Manufacturing butter involves separating cream from milk, churning it to create butterfat, and then processing and packaging it. The process can be done on a small scale using simple equipment or on a large industrial scale with advanced machinery.
India is one of the leading butter producers in the world, with lots of butter produced annually. India's butter manufacturing process follows the same basic principles as butter production worldwide. However, the differences in techniques, ingredients, and equipment make the Indian butter production process unique.
Did you know? India is the largest milk producer in the world, and butter is one of the major dairy products produced in the country. India's major butter-producing states include Gujarat, Maharashtra, Punjab, and Haryana.
Overview of Butter Manufacturing in India
Butter production in India is a well-established industry with a long history of producing high-quality butter for domestic consumption and export. The primary raw material used in butter production in India is milk, which is sourced from local dairy farms and cooperatives.
Butter manufacturing involves several steps, including cream separation, pasteurisation, churning, and packing.
The Indian butter industry is regulated by the Food Safety and Standards Authority of India (FSSAI), which sets standards for butter production, packaging, and labelling. Quality control measures are in place to ensure Indian butter meets these standards, including regular milk and butter testing.
Among the major importers of Indian butter are the US, UAE, Middle East, and Southeast Asia.
Also Read: Zipper Manufacturing in Details | Materials Used and Steps
Raw Materials and Ingredients for Butter Making
The primary raw material used in butter production in India is milk, which is sourced from local dairy farms and cooperatives. Milk is the primary ingredient in butter, and its quality and composition are essential to the final product's quality.
In India, butter production uses whole milk made of water, fat, protein, and lactose. Milk fat content is significant because it determines the yield of butter produced. Milk with a higher fat content results in higher butter yields.
In some cases, butter manufacturers in India may also add other ingredients like salt and colour to improve the taste and appearance of the butter. These ingredients must be food-grade and comply with FSSAI regulations.
Step-by-Step Butter Manufacturing Process
India's butter manufacturing industry is well-established, with a long history of producing high-quality butter for domestic consumption and export. Butter production in India uses milk sourced from local dairy farms and cooperatives.
1. Cream Separation
The butter manufacturing process begins with separating cream from milk using a centrifuge or cream separator. The cream contains butterfat, which is collected for further processing.
The cream is then pasteurised to kill any bacteria and stabilise for churning. This is done by heating the cream to a specific temperature for a specific period.
2. Churning
The pasteurised cream is then churned to separate the butterfat from the remaining liquid, which is called buttermilk. Churning is typically done using a mechanical churner. This agitates the cream until the butterfat particles clump together and separate from the buttermilk.
The churning process takes around 30 to 45 minutes, depending on the quantity of cream and the type of equipment used.
3. Washing
After churning, the butter is washed to remove any remaining buttermilk and to improve the texture and taste of the butter. The washing process uses cold water, which takes 15 to 20 minutes. Washing also removes any impurities present in butter.
4. Kneading, Shaping and Cooling
After washing, the butter is worked, which involves kneading, shaping, and cooling it to a desired consistency. The working process removes any remaining water from the butter, improving its texture and shelf life. Butter is then shaped into blocks or rolls and cooled to 4 degrees Celsius.
5. Adding Salt
At this stage, salt can be added if desired. Salt enhances butter flavour and improves preservation. Salt can be added in different amounts depending on the desired taste and functionality.
6. Packaging
The final product is then packaged and stored at the right temperature until ready to distribute. The packaging must comply with FSSAI regulations and indicate the production date, expiration date, and other information. Butter can be packaged in varied sizes, such as tubs, blocks, or rolls, depending on the manufacturer's and customer's preference.
Butter manufacturing involves several steps, including cream separation, pasteurisation, churning, washing, working, salting (if desired), and packing. The process is simple and follows FSSAI regulations to ensure the final product is high-quality and safe for consumption.
Throughout the process, the butter should be monitored for quality and safety, and regular testing should be done to ensure compliance with industry standards.
Also Read: Forming Processes in Manufacturing | Types of Forming Process
Quality Control and Standards for Indian Butter
Indian butter standards are set by the Food Safety and Standards Authority of India (FSSAI). The standards are based on the Food Safety and Standards (Food Products Standards and Food Additives) Regulations, 2011. These regulations outline the quality parameters for butter production, distribution, and sale.
To meet FSSAI standards, Indian butter must be free of foreign matter, such as insects, dirt, or other contaminants. It must also be free of hazardous bacteria, such as Salmonella, E. coli, or Staphylococcus aureus.
Butter must also have a fresh, pleasant smell and taste. In terms of packaging, butter must be packed to prevent environmental contamination. The container must be properly closed and labelled with the manufacturer's name and address, the date of manufacture, and the product's shelf life.
Packaging and Distribution of Indian Butter
Indian butter, or ghee, is typically packaged in small glass jars or tins. It is usually poured into the container while still hot and sealed tightly to maintain its freshness. This gives the ghee a long shelf life and does not require refrigeration.
Distribution of ghee varies depending on the company and brand producing it. Some companies distribute their ghee through local markets and supermarkets, while others sell it online or export it to other countries. Some ghee producers may also sell their products through wholesale or bulk distribution channels to reach a broader range of customers.
Ghee is not just Indian and is consumed in many other countries for its taste and health benefits. Therefore, the method of packaging and distribution may vary based on the target market.
Challenges Faced in Butter Production in India
1. Access to Quality Milk Supply: Finding a consistent and reliable source of quality milk is one of India's most significant challenges butter manufacturers face. The demand for quality milk far exceeds the supply, making it difficult for butter manufacturers to get the consistent quality they need to produce quality butter.
2. Cost of Equipment and Machinery: Butter manufacturing requires specialised equipment and machinery, which is high in India. This makes it difficult for small-scale butter manufacturers to invest in the necessary equipment and machinery.
3. Shortage of Skilled Labour: Finding skilled and experienced workers who can operate the equipment and machinery needed for butter manufacturing is another challenge faced by manufacturers in India. This is due to the need for more technical training in the country.
4. Inadequate Storage Facilities: Adequate cold storage facilities are essential for adequately storing butter and other dairy products. Unfortunately, there is a severe shortage of such facilities in India, resulting in frequent spoilage of butter and other dairy products.
5. Government Regulations: The Indian government has imposed several regulations on the butter manufacturing industry, which makes it difficult for manufacturers to operate efficiently. These regulations include quality standards, labelling requirements, and safety regulations.
Future of Butter Production in India
India's butter production future looks promising. India is already one of the world's largest butter producers. The country is estimated to continue to increase production in the coming years due to the increasing demand for dairy products.
India's government is also investing heavily in the dairy sector, which will increase production further and improve butter quality.
Also, advancements in technology and the increasing availability of modern machinery will enhance efficiency in butter production and reduce costs. Therefore, it can be expected that butter production in India will remain strong and grow.
Also Read: Conventional Manufacturing Process | Types, Advantages, Applications
Conclusion
In conclusion, butter production in India is a complex and labour-intensive process that requires careful attention to detail and traditional and modern techniques. The result is a delicious, nutritious product and is a key ingredient in many of India's most popular dishes.
India's butter manufacturers have developed and refined their processes over the years to ensure the highest quality product, which is why it is highly sought after domestically and internationally.
Follow Khatabook for the latest updates, news blogs, and articles related to micro, small and medium businesses (MSMEs), business tips, income tax, GST, salary, and accounting.
