Butter is a high-calorie product with pleasant taste and aroma. It is produced from the cream of cow or buffalo milk.

There are two oil production method:

1. churning medium fat cream (35–38%) in butter makers;
2. converting high fat cream (82.5–83%) into butter.

The milk received by the organization is separated to obtain cream.

Oil production flow diagram the churning method is as follows: sorting and preparing cream -> pasteurization -> cooling and ripening of cream -> churning cream into butter grains -> washing and mechanical processing of butter grains -> packaging and packaging of butter.

Cream is sorted by organoleptic indicators and acidity, normalized by fat content and pasteurized at a temperature of +85...95 °C.

After pasteurization, the cream is immediately cooled. At a cream temperature of +1...3 °C - the duration of ripening in summer is 2 hours, in winter - 1 hour, at a cream temperature of +4...8 °C - the duration of ripening in summer is 4 hours, in winter - 2 hours.

According to the given production mode, part of the cream is used for churning (to obtain sweet butter), part for maturation, i.e. cooling the cream with added starters to the ripening temperature (for cultured butter).

Fermentation of cream, depending on the temperature, lasts 14–16 hours. In the first 3 hours, the cream is stirred every hour, and then it is left alone. The end of ripening is determined by the increase in acidity to 65 °T in summer and 80–85 °T in winter.

Long-term pasteurization baths are also used for cooling and maturation. By quickly cooling the fermented cream to +5...6 °C, the ripening process can be reduced to 6–8 hours. During the ripening process, 40–50% hardens milk fat.

Used to obtain oil batch oil producers, in which the cream is churned, i.e. obtaining butter grains and buttermilk, processing the resulting oil.

Under the right conditions, churning should continue in oil producers for 50–70 minutes and end when an oil grain of 3–5 mm is obtained. The size of the butter grain determines its ability to hold buttermilk.

In order to increase the stability and lengthen the shelf life of the oil, the resulting oil grain is subjected to double washing with water, having previously removed the buttermilk from the oil maker. The temperature of the wash water should be equal to the temperature of the buttermilk, and during the second wash it should be 1–2 °C lower.

The purpose of oil processing is to obtain a uniform consistency with the desired moisture content evenly distributed throughout the oil. The degree of moisture dispersion in the oil depends on the duration of rotation of the oil manufacturer. The moisture content in the oil should not exceed 14%. The oil should appear dry.

Work more efficiently continuous oil producers. In a butter maker, cream with a fat content of 38–42% is churned. The ripened cream enters the regulating receiving tank, and from there into the whipping cylinder, which is a stainless steel drum with a jacket and circulation cold water. A mixer rotates in the cylinder at high speed, whipping the cream into butter grains in 20–30 seconds.

The oil grain together with the buttermilk enters a screw-type processing cylinder, consisting of several chambers: for separating the buttermilk, for washing and processing the oil.

In the first chamber, the oil grain is separated from the buttermilk using screws, which flows through a filter into the buttermilk outlet siphon, then the grain is sent to the oil washing chamber, where it is washed with a stream of cold water (+3...5 °C) supplied under high pressure, and at the same time loosens.

Next, the oil is pushed by screws into a processing chamber under vacuum, where the water is removed. Ready oil in the form of a continuous rectangular belt, it is pushed out of the oil maker by a screw through a conical nozzle and sent to the machine for packaging into boxes or packs. When making amateur oil, washing is not carried out.

In-line butter is produced using three main devices– pasteurizer, separator and oil former:

Installation diagram for butter production

1 – tank with jacket and stirrer; 2 – dispersant; 3 – pump; 4 – tubular pasteurizer; 5 – three-cylinder oil former; 6 – automatic oil filling machine

First from fresh milk produce cream with 35–40% fat content. Then they are pasteurized at a temperature of +85...86 °C and higher in a centrifugal pasteurizer and sent to a separator to obtain high-fat cream with a fat content of 83%.

The resulting high-fat cream is an emulsion of fat in water and does not have the structure of butter. To give this structure they are processed in special devices- oil formers.

The technological process of butter production includes concentrating milk fat, breaking the fat emulsion and forming a product structure with desired properties.

There are two ways to produce butter: churning (traditional) and converting high-fat cream.

When producing butter by churning, 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. Crystallization of milk fat glycerides is completed during physical maturation until machining oils

When producing butter by converting high-fat cream, the fat phase of milk is concentrated by separation. Normalization of high-fat cream for moisture is carried out before the start of thermomechanical processing. The breakdown of the cream fat emulsion and the crystallization of milk fat glycerides occurs mainly during thermomechanical processing.

The received milk is separated at a temperature of 35...40 °C to obtain cream with the desired mass fraction fat To produce butter using the churning method, continuous butter producers use cream with a fat mass fraction of 36.. ;50%. When producing butter by churning in batch butter producers and by converting high-fat cream, medium-fat cream with a fat mass fraction 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 first-grade cream 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 the plasma of the cream is replaced. Deodorization of cream is usually combined with heat treatment.

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

Reception and storage of milk;

Warming and separating milk;

Heat treatment of cream and its ripening;

Cream churning, washing, salting, mechanical processing of butter;

Oil packaging and storage.

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

Reception and storage of milk;

Heating and separation;

Heat treatment of cream;

Cream separation (production of high-fat cream);

Normalization and thermomechanical processing of high-fat cream;

Oil packaging and storage.

Characteristics of equipment complexes. A line for the production of butter by churning cream begins with a set 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 heat treatment of cream and its maturation, which includes plate heat exchangers and pasteurization-cooling units and containers 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 options for the machine and hardware diagram of a butter production line using the traditional method of churning cream.

Rice. Machinery diagram of the oil production line using the churning method

Design and operating principle of the line. The received milk is sent to container 2 using pumps 1, heated in a plate pasteurization-cooling unit 3 and separated in a cream separator 4.

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

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

After separation, skim milk is sent for pasteurization and then for processing or for return to distributors.

After physical maturation, the cream is sent by screw pump 12 either to a batch butter maker 13 or to a continuous butter maker 16, where the cream is churned, the oil grain is washed, salted and the butter is processed.

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

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

The main working parts of the continuous oil separator 76 are the churner 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 evacuation of oil), a salting block with a dosing device 19 and the oil mechanical processing unit. The moisture content in the oil is regulated by adding the missing amount of water by dosing pump 20. The finished oil is sent by conveyor 21 to machine 22 for packing.

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

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

Production technology for making butter:

The first method involves converting high fat cream.
The second method consists of churning cream, where the permissible percentage of fat content should be 30-35 percent.

The second method is used in the production of small volumes traditional oil among city dairies.

Butter is produced by the transformation 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 is: MJ cream with 35 percent.

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

Butter production - main operations

Any butter production plant involves a production process that is based on the following stages:

1. Taking milk.
2. Next comes the separation whole milk, after which cream is obtained.
3. Normalization of the resulting cream by fat. Removing possible odors and tastes.
4. Pasteurization of cream at a temperature of 85 degrees without holding.
5. Next comes the low-temperature preparation of the cream.
6. Creaming.

The production of butter involves the use of various structures on which the process of churning the cream takes place, the butter grains are washed, salted, and mechanical processing of the butter is also carried out. To carry out these processes it is used equipment necessary for the production of various butters.

As for the cream, it goes through filtration before it enters the butter maker. The butter churn is filled with cream 50 percent 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 greater shelf life. Thus, during the washing process, buttermilk residues are removed, which acts as a breeding ground for many microorganisms. The rinsing water must be of potable quality.

8. Salting butter.

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

9. Mechanical processing of oil grains.

This procedure is carried out in order to combine scattered grains into a single layer of oil. For mechanical processing of oil, oil producers use rollers or augers.

10. The product is packaged in parchment, corrugated boxes, and also in cached foil.

Thermostating involves a certain process where the production of butter in the first days (up to 5 days), after the oil is produced, it must be kept at temperatures up to 15 degrees. This is carried out 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 butter production technology must be maintained.

Making butter is also profitable in small-scale production. This sector of the economy is promising and tends to grow.

Stable demand for butter

The recommended amount of oil per person is about five kilograms, but a significant part of the population (about 20%) consumes less than 1 kg per year. This product contains a set of vitamins from A to E, normalizes cell growth, vision, skin, nails, hair, skeletal system, nerve tissue and hormonal balance, That's why natural oil will always be in demand.

Creation of a food mini-factory

Butter production begins with the following steps.

1. Registration of an LLC is carried out, selection of strategic partners involved in the supply of raw materials and sales (dairy farms, bases, wholesale warehouses). Supermarkets provide maximum continuous sales, so you should adapt your activities to them.

2. A reporting package template is purchased, ordered, or generated.

3. A set of state standards, acts, technical specifications mandatory for food production.

4. A room of at least 150 square meters (for a creamery) is selected that meets the standards of sanitary, hygienic and other services. Buying technological equipment. For service technological line four workers required.

5. A business plan is created (calculation of all costs and net profit by day, month and year).
Advice from the site: It is best to plan the payback of a mini-plant for a period of at least one and a half years. To achieve this, the average return on sales should be kept at more than 45%. To reduce risks, a backup technological option is provided, for example, the production of margarine or low-calorie spread with a milk fat content of less than 49%.

6. Passing the procedure for documentary certification of oil and packaging, confirming the quality of the product, its compliance with technology and proprietary specifications.

Butter production technology

There are two methods for making the product.

1. Cream conversion. After checking, the milk is poured into a separator, where the heated cream is separated, then it is cooled to ripen the semi-finished product and the mass is whipped, followed by washing and molding, dosing and packaging.

2. Cold beating method. In the separator, the fat content of the cream is adjusted to 39%, whipped in a mixer, then pasteurized and kept for 24 hours. Then the raw materials are loaded into the oil drum of the unit (half the volume) washed with iodine solution for thirty minutes. Next, add salt to the mixture and repeat the beating process. The process is completed by a fulling machine that sends formed portions of butter to packaging.

The laboratory carries out random quality control of the product and only after that it is sent to the consumer. Oil is classified by fat content: from dietary (50%) to traditional (82.5%). Melted butter has a higher fat content, but it does not contain many substances, and dry oil just dilute with water. Fruit, honey, chocolate fillers and other ingredients diversify the product range, and vitamins, preservatives, dyes and emulsifiers can be added to inexpensive varieties. Natural butter does not contain vegetable fats; the packaging is marked with large, legible text.

To stimulate interest, it is necessary to give discounts to wholesalers, participate in advertising competitions, print booklets, arrange preferential sales, create a corporate brand and appropriate packaging. According to statistics, the maximum profit comes from direct work and excellent quality oil. In second place in terms of profit are “economy” oils without packaging.

Video - how to make butter

In this article:

This industry is quite promising because it receives government support. In addition, the whole milk products market is characterized by dynamic development, and the entry of new participants into it is not particularly difficult. Product healthy eating characterized by demand among the population with the most at different levels income. To organize a business, capital investments in the amount of 2,310,000 rubles will be required.

This business plan can be a good help for those who want to earn a stable income in the production of dairy and cream products.

List of organizational points for creating a mini-factory

After registering a business entity, it is necessary to enlist the support of the SES, which will examine the production workshop for compliance with established requirements. In progress registration actions you need to familiarize yourself with the OKVED codes:

• 15.51.3 Production of cow butter

Before releasing the first batch, you should study GOSTs:

• GOST R 52253-2004 "Butter and oil pastes from cow's milk."
• GOST R 52969-2008 “Technical conditions”.

To produce butter, you must undergo a mandatory certification procedure. Inspection control includes determining the quality of certified products, namely, the compliance of dairy products with respect to their name (in particular, fat content indicators) is identified. The provided documents are studied, the batch of selected samples, packaging, labeling, etc. are visually inspected.

Technological process of butter production

There are two main technologies for the production of butter: the method of whipping cream and its conversion. Let's take a closer look at the first method.

Oil production begins with the arrival of the tank with cow's milk from the supplier. Before pouring the feedstock into the tanks of the mini-plant, it must be checked for color and odor. Raw milk enters a machine called a separator, where a drum separates the fat from the liquid. This fat is called cream, and the liquid is skim milk.

The main component for the production of butter is cream. They are a thick liquid of creamy consistency with a fat content of about 38%. Some of them are used to make oil from low level fat content A worker adjusts the valve to pour back some skim milk.

Thus, the less fat in the main ingredient of butter, the thinner and more transparent it is. The cream is poured into the so-called bulk tank, where it is whipped with a mixer in order to maintain consistency. After the pasteurization process and aging for 24 hours, the cream is redirected to another unit - an oil press.

First, the container should be rinsed with an iodine solution previously diluted in water. This is how you can kill germs remaining after previous operations. Rinse the oil tank for about 5 minutes before draining the water. Next, cream is fed in, filling the drum halfway.

It is extremely important to leave free space in the unit. In this case, the air that will be released during the beating process will escape.

For this purpose, there are 2 valves at the top of the unit.

The drum performance is 28 rotations per minute.

This causes the fat molecules to whip together and release air and water. Every 5 minutes a worker stops the machine to open the valve. Seeing that all the air has come out, he closes it and starts the oil press again. After 30 minutes of churning, the fat molecules in the cream clump into clumps called “popcorn.”

These lumps remain inside the unit, while the remaining liquid (“buttermilk”) is poured down through the hole.

A vacuum pump pumps the buttermilk through a hose into a nearby container. This process is quite fast. For example, pumping 500 liters of liquid will take about 6-7 minutes. The remaining "popcorn" in the reservoir has a similar consistency to traditional butter at room temperature.

Next, the workers begin salting the floor. finished product salt. The drum door is then closed and the mixing process is repeated. After 30 minutes, the oil molecules whipped up even more, and due to thorough mixing, a homogeneous mass was obtained yellow color due to its richness in vitamin A.

Here it is pushed to the final production stage - the formation of square bars with their further packaging. This process is performed by an injector, which itself is brick-shaped. The unit puts ready-made portions of oil into packaging.

It is noteworthy that the packaging paper must have a layer of foil that will protect the finished product from external influences and ensure its safety. This is especially true of the harmful effects of direct sunlight, which instantly deteriorates the oil.

A worker checks every 20 pack of butter to make sure it weighs exactly 250 grams. The method of converting cream with high fat content can significantly reduce production time.

The milk mass is heated, passed through a separator and pasteurized - everything is identical to the previous method.

Normalization is done by adding pasteurized milk (buttermilk).

Next comes the thermostating stage, when the finished product is given a rich smell and taste. Then the mass is placed in an oil former, and after that the product is salted and crystallized. Packs of oil are kept for 3-5 days (temperature 5-10 degrees). If necessary get yellow saturated color, then carotene is added to the semi-finished product (no more than 0.1%).

If it is necessary to make honey or chocolate butter, at the stage of normalizing the cream, it is necessary to add appropriate fillers (transparent honey, sugar, vanillin, cocoa, etc.).

This method will be preferable in case of production of large batches finished products.

Business plan for butter production

Requirements for a production workshop

The preferred room area should be at least 150 square meters. You should also take care regarding the availability of utility rooms, a warehouse for raw materials and finished products.

We purchase equipment:

• separator - 200,000 rubles (see picture);
• baths for normalization - 100,000 rubles (see picture);
• vacuum deodorization units – 450,000 rubles (see figure);
• baths for long-term pasteurization 350,000 rubles (see picture);
• filling machine – 500,000 rubles (see picture);
• homogenizer-plasticizer – 310,000 rubles;
• pump – 50,000 rubles;
• tank with remote control – 350,000 rubles.

Separator

Deodorization unit

Bath for normalization

Long-term pasteurization bath

Filling machine

Total capital investments: 2,310,000 rubles.

Direct and raw material costs

The monthly production volume is expected to be 1000 kg. butter (4000 packs of 250 grams). Accordingly, the mini-plant will produce 46 kg in one work shift. finished product (182 packs of 250 grams). For the convenience of customers and delivery of butter to retail chains, butter will be packaged in 250 gram packages.

The retail price of 1 kilogram of oil will be 394 rubles.

Calculation of direct costs for production of 1000 kg. butter:

• 12,000 liters of milk 5% fat – 156,000 rubles (13 rubles per liter);
• table salt – 200 rubles.

Total raw material costs are 156,200 rubles.

• Auxiliary materials per 1000 kg. finished product:
• labels – 5,000 rubles;
• packing tape – 15,000 rubles;
• boxes – 5,000 rubles.

Total: 25,000 rubles.

We are hiring staff

The number of personnel for the mini-factory is 8 people, of which 4 production workshop workers, 1 director, 1 technologist, 1 laboratory assistant, 1 head of the supply, sales and advertising department.

The monthly payroll will be 40,000 rubles.

Calculation of the cost of butter:

1. The cost of raw materials and basic materials is 156,200 rubles.
2. Auxiliary materials – 25,000 rubles;
3. Transport and procurement costs (2.5% of point 1) – 4880 rubles;
4. Payment of utility costs – 10,000 rubles;
5. Rent – ​​10,000 rubles;
6. Employees' wages are 40,000 rubles.

The total cost is 246,080 rubles.

Sales revenue is determined by multiplying the retail price by sales volume: 394 rubles x 1000 kg. = 394,000 rubles.

Profit = 394,000 – 246,080 = 147,920 rubles;

Net profit (including taxation) – 170,108 rubles;

Return on sales is 43%.

The payback period for capital investments with a monthly production of 4000 packs will be 1 year and 2 months. Thus, subject to 100% sales of products, the butter production business has every chance of becoming a very profitable activity.

Sales of finished product (butter)

It is noteworthy that in winter and spring the cost of butter increases by an average of 10%. To organize a trouble-free implementation, it is necessary to carefully consider the advertising campaign. For example, developed unique packaging will help create a memorable brand. However, we should not forget about the quality of butter, because this is a fundamental factor for increased demand from consumers.

Basic methods of sales promotion:

• bright and colorful packaging combined with excellent quality;
• periodic holding of promotions;
• providing discounts to wholesalers subject to self-pickup;
• opening your own retail outlet (stall in the market);
• outdoor advertising, etc.

Many factories produce economy oil. His distinctive features are the lack of packaging and packing.

The product is sold by weight and is intended for residents with middle and low incomes. Preferred place of sale– food markets, shops and even supermarkets.

A good option is mutually beneficial cooperation with a supermarket chain, which specialize in selling products (including butter) under their own trademarks. This option can be used in case of low sales volumes to avoid unprofitable activities. In this case, the created mini-factory will be a production base that will produce products based on the order and package it in the packaging of the retail chain.

Good product quality and strict adherence to delivery deadlines determine the long-term and efficient functioning of a business entity.