
• cream skimmed from buffalo milk;
• curd whey cream;
• a mixture of milk fat with milk plasma;
• 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 - salted and unsalted, sweet cream and sour cream, fat content 82.5%. The liquid content in sweet and sour - up to 16%, in salty - up to 15.
2. Amateur - salted 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, fat content 72.5%. The liquid content in sweet and sour - up to 25%, in salty - up to 24%.
4. Sandwich - unsalted, sweet cream and sour cream, fat content 62.5%. Liquid content - 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 - fat content 52% and 57%.
8. Dessert - 62% fat with coffee, cocoa, chicory, fruits, berries.
9. Snack - 55% and 62% fat with vegetables and herbs.
10. Delicacy - fat content 55% and 62% with seafood, fish, meat and mushrooms.

In addition, they produce:

• melted butter, fat content 99%;
• milk fat, fat content 99.8%.

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

Manufacturing technology

Butter production technique includes two approaches:

1. Cream is churned in batch and continuous butter makers. To do this, the heated milk is separated, normalized, cleaned and deodorized. Then the cream is hot pasteurized, cooled for several hours and whipped in a butter-former. The buttermilk obtained in the process is drained, and the oil grains in the same unit are washed with cold water 2 times. Then salt is added and a large piece of butter is formed, which is cut into standard bars. This method takes a lot of time and is not used in large industries.
2. High-fat cream is converted according to the Meleshin method. Cream is pasteurized in the same way as in the first case, then they are normalized. Further, in the process of aging, the oil becomes more odorous and acquires a pronounced taste. Cream is whipped in a butter-former 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 for large factories.

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

The step-by-step technological process for making butter is as follows:

• Delivery of milk to the oil mill. 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 with filters.
• Separation with heating up to 39°C, as a result of which cream, a fatty substance similar to cream, is separated from the milk.
• Cream pasteurization is carried out for 15-20 minutes at 85-90°C in summer and at 92-95°C in winter. At the same time, harmful bacteria that cause spoilage of the product are destroyed.

№	Whipping cream method	Cream conversion method
7	Ripening of cream as a result of cooling to 4-8°C and keeping at this temperature for several hours.	Aging for 24 hours pasteurized cream.
8	Churning cream in a churn for about half an hour to obtain a butter grain. At the same time, all the air is vented and a liquid is released - buttermilk, which is drained into a separate container.	Separation of cream with heating to high temperatures and obtaining high-fat cream.
9	Washing the oil grain with cold water 1-2 times.	Cream normalization, for which high-fat cream is diluted with pasteurized milk.
10	Add salt to the oil and stir for another half hour.	Crystallization of fats in a butter-former with constant stirring and cooling to 10-13°C in several steps. At the same stage, the oil is salted.
11	Transfer of the entire finished volume of oil to the unit, which forms standard bars.	Packaging of incompletely cured product.
12	Wrapping packaging.	Temperature control of oil for 3-5 days at a temperature of 5-10°C. At this time, complete hardening occurs and the product acquires a marketable appearance.
13	Moving to a warehouse for storage and sale.	Storage and sale of oil.

The main difference between these two methods of butter production technology lies in the temperature regime used. Whipping 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 rapid cooling and solidification of glycerides.

To ensure the safety of the oil at the plant until 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 packaging material.

Traditional, peasant, amateur products are 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 stored for no more than 3 days.

Here you can download for free as a sample.

Equipment

The necessary equipment for the production of butter in a 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. Starter.
11. Homogenizer.
12. Butter churns of periodic and continuous action.
13. Packing machines.
14. Butter stacking machine.
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 production business, you need to take into account all the costs of doing business, both initial and regular. And also calculate the expected 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, vegetable fats can be used, but this will adversely affect the quality of the product.

Planning the volume of oil production per month is 1 ton in packaging of 250 gr. 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 Extra fine salt, packaging material, boxes for storing and transporting butter, and disinfectants.

For the location of the mini-factory, you need to rent a room with an area of ​​\u200b\u200babout 150 square meters. m., which will house the production line, raw materials warehouse, finished products warehouse, utility rooms.

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

Employees of the mini-factory must have sanitary books and undergo safety training. 3 employees, 1 technologist, 1 specialist in the purchase of raw materials and sales of products, 1 accountant are enough for the operation of the workshop.

The initial investment for the launch of the project includes:

№	expenditures	Amount, rub.
1	Workshop rent (for 2 months)	120 000
2	Repair work	100 000
3	Legal Registration and Permits	50 000
4	Equipment and inventory	2 500 000
5	Purchase of raw materials	250 000
6	Product promotion	60 000
7	other expenses	100 000
Total		3 180 000

Fixed monthly production costs are:

Gross revenue from sales per month at an oil price of 600 rubles / kg will be 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 deliveries with confectionery enterprises. To create a memorable brand, original packaging is developed, a trademark is registered. A more economical option to ensure stable sales is the supply of products for large retail chains under their own brand.

If you find an error, please highlight a piece of text and click Ctrl+Enter.

Butter is absolutely deservedly considered one of the most popular and versatile products. Each housewife uses it with pleasure in the process of creating culinary masterpieces. Here we will talk about the butter production business, the line and equipment for it, see the technology and manufacturing methods on the video.

Oil types

There are a great many types of butter, similar in appearance, but different in taste and nutritional qualities. The main types of this product differ in fat content, moisture and taste. A kind of rating for the above parameters is as follows:

1. Ghee must contain at least 99% fat and no more than 0.7% moisture;
2. Vologda - 82.5% fat, 16% moisture;
3. Amateur - 78% fat, 20% moisture;
4. Peasant - 72.5% fat, 25% moisture;
5. Sandwich - 61.5% fat, 35% moisture;
6. Chocolate - 62% fat, 16% moisture, at least 18% sugar, at least 2.5% cocoa.

Butter business can be a very lucrative business.

Necessary equipment and raw materials

Butter production line consists of the following machines and machines:

1. separators;
2. Vacuum deodorizers;
3. Normalization baths;
4. Long-term pasteurization bath;
5. Oil formers of continuous action;
6. Homogenizer-plasticizer;
7. Pump;
8. Reservoir with a volume of 10 sq.m.

The prices for all this equipment for the production of butter depend on many factors and can vary significantly, here everyone chooses the best option for themselves. In order for the line to work with maximum efficiency, it is necessary to hire a technologist, foreman and workers.

Line for the production of butter P8-0LF-01 / Price from 2.5 million rubles

The packaging machine will cost another 300 thousand rubles.

The quality of butter directly depends on the quality of raw materials, it is not worth saving on it. Milk is better to buy fatter. When buying cream, the following criteria are taken into account:

1. Cream of the 1st grade - homogeneous consistency; sweetish, fresh taste; no protein flakes are formed during boiling.
2. Cream of the 2nd grade - there are lumps of butter; the taste is weakly expressed; flakes are formed during boiling.

For the production of 1 kg of butter with 82% fat content, 17 liters of milk with 5% fat content or 29 liters of milk with 3% fat content will be required. It is possible to introduce vegetable fats to make the product cheaper. Based on the foregoing, it is possible to calculate the profitability of the enterprise quite accurately.

Production technology - manufacturing methods

There are two main technologies for making butter: whipping cream and converting high-fat cream.

The method of whipping cream consists of several stages. The milk must be warmed up and driven through the separator. The resulting cream must be normalized to 35% fat, cleaned and deodorized. The next stage is pasteurization of cream at a temperature of 85 degrees. The cream cooled to 4-6 degrees is aged for 7-15 hours. Then they are placed in an oil former and beaten for about an hour in a drum at a speed of 30-40 revolutions per minute. The result should be butter grains and buttermilk, which is drained. After that, the oil grains are washed twice with cold water in the same drum at a speed of 10 rpm. Then the future butter is sprinkled with fine salt "Extra" and with the help of rollers and screws of the same butter former, one large piece of butter is created. After that, it remains only to cut and package. The method of whipping cream is not very good for production in large quantities due to the significant time required for the whole process.

The method of converting high-fat cream can significantly reduce the production time. The milk mass is heated, passes through the separator and pasteurized in the same way as in the first method. Normalization occurs by adding pasteurized milk or buttermilk. The output humidity should be 15.8%. To give a richer smell and taste, the cream is subjected to a thermostating process. Next comes the oil former, mixing takes 180-200 seconds in summer, 140-160 seconds in winter, after which the oil is salted and crystallized. Ready, packaged oil should be kept for 3-5 days at a temperature of 5-15 degrees. Yellow saturated color is achieved by adding carotene, it should be no more than 0.1%.

In order to obtain chocolate butter, during the normalization of the cream, the fillers provided according to the recipe are added to the baths. According to the standards, the percentage of their content is as follows: Honey - 36%, syrups - 16%, fruit and berry fillers - 10%, vanillin is given at the rate of 15 grams per ton.

After adding all of the above ingredients, the cream is heated to 65-70 degrees and after twenty minutes they begin to process with a butter former.

Storage Requirements

Butter is stored at a temperature not higher than 3 ° C, humidity - not higher than 80%. Under such conditions, the implementation period is no more than 10 days after packing in parchment, 20 - in aluminum foil, 8 - in the same material with a net weight of 15-30 grams, 15 - in polymer cups. Butter can be stored for 90 days in a metal container.

Sales of finished products

In winter and spring, butter costs 10% more. The market for this product is unimaginably wide. In order to avoid problems with the sale of products, it is important to organize an advertising campaign smartly. Interesting packaging will also create a memorable, popular brand. But still, quality is the main trump card of any butter manufacturer, in other things, like any other product.