{"id":59,"date":"2018-07-24T05:48:26","date_gmt":"2018-07-24T05:48:26","guid":{"rendered":"http:\/\/ftp04.epgpbooks.inflibnet.ac.in\/?post_type=chapter&p=59"},"modified":"2018-12-12T05:34:37","modified_gmt":"2018-12-12T05:34:37","slug":"technology-of-ghee-making-direct-cream-creamery-butter-continuous-method","status":"publish","type":"chapter","link":"https:\/\/ebooks.inflibnet.ac.in\/ftp04\/chapter\/technology-of-ghee-making-direct-cream-creamery-butter-continuous-method\/","title":{"rendered":"Technology of Ghee making \u2013Direct cream, Creamery butter, Continuous method"},"content":{"raw":"
\"epgp<\/a>\r\n<\/span><\/div>\r\n
\r\n\r\n \r\n\r\n \r\n\r\n \r\n\r\nIntroduction<\/strong>\r\n\r\n \r\n

The word ghee is evolved from Sanskrit word \u2018ghrut\u2019. Ghee is a common Indian name for clarified butter fat. The word itself stems from the old Sanskrit \u2018ghr\u2019 which means bright or to make bright.<\/p>\r\n \r\n

FSSAI specifications for ghee<\/strong><\/p>\r\n \r\n

According to Food Safety and Standards Authority of India (FSSAI) ghee means the pure clarified fat derived solely from milk or curd or from desi (cooking) butter or from cream to which no colouring matter or preservative has been added. The standards of quality of ghee produced in a State or Union Territory in India is as shown in Table 1A and 1B. Ghee may contain butylated hydroxyl anisole (BHA) at concentration not exceeding 0.02%. Baudouin test should be negative. Positive test indicates presence of dalda (hydrogenated vegetable fat) as an adulterant in ghee.<\/p>\r\n \r\n\r\n\"\"\r\n\r\n\"\"\r\n\r\n \r\n\r\nAgmark certification of ghee<\/strong>\r\n\r\n \r\n

In India, ghee is marketed from organized dairies under Agmark certification, wherein there are three grades based on the Free Fatty Acids (FFA) contents: Special (Max. 1.4% FFA), General (Max. 2.5% FFA) and Standard (Max. 3.0% FFA) (Table 2). Irrespective of the grade of ghee, the BR reading and Polenske value should lie between 40.0-43.0 and 1.0-2.0 respectively. The Reichert Meissl (RM) value should be minimum 28.0, whereas the moisture content should not exceed 0.3%. Baudouin test should be negative.<\/span><\/p>\r\n \r\n

General characteristics: <\/em>Ghee shall be pure, clarified milk fat only and shall have a natural, sweet pleasant odour, agreeable taste and free from rancid or other objectionable flavor. On melting, ghee shall be clear, transparent and free from sediment or foreign colouring matter. The phenolphthalein test, the phytosterol acetate test and test for presence of nonmilk animal fats shall be negative. The physico-chemical constants of ghee shall be characteristic of the type of milk (cow, buffalo or their admixture) from which it is produced and of the season of the year and the place or district where it is produced.<\/span><\/p>\r\n \r\n

Colour: <\/em>White with or without yellowish or greenish tint, and shall be uniform throughout.<\/span><\/p>\r\n \r\n

Texture <\/em>(below fats melting point): The solid phase should be of well defined granular structure. Marking provisions: The grade designation mark (i.e. special, standard, general) in the form of label shall be securely affixed to each sealed container of ghee. The grade designation mark in the form of replica shall be clearly an indelibly printed or embossed on such containers as permitted by the Agricultural Marketing Adviser.<\/span><\/p>\r\n\r\n<\/div>\r\n

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In addition to the grade designation mark, each container shall be clearly marked with the following particulars namely:<\/p>\r\n\r\n<\/div>\r\n(i)\u00a0\u00a0 Name of the packer, (ii) C.A. Number, (iii) Place of packing, (iv) Melt number, (v) Date of Packing, and (vi) Net weight of ghee.<\/span>\r\n\r\n \r\n\r\nMethods of preparation<\/strong>\r\n\r\n \r\n\r\nGhee can be made by any of the following techniques:<\/span>\r\n

    \r\n \t
  1. Indigenous method (via Makkhan)<\/span><\/li>\r\n \t
  2. Direct cream heating method<\/li>\r\n \t
  3. Creamery butter method \u2013 with or without pre-stratification and<\/li>\r\n \t
  4. Continuous method.<\/li>\r\n<\/ol>\r\n \r\n

    The creamery butter (CB) and direct cream (DC) method are more suitable for commercial operations, since less fat is lost. DC method gives longer shelf life to ghee compared to CB method. Pre-stratification method is advantageous with regard to economy in fuel consumption and preparation of ghee with lower acidity.<\/p>\r\n \r\n

    In principle, ghee making involves three distinct operations:<\/span><\/p>\r\n\r\n

      \r\n \t
    1. Concentration of milk fat<\/span><\/li>\r\n \t
    2. Heat clarification of fat rich milk portion<\/li>\r\n \t
    3. Removal of residue from the pure heat clarified fat<\/li>\r\n<\/ol>\r\n
      \r\n\r\n \r\n

      During the moisture removal process by heat, ghee acquires its characteristic flavor and the SNF content is converted to denatured brown ghee residue. Clarification by heat is done either on an open fire or in a steam-jacketed hemispherical kettle. During initial heating of butter, extensive frothing takes place, which must be controlled to avoid losses associated with boil-over. As the moisture evaporates and frothing subsides, caramelization of curd particles is noticeable. At this stage frothing completely subsides and emission of moisture bubble also ceases. Heating is discontinued as soon as curd particles attains desired golden yellow or brown colour. The residue is allowed to settle and clarified fat is decanted. The ghee residue can be separated by (a) decantation, (b) cloth or pressure filtration, or (c) centrifugal clarification techniques.<\/p>\r\n \r\n

      Indigenous method:<\/strong> Makkhan (traditional unsalted butter made by hand churning of whole milk dahi at room temperature) is placed in a steam jacketed vessel (ghee boiler) and heated to about 110-120oC with constant stirring to evaporate practically all of the moisture. Next, the ghee residue is separated from ghee by filtration and the ghee packaged in suitable containers (tin cans, pouches).<\/p>\r\n \r\n

      Direct cream heating method: Cream is taken in a ghee boiler and heating is continued till temperature of about 110-120oC is attained. This is followed by removal of ghee residue by stack filters, pressure filters and centrifugal separators. The ghee, now freed of ghee residue is allowed\u00a0to cool to 40-42oC and then packaged in individual packages. Clarification temperature is kept higher at about 120-140oC in southern India.<\/span><\/p>\r\n \r\n

      This method of ghee-making from medium fat cream (~40%) yields a higher quantity of ghee residue and consumes more fuel and takes longer time. To avoid such problems, a high-fat cream (60-75% fat) may be used; cream may be washed with warm water to reduce the content of SNF, which will yield less ghee residue, enabling higher fat recovery in ghee.<\/span><\/p>\r\n \r\n

      Creamery butter method:<\/strong> Unsalted creamery butter (white butter) may initially be melted in a butter-melter, followed by pumping into a ghee boiler. In the ghee boiler, the moisture in butter is evaporated with constant stirring to reach a temperature somewhere between 110-120oC. Other steps followed are the same as mentioned in the previous method.<\/span><\/p>\r\n \r\n

      Creamery butter with pre-stratification:<\/strong> A modification to the above method involves heating the melted butter to ~80oC followed by quiescent storage at that temperature in a pre-stratification tank for several hours. Based on density difference, the scum, fat and serum gets separated in different strata in the same tank. The lower-most serum portion is allowed to drain out through an outlet at the bottom of the tank, by which about 74% of the water present in white butter is removed. Less water remains to be evaporated in the ghee-boiler, thereby economizing on the fuel. Thereafter, the mixture of scum, fat and curd is pumped to the ghee boiler for removal of the remaining moisture, wherein the colour and flavour of ghee is developed at 110-120oC. Rest of the steps remains the same as discussed previously for creamery butter method.<\/span><\/p>\r\n\r\n<\/div>\r\n\"\"\r\n

      \r\n\r\n \r\n\r\nContinuous ghee making<\/strong>\r\n\r\n \r\n

      In a continuous method developed by National Dairy Development Board (NDDB), Anand, Gujarat, the concentration of fat and breaking of oil-in-water emulsion is done mechanically with the help of centrifugal forces in the clarifixator and concentrator and use of heat is limited to the development of flavour and removal of last traces of moisture. The crude oil coming from the fat\u00a0concentrator goes to SSHE and then to vapour separator, filter\/clarifier and then to the ghee cooler (see powerpoint). A continuous process developed by National Dairy Research Institute (NDRI), karnal consists of receiving-cum-heating vat for cream\/white butter, gravity separator (not used when cream is the feed material), scraped surface heat exchanger (SSHE), coupled with vapour separators and positive displacement pumps to move the raw material through the different units. Final heating takes place at about 110-115oC in SSHE as is the case in batch method of ghee making. The NDRI equipment is a 3-stage pressurized, swept-surface separator. The design of such machine is sanitary.<\/span><\/p>\r\n \r\n

      Some plants in India are already utilizing this principle (Mother dairy, Gandhinagar, Gujarat; Panchamrut Dairy, Godhra, Gujarat; Nestle, Moga, Punjab, etc.) in producing ghee. The principle involved is concentration of fat in cream along with de-emulsification of fat (through use of clarifixator or centrifixator), followed by serum separation and finally heating the oil (95-99% fat) in a SSHE in order to develop the desirable cooked and caramelized flavour. Such continuous production preserves the fat soluble vitamins better than in conventional method of ghee manufacture.<\/span><\/p>\r\n \r\n

      Quality of ghee<\/strong><\/p>\r\n \r\n

      The quality of ghee obtained is dependent on the following factors:<\/span><\/p>\r\n\r\n<\/div>\r\n

      \r\n