Coursework: Technique and technology for the production of butter. How butter is made

MINISTRY OF AGRICULTURE OF THE RUSSIAN FEDERATION

FEDERAL STATE EDUCATIONAL INSTITUTION

HIGHER PROFESSIONAL EDUCATION

"NOVOSIBIRSK STATE AGRARIAN UNIVERSITY"

TOMSK AGRICULTURAL INSTITUTE (BRANCH)

FACULTY

By discipline: Equipment and automation of processing industries

Technique and technology of butter production

1. OIL PRODUCTION

Oil is a fatty substance prepared from substances of animal origin.

MAIN TECHNOLOGICAL OPERATIONS

The technological scheme for the production of butter includes the following operations:

Receiving milk, obtaining cream, pasteurization and deodorization of cream;

· When churning cream - cooling and physical ripening, churning cream, mechanical processing of butter grains, washing, salting, packaging;

· When converting high-fat cream - separation of cream, normalization and thermomechanical processing of high-fat cream, packaging.

After ingestion, the milk is separated. When separating, the mass fraction of cream fat is determined taking into account the method of butter production.

For cream pasteurization, plate pasteurization-cooling units are used, in which cream is heated evenly in a thin layer.

In the case of foreign tastes and odors, the pasteurization temperature is increased and deodorization is applied. It is not recommended to deodorize cream of the first grade.

The essence of churning cream is to obtain butter grains with subsequent mechanical processing into butter. Cream is churned in batch and continuous butter makers.

1.1 TECHNOLOGICAL OPERATIONS IN THE PRODUCTION OF BUTTER WHEN CREAM

Target cooling and physical ripening of cream- transfer part of the fat (at least 32 - 35%) into a solid state. When the cream is cooled, crystallization centers form and the glycerides partially solidify. Apply a long and accelerated mode of preparation of cream for churning.

In a long mode, the cream is kept for 5 to 20 hours at the temperature of mass crystallization of milk fat glycerides. Single and multi-stage cooling is used.

With single-stage cooling, the cream is quickly cooled to the ripening temperature and kept at this temperature until churning; with multi-stage cooling, the cream is cooled in stages.

churning cream consists in the aggregation (adhesion) of fat globules, culminating in the formation of oil grains.

One factor in obtaining butter grain is the temperature at which the cream is churned. It affects the duration of their churning, the fat content of buttermilk and the consistency of the butter. Under production conditions, cream is churned at 12 -16 ° C.

The duration of whipping cream depends on the ability of their foaming and the rate of destruction of the resulting foam. To accelerate the churning, it is necessary to increase the foaminess of the cream, reduce the stability of the resulting foam and create favorable conditions for its destruction.

The duration of whipping cream also depends on the mass fraction of fat in them. With an increase in it, the duration of churning of cream is reduced and the fat content of buttermilk increases.

Oil grain washing- an operation that affects the taste, smell, consistency of the oil and its stability during storage.

In accordance with the current technological instruction oil grain washing is optional. When using high quality cream, plasma has a high antioxidant capacity. When producing butter from cream with a pronounced fodder flavor and smell, concentrating in the plasma, washing the butter grain is mandatory.

Butter is salted dry and wet (brine) methods. To do this, extra-vacuum table salt with crystals up to 0.8 mm in size is used.

The dry method is used when using oil makers of periodic action, and the wet method is used when using oil makers of both periodic and continuous action. In the dry method, salt is applied directly to the oil grain or to the semi-pressed formation. Advantages of salting into the reservoir: the degree of salt utilization increases up to 97%, the error in salt calculation decreases.

At wet salted brine is added to the product (oil grain, layer) in advance at the rate of 10-12 liters of brine for every 100 kg of oil. To prepare the brine, take 1 kg of salt for every 2.8 liters of water. The brine is pasteurized, allowed to stand for 1 hour, then filtered and cooled. When using periodic oil makers, the brine is added after removal of buttermilk or washing water in an amount of 10-15% relative to the mass of the oil grain (layer) and it is worked in with closed taps in the hatch of the oil maker. After several squeezes (8-15 times), the brine is drained. Then, the same amount of the remaining brine is introduced into the oil maker and it is worked in until the required content in the oil is obtained. After that, the brine is drained and oil processing is completed.

For salting in continuous oil makers, the brine is introduced by dosing devices.

Mechanical processing of oil grain used to form a layer of oil from disparate parts of the oil grain, as well as for uniform mixing of components, averaging the composition and plasticizing the product, which affects its taste, consistency, storage stability and commercial indicators of the finished product. The mechanical treatment of oil grains begins immediately after the extraction of buttermilk or washing water.

Completion rate machining- the degree of dispersion of plasma at the border of its contact with fat. For oil produced by churning in oil makers, both periodic and continuous, this figure is 1.28 and 1.37-1.41 m 2 /cm 3, respectively.

Butter made by churning cream is packaged after it leaves the butter maker, forming large monoliths and small briquettes of various weights (from 10-15 to 50-100 g). As containers, wooden boxes and cardboard boxes are used. Before filling with oil, their inner surface is lined with packing material: parchment, laminated foil, polymer films approved for contact with oil, and other materials. The oil monolith in the box must be tight (no voids) with a flat surface.

Boxes (boxes) with oil are sent to the cooling and storage chamber, where they are placed in 3-4 rows in height. To speed up cooling, thin wooden slats are laid between the rows of boxes. After the oil has hardened (usually the next day), the boxes are stacked up to eight boxes high.

1.2 FEATURES OF THE PRODUCTION OF BUTTER BY CREAMING CREAM

By churning cream, sweet-cream, sour-cream, Vologda, peasant butter is produced.

sweetly butter. It is made from fresh pasteurized cream in batch and continuous butter makers. Salted and unsalted sweet cream butter is produced.

After receiving, primary and mechanical processing, the cream is sent for pasteurization and deodorization. Then the hot cream is cooled to 4-7 °C. The cream is cooled down in cream-ripening baths. If necessary, the cream can be kept for 15-17 hours in order to ripen. At the end of maturation, the cream is sent to butter producers. After maturation, the cream is heated to churning temperature in cream maturation baths.

Similarly made salted sweet butter. The ambassador is carried out in grain dry (salt) or wet (brine) way.

Sour milk oil. It is produced from pasteurized cream in batch and continuous butter makers. The sour-milk taste and pleasant specific aroma of this oil are due to the vital activity of lactic acid bacteria introduced with sourdough. The acidity of the sour cream butter plasma is 35 - 55 T.

Cream is pasteurized at 85-90 °C. Raw materials with foreign flavors are deodorized under intensive conditions. Pasteurized and deodorized cream is cooled to 16-20 °C, bacterial starter is introduced and kept at this temperature for 4-6 hours, stirring 3-4 times for 3-5 minutes.

For fermentation of cream, a bacterial ferment prepared on pure cultures of lactic acid streptococci is used, in the amount 2-5% from the volume of cream. The temperature and duration of the curdling of the cream is regulated based on the increase in the acidity of the cream plasma.

For getting Vologda oil with a pronounced taste and aroma, the pasteurization temperature is set depending on the mass fraction of fat in the cream. It is allowed to pasteurize cream at 97-98 °C, followed by holding it at this temperature for 10 minutes in a closed system. After pasteurization, the cream is cooled to 4-7 ° C, kept at this temperature for 4-5 hours, and then churned. The oil grain is not washed.

Peasant oil. Produced from milk and cream, as well as from cheese cream. Use the starter cultures of pure cultures of lactic acid streptococci, drinking water and table salt. It is allowed to use differentiated, stepped and soft modes for ripening cream.

Sweet Cream Peasant Butter salted in the same way as sweet cream salted butter.

Sour cream peasant butter produced from cream fermented with pure cultures of lactic streptococci.

1.3 TECHNOLOGICAL OPERATIONS IN THE PRODUCTION OF BUTTER BY CONVERTING HIGH FAT CREAM

The essence of the method is the concentration of the fatty phase of milk in the separator and the subsequent conversion of the obtained high-fat cream into butter. Separate technological operations are the same as in the production of butter by churning cream, but at the final stage these schemes differ.

Getting high-fat cream includes the following stages: separation of milk at a temperature of 45-50 °C in order to obtain cream, thickening of the fatty phase as a result of deformation of the fat globules - during the separation of cream (temperature 70-90 °C).

High fat cream normalize by mass fraction moisture and SOMO, using buttermilk, pasteurized whole milk or cream for this. The resulting oil has a pleasant aftertaste of pasteurization, which becomes more pronounced with an increase in the content of milk plasma (SOMO + water).

At oil salt dry method is used. 0.8-1% is added to high-fat cream table salt extra varieties. It is preliminarily calcined for 2-3 minutes at 120-130 °C and sieved. Store in a special container in a dry clean room.

During salting, salt is scattered over the surface of hot high-fat cream in a bath until it is normalized in terms of moisture, after which high-fat cream is thoroughly mixed and samples are taken to determine the mass fraction of moisture in them.

Thermomechanical processing of high-fat cream is carried out in butter-formers, where intensive cooling of high-fat cream and mechanical processing of the crystallizing mass of the product take place. Cooling and mechanical processing of high-fat cream in butter-formers proceed simultaneously. The oil is packaged when it flows out in the form of a free-falling jet from the oil former. The cardboard box is closed with a lid and sealed with a special paper tape.

1.4 FEATURES OF THE PRODUCTION OF BUTTER BY CONVERTING HIGH FAT CREAM

In the production of butter by converting high-fat cream, the concentration of the mass fraction of fat to the required fat content of the butter is achieved by separating the cream, followed by their thermomechanical processing in the flow. The advantage of the method is that the duration is significantly (by a factor of 2) reduced. technological process.

The transformation of high-fat cream produces sweet-cream, sour-cream, Vologda, peasant butter, butter with fillers, etc.

Sweet butter. High-fat cream is obtained by separating the original cream at a temperature of 60-85 C. High-fat cream is normalized by the mass fraction of moisture with buttermilk. After normalization, high-fat cream is immediately sent to the butter former. When producing salted sweet cream butter, salt in the amount of 0.8-1% is added by scattering over the surface of high-fat cream in baths until normalized by the mass fraction of moisture. A butter former is used to convert high-fat cream into butter. In it, rapid cooling of normalized high-fat cream and intensive mechanical processing take place. The oil from the oil former enters the container (boxes, boxes). The container with oil is sent to the cooling and storage chambers.

Sour cream oil. They are made in the same way as sweet cream. Features of the technology - the introduction of high-fat cream 2-4% of their volume of starter pure cultures of lactic acid streptococci. In this case, the temperature of high-fat cream should be 41-45 ° C. After adding the starter, high-fat cream is stirred for 5-7 minutes. In the production of salted sour cream butter, salting is carried out in the same way as in the production of sweet cream butter. After adding salt, high-fat cream is cooled to 41-45 C. Prepared normalized cream is pumped into the butter former, where it is converted.

Vologda oil. The technological process for the production of Vologda butter is the same as for the production of sweet cream butter by converting high-fat cream.

Peasant oil. Sweet-cream salted, unsalted and sour-cream unsalted peasant butter is produced by the transformation of high-fat cream. In the production of salted peasant butter, salt is scattered on the surface of high-fat cream before normalization in baths. The normalized high-fat cream is pumped into the butter-former, where it is converted into butter.

Butter with fillers. They produce the following types:

chocolate, fruit, honey.

When developing chocolate butter when separating cream, the mass fraction of moisture in high-fat cream is regulated in the range of 19.1-19.5%, honey butter - 15.4-16%. When producing fruit oil, the maximum permissible mass fraction of moisture is determined in relation to the filler used (natural fruit and berry juices, jams, extracts).

High-fat cream from the separator is sent to normalization baths, where fillers are also added to make the mixture. In production chocolate butter fillers are cocoa, sugar, vanillin. They are added to high-fat cream in dry form. Vanillin is added at the rate of 15 g per 1 ton of oil. A mixture of fillers to normalize the amount of buttermilk is added to high-fat cream and mixed.

For the production of fruit oil, fruit and berry juices (cherries, raspberries, cranberries, blueberries, strawberries, apples), juices with pulp (plums, apricots, cornelian cherry, black currants, etc.) and fillers in the form of syrups are added to high-fat cream.

In honey oil, the filler is natural bee honey, transparent, without impurities. Honey selected for the production of oil is filtered. Its quantity is determined based on the mass fraction of honey solids in the finished oil of at least 28.8%, which corresponds to 36% of natural honey. Honey is added to a bath with high-fat cream and mixed. Fruit and berry fillers are added to high-fat cream in the amount 10%, and syrups - 16%.

The mixture of high-fat cream and fillers is heated in a bath for normalization with constant stirring to a pasteurization temperature of 65-70 ° C and kept for 20 minutes. Then the pasteurized mixture is sent to the oil former. To obtain oil of uniform color and uniform consistency, its temperature at the outlet of the oil former should be 14-16 °C. The finished product is sent for packaging, packaging, labeling, storage and sale.

2. EQUIPMENT FOR BUTTER PRODUCTION

2.1 EQUIPMENT FOR PRODUCING CREAM BUTTER

In the production of butter by churning cream with the main technological equipment are cream-ripening machines and oil makers of periodic and continuous action.

Cream aging machines. Designed for the physical ripening of cream. The principle of their operation is based on the uniform effect of heat (cooling) on ​​the cream in order to convert part of the milk fat into a solid state.

Slivkosozrevatelny devices happen vertical and horizontal types. Their design feature is a housing with thermal insulation, a mixing device and a heat exchange jacket.

Cream curing apparatus vertical type. The main part of the apparatus is a cylindrical heat-insulated tank with a stirrer and a washing device. Feature of the device - a heat-exchange jacket, a stirrer and the device for a sink.

The heat exchange jacket is made in the form of a coil, which allows the refrigerant to be pumped under excess pressure, thereby increasing the efficiency of heat transfer. The agitator, mounted vertically, has the shape of a tubular contour with a diagonal blade. The stirrer drive is mounted on the lid of the apparatus.

The apparatus is filled and emptied through the nozzle, which is located at the bottom of the tank. A glass thermometer and a resistance thermometer are installed to control the product temperature. Level sensors are used to determine the level of the product in the device, and a low level sensor is used to signal emptying. A sample of the product to determine the acidity is taken through a tap located in the cylindrical part of the tank.

The device is equipped with means of control, automatic and remote control of processes.

Cream curing apparatus of vertical type with a frame agitator used for the preparation and processing of cream, in the production of butter, sour cream and other products.

The main part of the apparatus is a vertical cylindrical tank with a conical bottom. On the outer side of the bottom and the side wall of the tank there are coils interconnected by a jumper. The space between the coils and the casing of the apparatus is filled with heat-insulating material.

Features of the apparatus - the design of the mixer and the device for washing. The mixer is intended for hashing of cream. The blades are attached vertically to the rack using guide rods and union nuts. The frame agitator evenly and effectively mixes the cream during its maturation. The drive is covered with a casing.

The device for washing the apparatus consists of three washing heads. A pneumatic valve for washing solution is installed on the cleaning solution supply pipeline.

The tank has a sensor for remote measurement of the cream level, and a test valve, a cream temperature sensor, a glass thermometer and a pH meter sensor are mounted on the side wall.

The operation modes of the device and the input of programs are carried out from the automatic control panel, the information is displayed on a single-line display and LED indicators of the automatic control panel.

creamy ripening vertical type apparatus with frame stirrer:

/ - washing head; 2 - drive unit; 3 - internal capacity; 4 - Luke; 5 - agitator shaft; 6 - thermal insulation; 7- coil; 8- product quantity sensor; 9 - drain pipe cold and warm water; 10 - branch pipe for supplying heat and coolant; 12 - stirrer blade; 13 - support.

Horizontal cream vats(the so-called cream-ripening bath) is a horizontal trough-shaped tank with a jacket, which is filled with water heated by steam. Steam comes from a tubular perforated bubbler located at the bottom of the tank.

For mixing the cream, a tubular mixer is used, which makes oscillatory movements.

The cream is poured into the bath, the tubular mixer, making an oscillatory movement, mixes them evenly. A coolant is supplied to the mixer (brine, ice, chilled water, etc.). To heat the product, steam is fed into the jacket, previously filled with water up to the overflow pipe, which condenses and gives off heat to the water, and through the walls to the product. When mixing the product, uniform heating is achieved.

Oil producers. This equipment is designed for churning cream. The main part of oil makers of periodic action is a drum, continuous action is a cylindrical chamber. In a batch oil maker, the drum can be cylindrical, pear-shaped, conical, cubic and other shapes. The most common oil makers with a cylindrical drum.

Batch oil maker with a cylindrical drum. A hinged hatch, viewing windows, a cock for the release of buttermilk and a valve for the release of gases generated during churning of cream are mounted on the surface of the drum. The inner surface of the drum is rough, which eliminates the sticking of oil grains. Above the drum is an irrigation device made of pipes with holes.

Batch oil maker with a conical drum. The drum consists of two cones welded at the base. At the top of one of the cones there is a hatch for unloading oil. The drum is equipped with a viewing window and two taps for draining the buttermilk. The drum has an obliquely welded blade for churning cream and processing butter. Its inner surface is rough, which prevents oil from sticking. The drum receives rotation from a two-speed electric motor through a V-belt transmission.

To cool the oil maker drum, an irrigation device in the form of a shower is provided. The shower has a valve connected to pipes for hot and cold water.

Continuous Oil Maker consists of serially connected devices for churning cream into butter grains (whippers, whippers, etc.) and a texturizer for processing butter grain into a layer.

Whippers are available with a churning cylinder in which the butter grain is completed, or with a churning cylinder and a separating cylinder in which the churning and separation of the butter grain from the buttermilk is completed.

The processing of oil grains in a texturizer consists in squeezing out excess moisture, and sometimes producing the missing amount of moisture. Texturators are available with one screw chamber or two placed in series or in parallel. Each of these chambers can be one-, two- and three-stage.

Cream enters the whipper through a tap from the end or tangentially to the wall. When entering from the end, the cream sprayed by the rotating disc evenly flows onto the mixer blades. With a tangential injection, the cream is guided through a pipe into a cone that rotates with the agitator. Evenly distributed over the cone, the cream is continuously fed to the mixer blades under the action of centrifugal force. Whipping cream takes place under conditions of vigorous stirring. As a result of churning, butter grains and buttermilk are formed. After draining the buttermilk, the oil grain is washed in the washing chamber and sent to the pressing chamber. In it, the oil grain is first forced by a screw through a narrow slot in the upper part of the housing, and then washed with water supplied by nozzles. After washing, the water is drained into a sump. From the washing chamber, the oil grain enters the processing chamber under vacuum, from where the finished product is unloaded and sent for storage.

Continuous oil maker:

/ - bed; 2 - electric motor; 3 - speed variator; 4 - tap; 5 - beater; 6 - heat exchange shirt; 7 - mixer; 8 - texturer; 9 - oil grain washing chamber; 10, 11 - settling tanks, respectively, of buttermilk and wash water; 12 - oil grain processing chamber under vacuum; 13 - perforated matrices with blades; 14 - dosing pump; 15 - conical nozzle; 16 - Remote Control

Continuous installation designed for continuous churning of cream and butter production.

Ripened, heated to the churning temperature, thoroughly mixed cream is fed through the equalizing tank by a screw pump to the churning machine, and then to the churning cylinder of the butter maker. The cream enters the beaters of the churning cylinder. The resulting oil grain with buttermilk enters the hopper of the first chamber of the auger texturer, where the grain is washed in buttermilk and processed by augers.

The formation of the oil layer begins in the first chamber of the oil maker. In the second chamber, the final washing of the oil and further processing of the grain take place. In the third chamber, a vacuum pump creates a vacuum to remove air, since the high air content in the oil negatively affects its resistance.

For final mechanical processing, the oil is forced through a series of grates, between which knives are installed to stir the oil. When the mass fraction of moisture in the oil is lower than necessary, the apparatus for dosing moisture is turned on. The finished oil enters the storage tank, from where it is sent for packaging.

After sorting and weighing, the incoming cream is pumped into storage tanks, then into the receiving tank of the combined heat exchanger, where they are preheated to 30-40 C in a plate apparatus, then processed in a deodorizer and regenerator for pasteurization to a temperature of 115 C - finally the cream is pasteurized in a tubular device. Further, the pasteurized cream enters the tubular regenerator, the cooling section of the lamellar plant and, at a temperature of 4-6 ° C, is sent for maturation to the cream maturation apparatus. The ripened cream is fed by a screw pump to the beater and then to the butter maker.

The resulting buttermilk from the tank first enters the plate cooler and then into the tank for short-term storage. The finished oil is packaged in briquettes and packed in boxes. Packed oil is sent to cold storage.

2.2 EQUIPMENT FOR PRODUCING BUTTER BY CONVERTING HIGH FAT CREAM

For the production of butter by converting high-fat cream, equipment for the production and processing of high-fat cream is used: separators, vacuum deodorizers, normalization baths, continuous butter formers (cylindrical and lamellar) and a homogenizer-plasticizer.

High-fat cream separators make it possible to separate cream with a fat mass fraction of 30-40% into high-fat cream with a fat mass fraction of 63.5 to 82.5%, depending on the type of butter. Separation temperature 80-90 °С. The acidity of the cream is 18 T.

High fat cream separator differs from the separator-cream separator by the separation system, the main unit of which is the drum.

The cream fed into the separator goes through the central pipe into a rapidly rotating drum. Through the holes of the plate holder, the cream passes into the vertical channels of the plates and is distributed in the inter-plate space, where it is separated into high-fat cream and buttermilk. Under the action of centrifugal force, buttermilk, as the heavier part, is thrown to the periphery of the drum, cream is pushed back to the axis of the drum. Buttermilk under pressure passes between the outer surface of the separating plate and the inner surface of the drum lid and enters the pressure chamber, is captured by the pressure disk and is discharged into the container through the outlet pipe. The high fat cream passes between the plate holder ribs and the plates and is ejected through the holes into the high fat cream bin.

Vacuum deodorizer designed to remove foreign odors and flavors from cream. The main part of its vacuum chamber, which is a sealed cylindrical container. At the top of it is a sprinkler. A vacuum of no more than 60 kPa is created in the chamber, and hot pasteurized cream enters the sprayer, where it is intensively crushed. At a pressure of 60 kPa in the chamber, the product boils, moisture evaporates and specific odors are partially released.

The product in the form of small drops falls to the bottom of the chamber, from where it is pumped out. The vapor-air mixture, together with volatile components, is sucked off by a vacuum pump from the chamber through a condenser, where it is condensed, and then discharged with water into the sewer network.

Scheme of vacuum deodorization plant:

/ - pump for pumping out the product; 2 - adapter with check valve; 3 - viewing window; 4- vacuum chamber; 5- inert bodies; 6- sprinkler; 7- sprinkler cover; 8- cover of the vacuum chamber; 9 - check valve; 10- vacuum gauge; 11 - capacitor; 12 - tee with plug; 13 - Vacuum pump.

According to the mass fraction of moisture, high-fat cream is normalized in baths for normalization, which is a double-walled cylindrical vertical vessel with an inclined bottom and a mechanical paddle stirrer.

If it is necessary to heat the product, the sealed container between the inner bath and the jacket is filled with a coolant. As a heat carrier, hot water or steam is used, which is introduced into a container pre-filled with water.

Bath cover is made in the form of a truncated cone; consists of two parts: movable (folding) and fixed, connected by hinged loops. On the fixed part of the cover there is a receiving hatch for feeding the product into the bath.

The frame paddle mixer is located perpendicular to the inclined bottom of the bath. The agitator shaft drive is located in the lower part of the bath on an inclined bottom. The inclination of the blades of the frame mixer and the inclined arrangement of its axis of rotation provide intensive mixing of the product and uniform distribution of moisture throughout the bath during normalization.

High-fat cream is fed into the receiving hatch in the lid and flows down the inner wall to the bottom, gradually filling the bath. After mixing, a sample of cream is taken and the mass fraction of moisture in them is determined, then the cream is normalized.

Bath for the normalization of high-fat cream:

/ - stirrer; 2 - lid; 3 - shirt; 4 - agitator drive

Cylindrical oil former consists of three unified sections connected by planks. The section includes a cooling cylinder with insulation, a displacement drum (dismembrator), a casing, a cover and a drive.

High-fat cream with a temperature of 60-70 ° C is first fed into the lower cylinder of the butter-former, then sequentially moves through the middle and upper cylinders. In each cylinder, high-fat cream during the rotation of the displacement drum is picked up by radial perforated blades, mixed and thrown to the periphery, then advanced in the annular gap between the cylinder wall and the drum.

When moving, high-fat cream is cooled by the coolant entering the jacket, cleaned from the heat-exchange surface of the cylinder with knives and intensively mixed, passing under the knives through the grooves and holes of the textured helical combs.

Next, the cooled product is subjected to mechanical processing, in which it passes through rotating perforated blades and six holes in the disk with blades into the cavity formed by this disk. The disk rotates simultaneously with the drum. Passing through three cylinders of the apparatus, as a result of thermal and mechanical treatment, high-fat cream is converted into butter, which, at a temperature of 14-16 ° C, exits through the drain valve of the upper cylinder.

Cylindrical oil former:

1 - output control valve; 2~ faucet for air removal; 3 - lid; 4 - displacement drum; 5 - casing; 6 - outer shell of the cylinder; 7 - spiral; 8 - inner shell of the cylinder; 9 - reducer; 10 - electric motor

Lamellar oil former consists of a frame with an electric motor, a cooler, an oil processor and a piping system. The electric motor drives the cooler shaft through a V-belt transmission and a gearbox. The oil treatment shaft is driven by a two-stage V-belt transmission from the same electric motor.

High-fat cream is fed by a screw pump to the cooler of the butter-former, where it is cooled from 75 to 11-14 C. Mechanical processing of high-fat cream is carried out in the butter-former's butter processor. As a result of mechanical processing and the release of latent heat of crystallization in the oil processor, the temperature of the product rises to 15-18 °C.

Plate oil former:

/ - Oil processor; 2 - cooler; 3 - three-way valve; 4- oil processor shaft; 5- bed; i - pulley; 7 - gearbox shaft; 8 - electric motor; 9 - support.

Homogenizer-plasticizer serves to give a homogeneous structure and uniform distribution of moisture in the butter. This is achieved by rotating two screws and the rotor towards each other. Screws and rotor are installed in the housing. The augers are fastened with two fixing rings in the socket of the body. The other end of the screws through the fingers connected to the gears of the gearbox. A crane is located in front of the body. It has an aperture and an aperture control. On top of the rotor, a microswitch is mounted in the housing, which turns on the homogenizer only when a tap is attached. A bunker is attached to the top of the body. On the left wall of the case there is a control panel, in front there is a socket for a switch. To transfer the movement to the rotor and screws, two electric motors are installed in the homogenizer-plasticizer.

The oil is fed into the bunker, from where it is forced through a rotating rotor and a valve with a diaphragm by two screws rotating in opposite directions. At the same time, moisture is evenly distributed in the oil, which enters the filling machine.

Homogenizer-plasticizer:

1 - wheel; 2 - bed; 3 - frame; 4,5- nests; 6 - fastening of a nozzle; 7 - nozzle; 8- lock; 9 - screw chamber; 10- bunker; 11 - Remote Control; /2 - augers

Bibliography

butter cream churning separator

1. Bredikhin S.A., Yurin V.N. Technique and technology for the production of butter and cheese. – M.: Kolos, 2007. – 319 p.

Butter is absolutely deservedly considered one of the most popular and versatile products. Each hostess is happy to use it 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 whipping cream method 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 manufacturer of butter, in other things, like any other product.

Butter, along with bread, meat, cereals and some types of vegetables, is a socially significant food product. In modern industry, several technologies for its production are used, which make it possible to obtain oil with different taste properties and fat content.

Butter is one of the most important products in the diet of a person who is popular all over the world. Its main advantages are high nutritional value, the presence a large number useful substances and naturalness. Despite the development food technology, the production of butter to this day requires the use of natural milk and not a single product in the world can act as its full-fledged substitute.

One of the oldest products in the world

Butter production methods were known in ancient India more than 3 thousand years ago. At that time, the product was created in a handicraft way using exclusively manual labor. First industrial equipment appeared only at the beginning of the 19th century. It was developed by Italian masters who sought to simplify the scheme for obtaining high-fat dairy product. Gradually, technologies improved and by the middle of the 20th century, butter in its characteristics became similar to modern butter.

Butter production technology

The essence of all currently known methods is to isolate milk fat. In modern industry, this task is carried out by thermomechanically converting cream or churning it. The latter method allows you to get a very tasty and healthy product, but it is characterized by low productivity. The technology of butter production by converting high-fat cream is used by most modern enterprises, it requires a minimum of labor costs (almost all operations are performed in semi-automatic or automatic modes), which leads to a low cost of the final product.

In general, the production process can be divided into the following stages:

• receiving milk;
• separation;
• normalization of cream, removal of various odors and flavors;
• pasteurization;
• maturation;
• churning or thermomechanical transformation;
• packing and packing.

Milk reception

In Russia, raw materials of the 1st and 2nd grades are selected for the production of oils. The latter type of milk may have a specific smell, taste defects and some other disadvantages. In Europe, butter is prepared exclusively from raw materials of the highest category. In the process of receiving cow's milk, samples are taken for analysis, after which the laboratory issues a conclusion on the characteristics of the supplied raw materials and permission to use it for production purposes. At the last stage, mechanical impurities are removed and milk is transferred to the separation.

Separation

The operation is performed at a temperature of 35-40 °C, which is achieved by heating the product with a tubular heater. The essence of the method is to place milk in a rotating drum, which contributes to the separation of cream. Before stopping, skimmed milk is placed in the separator, which forces the cream to the surface.

Cream normalization, removal of various odors and flavors

Modern methods of butter production require the use of cream with the same fat characteristics. Therefore, before churning, fat content is normalized. For this, a special bath is used, in which cream, skim milk and buttermilk are placed. To increase the fat content, cream with a higher mass fraction of fat is sometimes used.

Pasteurization

Pasteurization is carried out to prevent the bacteria contained in milk for the production of butter from quickly spoiling the cream. The essence of this procedure is to heat the mass to a temperature of 92-95 ° C in winter period and 85-90 °C in summer for 15-20 minutes. During the specified time, most microorganisms are neutralized, due to which the shelf life of the cream is increased by 3-4 times.

Maturation

The hot mass is cooled down to 2-8 °C in a bath that was used for standardization and pasteurization. A rapid decrease in temperature occurs due to the continuous supply of cold water to the jacket and smooth mixing of the mass. Ripening occurs naturally during settling. At the same time, part of the milk fat hardens, forming clusters, which are then broken into oil grains. The maturation process is accelerated by lowering the temperature to minimum values ​​and by continuous mechanical stirring.

Butter production by churning

The transformation of cream into butter is carried out in butter-making machines. They are movable metal or wooden (already practically not used) cylinders. During rotation, the fat particles crystallize, turning into an oil grain. The process stops after the buttermilk begins to splatter.

After that, the formed grains are washed several times. Thanks to this procedure, the butter acquires additional stability during storage. The rinsing also removes the remaining buttermilk. At the next stage, the oil is salted with pre-calcined salt and the grains are mechanically processed. The resulting mass passes through special squeezing rollers, due to which a continuous oil layer is formed, ready for further packing and packaging.

Cream thermomechanical conversion method

The main feature of this technological process for the production of butter is the use of raw materials with a high mass fraction of fat. The cream passes through a butter-former, in which, under the influence of high temperature and mechanical loads, the fat crystallizes. The duration of the process is several days, after which the product is ready for packaging.

In accordance with Russian standards, butter can be produced from fermented or butter cream with different fat content. The resulting varieties are identical in nutritional properties and differ only in organoleptic qualities.

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 stages:

1. Milk intake.
2. Next, the separation of whole milk takes place, after which 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 the milk fat itself, in order to improve the structure and physical properties of the oil.

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

Buttermaking is one of the main areas of the dairy industry. Butter is a highly nutritious high-calorie product with a fat content of 55 to 85%. It contains fat and water soluble vitamins. The oil is a water-in-oil inverse emulsion. Such an emulsion is stable only at a fat level of more than 70%; taking into account this feature, stabilizers are introduced into the composition in the manufacture of oil with a lower fat content.

Technology and stages of butter production

It consists in the chemical-physical separation of concentrated fat from the cream, the uniform distribution of its components and plasticization. Two technologies have been developed for concentrating the fat fraction of cream: cold whipping and hot separation. In accordance with the method of concentration at the intermediate stages of the technology, they work with butter grains or high-fat cream, which differ significantly in individual characteristics from butter. According to the norms of the standard, the raw material for the production of butter is represented by milk.

The oil production line includes complex equipment for receiving and storing raw materials (compression pumps, containers, baths and weighing devices). In addition, there is equipment for heating and separation (pasteurization-cooling units and separation cream separators). Then in the production line there is equipment for heat treatment of cream (plate heat exchange and pasteurization-cooling units, containers for cream maturation). This is followed by complex equipment for churning the creamy fraction, washing, and mechanical action. The line is completed by a packing machine.

The initial stage of the production technology is the acceptance of dairy raw materials, which includes a qualitative analysis, inspection and sorting of each batch received. At the same time, the container is inspected, its cleanliness, the integrity of the seals, the filling feature, the condition of the ring inserts under the lids are assessed. Dairy raw materials are transported in clean, internally sterilized road tanks or flasks. The milk delivered to the enterprise is mixed, samples are taken for organoleptic evaluation. Biochemical analysis is a mandatory step in the production process.

Before the separation stage, milk is filtered using filters acceptable in the food industry. Excessively contaminated raw materials are freed from impurities in the separator-purifier. If it is necessary to store milk, it should be cooled: at 8 ° C, the storage time is 6 hours, at 4 ° C - a day.

The next mandatory step in the production scheme is, which is performed at 36-39 ° C and acidity 16-20 ° T. The raw material is heated in a flow tube heater, while the throughput of the heater must be in accordance with the passport parameters of the separator.

The technological scheme of butter production provides for the use of cream of uniform fat content, since otherwise different whipping modes will be needed. Under optimal whipping conditions, the duration of butter formation is in close inverse relationship with the fat concentration in the cream. For the manufacture of butter, the required fat content is 25-37%. Normalization of the creamy fraction is carried out by adding whole milk. The process itself takes place in a continuous pasteurization bath.

At the end of the separation technological line includes the stage of pasteurization of normalized cream in a special bath. Separation regimes depend on the season. In summer, the process is carried out at 85-90 °C for 15-20 minutes, in winter - at 92-95 °C during the same time. When choosing pasteurization parameters, the level of acidity of the primary cream should be taken into account. Only cream with an acidity below 20 °T is allowed to be pasteurized.

Further, the production line provides for the stage of cooling the hot cream to 4-8 ° C by filling the tub jacket with cool water. To reduce the time spent on cooling, the cream is evenly mixed.

Any of the production methods includes the cream ripening stage, due to the hardening of the fat and the possibility of the formation of oily grains during their further whipping. The level of hardening of the fat is closely related to the cooling temperature and the duration of exposure. The lower the temperature parameters for cooling the cream and the longer the aging process, the better the level of fat hardening. The duration of cream exposure at a certain temperature corresponds to obtaining the optimal level of fat hardening (about 30%) and the equilibrium state between different fat fractions.

Production methods

In Russia, the production of butter is carried out according to the technology of converting high-fat cream. At the same time, the main factor in the preparation of high-quality products is a stable fat-emulsion base. The emulsification step is very important for the quality of the product. It allows you to achieve the required level of fat emulsification.

Oil production creamy method transformation consists in changing the qualitative properties of fat globules with further release and concentration of the fat fraction while creating the oil structure in parallel. The main chemical and physical elements of oil formation are the solidification of the fatty phase, the crystallization of lipids and the formation of the oil structure.

High-fat cream is a rather stable emulsion medium, the fat globules of which are separated by water-protein layers of the dispersion material. The change in the structure of the cream is carried out in the process of churning.

In the butter-former, high-fat cream heated to high temperatures is subjected to the continuous influence of low-positive temperatures and active mechanical stirring. In the course of this, intensive disintegration of the shells of fat globules and the release of the non-solidified liquid phase of fat are carried out, after which hardening and crystallization of lipids from liquid fat occur.

With intermittent cooling (up to 20-22 ° C and then to 10-13 ° C), the stage of separate-group crystallization of lipids is performed: initially, high-melting lipids are mainly crystallized, then low-melting lipids. At the same time, the transition of the most unstable polymorphic types of lipids into stable ones occurs. Hardening of a rational volume of fat in the equipment of the butter-former is not carried out - the product at the exit consists of only 12% of hardened fat. The main hardening phenomenon occurs in the butter monolith during thermostating.

In factories for the production of butter, the solidification of the fat fraction is not uniform, since milk fat is a mixture of lipids with different solidification temperatures. A certain number of shells of fat globules in the oil-forming agent do not disintegrate, in addition, secondary emulsification of the liquid phase of fat occurs.

In parallel with the hardening of the fat in the oil former, the direct emulsion fraction is transferred to the reverse one, during which the liquid fat is converted into a continuous stream in which various components and phases are evenly distributed.

At the end of mixing, when the volume of fat released becomes maximum, the reverse emulsion phase dominates. About the change of phases, a conclusion is made by the number of free fat fraction or by the volume in the oily plasma of the emulsion fat. Phase change is accompanied by crystallization of the fatty phase and polymorphic changes in lipids. In the course of this, the resulting fatty crystals react with each other and form a three-dimensional oil structure. The dominance of crystallized or coagulative components in it directly affects the oil consistency.

The volume, uniformity of distribution, microdispersion of plasma and air fraction affect the mechanical characteristics and preservation of butter. Butter produced using the technology of converting high-fat cream is distinguished by a high level of dispersion and the most homogeneous plasma. Its composition is dominated (over 90%) by drops with a radius of 0.5 ... 10, less air content and more volume of emulsified fat. The degree of fragmentation of plasma particles to a greater extent affects the nature and activity of oxidation and microbiological spoilage of butter.