Profitable food business: butter production. Video - how butter is made
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 the 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 raw milk, 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 peculiarity of filling, 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.
Upon completion of separation, the 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.
The production of butter by the conversion method consists in changing the qualitative properties of fat globules with further release and concentration of the fat fraction while creating the butter 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 occurs.
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.
The business idea involves the purchase of a production line on which it is planned to organize the production of butter. In view of the fierce competition in the retail market, the target audience is regional supermarkets that will sell the product under their Private Labels. Finished products will be packaged in the customer's packaging (200 and 250 gr.).
prospects
Butter is a food product that is made on the basis of milk cream, by separating or whipping it. Oil belongs to the category of basic products and is a commodity of daily demand, the consumers of which are almost all citizens of Russia.
The Russian butter market itself is quite capacious - the annual volume of its production is more than 200 thousand tons. Thus, according to the results of 2012, more than 213 thousand tons of products were produced in Russia.
In general, domestic producers independently provide most of the demand for butter, while imports account for no more than a quarter of its volume.
Butter presented in Russia differs in the level of fat content, while the most popular products are with a fat level of 50-80% - in 2012 it was produced in a total volume of 185.7 thousand tons.
However, the total volume of consumption of butter in Russia (for about the last 10 years) remains at the same level. This, as well as fierce competition between leading manufacturers in retail, significantly complicate the entry of a new company into the market. But free niches that can be occupied by a new player from the category of small and medium-sized businesses still remain.
Firstly, there is an “economy” niche (without a trademark and good packaging, with packaging in ordinary polyethylene film), which can be sold on the markets. Its consumers are residents of low-income regions.
Secondly, cooperation with food supermarkets that sell products under their own trademarks (private labels) is seen as more promising. In this case, the entrepreneur will act as a production base for the supermarket, manufacturing the finished product to order and packing it into the customer's packaging. With good quality products, as well as strict observance of delivery times, the second development option seems to be very promising.
Butter production technology
Butter can be obtained in two ways - by churning cream and by converting heavy cream. However, in any case, the first stages of the technical process are the acceptance and storage of raw materials (milk), with its subsequent heating and separation. The result is cream.
But the further processes are different. So, when using the churning method, the cream is heated to a certain temperature, after which they ripen. Next, the ripened cream is churned, washed, salting and mechanical processing of the butter is performed. After that, the resulting product is packaged and sent to the cold store for storage.
In the second case, the cream obtained from milk is subjected to heat treatment, after which separation is performed - the production of high-fat cream. Next, the resulting semi-finished product is normalized and mechanically processed. After that, the finished product is packaged and sent to the camera - for storage.
Necessary equipment
In Russia, there is a fairly large selection of integrated lines for the production of butter of various capacities - from 150-200 kg per hour for mini-workshops, up to several thousand kg. per hour for large oil refineries.
To meet the needs of small and medium-sized businesses, the Russian manufacturing company Molmash offers its equipment. Its P8-0LF line is presented on the market in three modifications, while it operates in the productivity range from 550 to 1000 kg of finished products per hour.
Part lines P8-0LF includes a butter former (in 3 versions), a pasteurizer, a separator and a bath for the normalization of high-fat cream, a tank, pumps, a control panel, a milk pipeline system and a filling table. At the same time, the manufacturer offers three options for completing the line:
- P8-0LF-01, with a capacity of up to 700 kg per hour, is equipped with a T1-OM-2T oil former;
Price from 2.5 million rubles. - P8-0LF-02, with a capacity of up to 800 kg per hour, is equipped with a Ya7-OM-ZT oil former;
Price from 2.7 million rubles. - P8-0LF-03, with a capacity of up to 1000 kg per hour, is equipped with an R3-OUA oil former;
Price from 3.3 ml. rub.
Oil production technology
In the production of any kind of butter, there is a great similarity between the individual operations of the technological process. In the conditions of dairy farms, it is more acceptable to manufacture sweet cream butter with a mass fraction of moisture in it of 16%. It is produced in two types: salted and unsalted in discontinuous and continuous butter makers. Such butter can also be made by converting high-fat cream.
Technology for the production of sweet cream butter by churning at a batch butter maker includes the following operations: receiving and sorting milk, obtaining cream, preparing cream for churning, churning cream, removing buttermilk, washing butter grains, settling, processing, packing and packaging, storing and transporting butter.
Receiving and sorting milk is subject to general requirements in accordance with the standard. Each type of milk must be separately separated to obtain cream.
Preparation of cream for churning consists in normalization, pasteurization, cooling, physical ripening, cream coloring.
pasteurized normalized cream Grade I at a temperature of 85 ... 90 ° C without exposure. Cream of the 2nd grade is pasteurized at a temperature of 92...95°C.
Cooling and physical ripening of cream. After pasteurization, the cream should be cooled to 4-7°C as soon as possible. At this temperature, mass crystallization of milk fat glycerides occurs. Cooling the cream prevents free fat from melting, while aromatic substances are better preserved, the fat passes from a liquid state to a solid state, which makes it possible to form an oil grain during subsequent cream churning. The cream is subjected to physical maturation, in which about 50% of the fat solidifies.
Under physical maturation understand the curing of cream at a low temperature. During this period, hardening of milk fat and physico-chemical changes in the shells of fat globules occur. To ensure optimal physical ripening of the cream, the following regimes are recommended: in the spring-summer season, the temperature is 4..6°C, the holding time is at least 5 hours; for the autumn-winter season) - 5 ... 7 ° C and at least 7 hours. During the ripening period, the cream is stirred 3 ... 4 times for 3 ... 5 minutes. To give the butter a normal yellowish color, the cream is tinted with carotene.
Filling the oil maker. Before starting work, the buttermaker is washed with a hot washing solution (75...80°C), and then with cold water (the temperature is 2...3°C lower than the cream temperature when churning). Cold water is removed from the buttermaker before filling it with cream. The walls of the butter maker must have a temperature not higher than the temperature of the whipped cream. If the barrel of the oil maker is wooden, then it is first steamed so that oil does not stick to the walls. Then a washing solution is poured (25...30% of the barrel capacity), the temperature of which is 95°C, and rotated for 3...5 minutes. After removing the solution, the barrel is filled with hot water and rotated for 3-5 minutes. Next, the barrel is washed with cold clean water (the temperature is 2...3°C lower than the cream churning temperature). Outside, the oil maker is washed with brushes and hot water.
Cream is brought into the butter maker in the spring-summer period at a temperature of 7 ... 12 ° C, in the autumn-winter period - 8..14 ° C. The barrel of the buttermaker is filled with cream to about 35 ... 40% of its capacity. After that, the hatch of the oil maker is tightly closed and the apparatus is put into operation.
churning cream lasts 40...45 min. In the first 3...5 minutes of churning, the buttermaker is stopped 1...2 times and air and gas released from the cream are released through the valve.
The churning progress is observed through sight glasses located in the end part of the oil maker. Removal of buttermilk and washing of butter grains. After making sure that the grain is ready, open the butter faucet to remove the buttermilk, filtering it through a sieve in order to retain small grains. Then proceed to washing the grain to remove the buttermilk more completely using drinking water. Wash the oil 2 times. Take 50 ... 60% of water from the amount of whipped cream, the temperature of the first wash water should be equal to the temperature of the whipped cream, the second - lower by 1 ... 2 ° C. Having closed the valve of the oil maker, water is poured through the hatch, the hatch is closed with a lid, 3 ... 4 turns are made, and then the water is drained through the valve. In the same way, washing is carried out a second time.
When producing butter from first-class cream, with strict observance of the requirements of technology and sanitation, the butter grain can not be washed. In the case of processing cream with pronounced flavors (silage, impure, etc.), washing of butter grains is mandatory.
Water can improve the consistency of the oil. If the oil is crumbly, the temperature of the washing water is taken 2°C higher, and if the oil is soft, 2°C lower.
Oil salting. Salt "Extra" is used for salting oil, which meets the requirements of the current standard. Before use, it is calcined at a temperature of 120 ... 130 ° C (2 ... 4 minutes) to kill microorganisms. The mass fraction of salt in the oil should be 0.8. ..1%, but not more than 1.5%, which corresponds to its concentration in the oil plasma of about 9 ... 12%. Such a high salt concentration inhibits the development of microorganisms, which explains the good stability of salted butter during storage.
Oil grain processing. It aims to connect the oil grain and obtain a layer of uniform consistency, give the oil a certain structure, marketable appearance, evenly distribute salt and moisture throughout the mass, and disperse water drops to a minimum size.
The method and intensity of oil processing affect its stability during storage. Processing is carried out by passing oil between the rollers of the oil manufacturer. Oil processing is carried out as follows. After 20..30 minutes after the settlement, the valve and the hatch of the oil maker barrel are closed, the rollers are turned on, the oil maker slowly rotates for 3...5 minutes. As soon as a layer is formed, the valve is opened so that free moisture flows out. When the moisture stops flowing out, the oil maker is stopped, the hatch is opened, and an average sample is taken from different places in the formation, which is analyzed for moisture content.
The finished oil is unloaded from the oil maker into a container and sent for packing and packaging. The released oil maker is rinsed with cold water, then filled with 1% hot (90...95 ° C) soda solution by 20 ... 25% and rotated for 5 ... 8 minutes; after removing the solution, the barrel is washed with hot water.
Before putting the oil in the boxes, they are inspected, the roughness is cleaned with sandpaper, lined with parchment, laminated foil or polymer film. Boxes lined with parchment are weighed with a lid and then filled with oil. Pieces of butter weighing 3 ... 5 kg are placed in the center of the box and compacted with a pestle. To prevent sticking of oil, the pestle is periodically moistened with water, and then the excess moisture is shaken off. When packing, it is necessary to pay attention to the fact that there are no voids in the oil monolith, between the oil and the walls of the container, as well as parchment and the walls of the container, as this can lead to the development of mold and deterioration of the oil during storage. After filling the box with the required amount of oil, the surface is leveled with a special ruler and carefully closed with a long butt end of parchment, then with a short one, then with side sheets, covered with a lid and hammered in with nails. If cardboard boxes are used, the lid is closed and sealed with special paper tape. Packed boxes are sent to the cooling and storage chamber.
Oil storage. The packaged oil should be cooled as soon as possible. Boxes with oil are placed in a refrigeration chamber in 3-4 rows in height in a checkerboard pattern at a distance of 30-50 cm from the walls (wooden slats are placed between the rows to speed up cooling). The temperature in the storage should be from 5 to minus 8 ° C. A day after the oil has hardened, the boxes are stacked in a checkerboard pattern up to eight pieces high. The shelf life of the oil in the factory is no more than 10 days at a temperature of minus 5 ° C and below, and at plus - no more than 3 days. Relative humidity in the storage is allowed not higher than 80%. Before being sent to the bases, the oil temperature should not exceed 10°C. In refrigerators, oil is stored at a temperature of minus 18 ° C, if its shelf life exceeds 3 months.
Oil production at continuous oil makers - the steps of the technological process are the same as in the manufacture of oil in discontinuous oil makers.
Prepared cream with 36...45% fat content, cooled to 8...14°C, enters the butter maker in a continuous stream and is churned within a few seconds. Then the oil enters the corresponding chambers, where all technological operations are carried out rather quickly; the finished oil from the oil maker comes out in a continuous stream. Oil producers are produced with a capacity of 200 to 5000 kg per hour.
Butter production by converting high-fat cream. The essence of the method lies in the concentration of milk fat in the centrifugal field of the separator and the subsequent transformation of the obtained high-fat cream. The finished product is obtained within a few minutes. In the production of butter by converting high-fat cream, such operations as the physical ripening of cream, the formation of butter grains and its subsequent mechanical processing are excluded from the technological process. The concentration of fat to the required index, corresponding to the fat content of the oil, is achieved by separation.
To give high-fat cream the structure and physical properties inherent in butter, the cream is subjected to in-line (in the butter former) thermal and mechanical treatment. The requirements for milk, cream and cream heat treatment are similar to those used in the production of butter by churning. The peculiarity of the heat treatment of cream is that they are not cooled, but at the pasteurization temperature they are sent for re-separation.
Butter is one of the necessary products that affect the improvement of human health. Breakfast cannot be complete if the sandwich is not smeared with fatty butter. A high percentage of fat content is a direct indication of the high quality of the product and its benefits. To save the product from the need to introduce preservatives into its composition can allow the production of butter with a moderate production of a sought-after product. .
Bread and dairy products are necessary for the proper nutrition of the population. They are classified as perishable. The absence of dairy processing enterprises in the region automatically frees up the market segment for products with a large number of preservatives and stabilizers.
Taking into account the recommendations of the Ministry of Health, every person’s daily diet should contain natural butter (15 gr.) And cheese (30 gr.) - this is a mandatory norm to maintain bone strength, quality of hair, teeth, nails, skin, digestive system health. Oil consumption standards will help calculate the need for a locality in the product.
Of course, not all residents will immediately switch to the consumption of a local product. For the title of the best manufacturers, you will have to fight with large concerns offering a lower price. The absence of preservatives and stabilizers, which increase the keeping quality of the product, have the best effect on the taste of the oil. Therefore, grocery stores of the nearest settlements can become points of sale.
Taste, aroma, color are the criteria by which housewives choose the type of oil for their family. On the shelves of stores there is a large assortment of oils with the addition of vegetable fats and purely creamy products. Their aroma is approximately the same; in spreads, the taste quality deteriorates significantly when palm oil is added. The lower the fat content, the less useful substances the oil contains. Buyers of "low-calorie" products will have to make up for the lack of amino acids with dietary supplements.
Conclusion: in order for the products to be in demand, they must be 100% natural. An oil that has a characteristic milky aroma that meets the technical specifications after freezing will be competitive.
Types of oil, choice of grade for production
Butter is the whipped cream or fat residue from the separation of fresh cow's milk. The fat content of butter, called butter, corresponds to an indicator of at least 82.5%. The lower content of animal fats indicates that this is a spread containing a certain proportion of vegetable fats and fillers (thickeners, stabilizers and other additives).
Sweet cream and sour cream butter, despite the name, can be sweet and salty. The difference between these natural products lies in the difference in the preparation of raw materials.
Sweet cream is made from fresh pasteurized cream, and sour cream is made from pasteurized cream fermented on milk sourdough. Under the condition of artificially inflating the cost of the product, it is extremely rare on store shelves. It is practically impossible to meet it in chain stores due to the fact that many peasant farms artificially lower the percentage of fat content of milk yield to the required norm by separating.
The fat content of natural cow's milk varies from 2.5 to 6.5%. Large producers, conducting mass purchases of milk from the population, measure only the level of fat content. However, "skimmed" milk loses its qualities, it is practically unsuitable for whipping. This affects the quality of the finished product, its density has to be increased with additives.
It turns out that due to the dishonesty of the milk deliverers, more and more often, instead of traditional butter with a fat content of 82.5%, high-quality and low-quality spreads with a nutritional value below the standard of 717 kcal appear on the shelves.
| Name | Fat content, % | Nutritional value (100g) in kcal |
|---|---|---|
| "Traditional" | 82,5 | 748 |
| "Amateur" | 80 | 709 |
| "Peasant" | 72,5 | 661 |
| "Sandwich" | 61% | 566 |
| "Tea" | 50%; | 546 |
| "Chocolate" | 62% | depends on the quality of the cocoa powder |
Fillers that give the oil a certain taste can be honey, fruits or artificial flavors, which is most often used to mask unpleasant odors and tastes during the period of feeding animals with silage and the close term of calving cows. During start-up, milk is poured out, it is not used for food. But when buying from the population, such raw materials can come across, spoiling the entire batch like a barrel of honey owed in the ointment.
Butter with a base fraction of animal fat below 60% is not only unhealthy, it can be harmful to the body. Especially when replacing natural milk fats with vegetable fats, such as palm oil.
Ghee has the highest nutritional value of 892 kcal, but after heat treatment, no useful substances remain in it.
How to make an oil with a rich taste and pleasant aroma
The recipe for making butter at modern enterprises does not change much. It is based on the development of Nikolai Vasilyevich Vereshchagin, the initiator of the "artel buttermaking". In its pure form, this recipe is used in the Museum of Buttermaking in the Vologda region. Due to the use of manual equipment, the production of the product is extremely small, it is dispersed around the world in clay pots, which simplify transportation and increase shelf life.
The cost of this hand-made product is quite high, but the quality of Vologda oil is incomparably higher than that of products made on modern production equipment. Not only the method of whipping cream and the amount of additives affect the result.
Vereshchagin compiled the recipe and technology for making butter in the middle of the 19th century. From the chronicles it follows that the first time oil was mentioned as early as the 5th century in the trade statements of the Irish. Traveling Norwegians had casks of oil on their grocery list in the 8th century. In Russia and Italy, oil began to be eaten in the 13th century.
The manufacturing recipe was varied. Peasants whipped butter from cream, sour cream and even fresh milk. Ghee butter has a longer shelf life; it was called "Russian" in other countries.
Conclusion: you can make butter more dense or tender, fragrant, sweet cream or sour cream by choosing the raw materials for whipping.
How to open a butter production line - business organization
To open a butter production business, you need a room that meets all the requirements of sanitary and epidemiological services, a warehouse with refrigeration equipment, a milk processing line, vehicles for collecting raw materials and delivering them to production, a truck for delivering finished products to retail outlets.
Workshop room
Sanitary requirements for dairy industry enterprises have certain standards for the layout of the premises, the selection of building materials, landscaping, maintenance of equipment and vehicles.
Production is divided into several zones:
- production;
- warehouses of raw materials and finished products;
- household premises;
- first-aid post;
- workshops;
- warehouses of spare parts and spare stock;
- garages;
- boiler room.
There can be many more rooms, but all auxiliary areas must be isolated from the production workshop.
Entrances to the oil mill cannot be unpaved, according to the standards, the roads must have an asphalt or concrete surface. The production area vacant from development is planted with greenery, at least 15% of the entire vacant area. Garbage containers, septic tanks, cesspools, sewer wells must be located at a distance of at least 25 meters from the workshop and warehouses with products and raw materials. Optimal placement of sewer and garbage collectors outside the fenced area of the plant.
With a single toilet, the entrance for mechanics, drivers and other workers not related to milk processing should lead to the yard or office building, bypassing the workshop.
The requirements for the location of warehouses in relation to the workshop are as follows - the flow of production requires a constant connection between the workshop and the warehouse of unprocessed raw materials and finished products. At the same time, the paths of the finished goods cannot intersect with the transported raw materials and dirty containers.
A mandatory requirement for dairy production is the availability of hygiene rooms, showers, a first-aid post, a drinking water supply system, used water diversion to disposal sites, and supply and exhaust ventilation. Equally strict requirements for the selection of finishing materials for the premises of the workshop itself:
- waterproof, smooth floors;
- wall cladding is made with glazed light ceramic tiles;
- only oil paint is suitable for painting walls;
- the height of the cladding and painting is not less than 1.8 m in height;
- large windows that provide an influx of daylight in relation to the flows from artificial lighting devices in a ratio of 1:6 - 1:8.
Compliance with all these rules is necessary in order to obtain permission from SanEpidnadzor to start activities. Yet the main purpose of all these rules is to take care of the health of workers and consumers.
Raw material supply channel
The most optimal option for the supply of fresh milk is a state farm, a large peasant farmstead, a developed farm. Unlike cows kept in the private sector, animals of a large livestock farm undergo systematic medical care. Animals receiving medical treatment are kept separately, their milk is not used while taking antibiotics and two weeks after the course of recovery.
Business registration
It is more expedient to register a dairy products workshop as an LLC. When exploring the market of your region, you need to pay attention not so much to competitors, but to farming, livestock farms with a large number of cattle that are free from constant obligations.
Transportation costs must be minimized, so suppliers of raw materials and sales points should be sought within a radius of 50-100 km from the location of a medium-sized dairy enterprise. Large dairy companies can act as franchisors, which will simplify the supply of the workshop with the necessary equipment, reduce the cost of developing their own logo, trademark, and advertising.
As an essential commodity, oil falls under the category of goods, part of which is paid for by the local budget, making it cheaper for the population. This assistance to developing production will be allocated in the form of subsidies, assistance in renting equipment and vehicles, which are on the balance of the city.
A package of necessary documents for product certification
The procedure for certification of butter for compliance with safety requirements largely depends on the fat content of the product being produced. Briefly, the list looks like this:
- statements for the applicant;
- copies of technical documentation for oil;
- description of the product itself;
- protocol of laboratory examinations.
Attention! If the scheme chosen for product certification does not provide for mandatory laboratory tests, then the applicant has the right to provide other evidence of product safety.
Drawing up a declaration by a butter manufacturer is complicated by the fact that this product falls under several technical regulations at once. Accordingly, the product will be checked according to all the criteria prescribed in the regulatory documents:
- food - TR TS 021/2011;
- dairy - TR CU 033/2013;
- compliance with the safety of technological additives - TR CU 029/2012;
- labeling of food products - TR CU 022/2011.
When certifying butter with a reduced fat content, a standard for fat and oil products will be added. Regardless of the fact that the marking is printed on the packaging, the product wrapper itself is also subject to separate certification. In addition to the butter itself, raw materials (milk) are also subject to certification.
To date, there are 5 certification schemes for butter, which complies with the regulation TR CU 033/2013. The choice of a specific goods declaration scheme depends on the following factors:
- type of supply;
- lot size;
- the origin of the goods.
For a domestic product, a production control system from SES is provided.
Registration of a certificate of state registration of products is a type of certification. Measures to confirm the compliance of products with the requirements of sanitary standards are carried out by relevant government departments. They are considered the most complex and complete. The document issued based on the results of the examinations carried out was a guarantor of the quality and safety of the goods.
The purpose of certification is to provide government authorities with evidence of the safety and compliance of goods with regulations. Documents of conformity in terms of quality, composition and other parameters are ready - the declaration is registered in the Unified Register, the GOST or TU marking appears on the packaging of the goods. Only after such a complex procedure can the goods be sold through a retail network.
What you need to start oil production at home
To prepare homemade butter in small quantities, you need: a separator, a mixer, earthenware (pot or lid), a sieve and gauze, a refrigerator.
To obtain 3-3.5 kg of butter, you need 10 liters of heavy cream or sour cream collected from yogurt. Sour cream with additives (preservatives, flavor and color stabilizers, other additives) with low fat content is not suitable for whipping.
It is more convenient to whip cream or sour cream in small portions of 1.5-2 liters, placing the raw materials in a rough deep bowl made of clay or unpainted wood. The most stable result is obtained by systematically mixing the semi-finished milk product with a wooden spoon or spatula.
It is quite difficult to withstand 3 hours of intense whipping without slowing down the speed. Therefore, it is better to choose a mixer with whisks made of high-quality durable stainless steel. In this case, no more than 1 hour will pass from the beginning of milk separation to the finished butter.
At the beginning of whipping, the mass increases in volume, becomes airy. After a short time of whipping, its color will begin to change, acquiring a yellowish tint. When using sour cream as a feedstock, the color of the mass may be non-uniform.
Within 10 minutes of intensive mixing (whipping), the mass will begin to delaminate into fat lumps and churning - the released liquid. This cream must be drained periodically. They can be used for baking - puffs, cookies, muffins, pancakes.
If about 2/3 of buttermilk is drained from each liter of starting material, then the whipping process can be considered completed. The oil is ready, but it can be salted or sweetened.
To increase the shelf life, you can rinse the oil several times with clean water. To do this, 1 liter of water is added to a container with oil, the mass is mixed and whipped. The water is changed to clean, the process is repeated until the liquid drained after washing is clear.
Gauze is laid in a sieve in 2-3 layers, oil is laid out on it. A sieve or colander is installed on the pan. This is necessary so that all the liquid is glass. After 1.5-2 hours, the oil must be pressed and sent to the freezer.
If you bypass the process of washing the oil, then the shelf life of the product in the refrigerator will be 7 days.
Marketing and distribution channels
Recent studies have shown that a marketing mix consisting of 4 components works great:
- product quality;
- price that differs up or down among goods with the same characteristics;
- distribution - uniform distribution of goods between points of sale;
- promotion.
Competent promotion is work on the recognition of the brand, name, logo. This is a whole range of activities. It is necessary to start with the development of the original packaging, it should not be similar to any other.
In addition to names that reflect prescription features, the oil should have a proper name, such as Praskovya Molochkova, Prostokvashino, Merry Milkman. The name of the brand in combination with the original image, registered as a trademark of the company, will be remembered by the buyer better than the name “amateur oil TU-….. in gray packaging with the image of a cow grazing on the lawn, the ribbon under the picture is green”.
By highlighting your products from the general range, you will greatly simplify the search for the goods the buyer needs. The benefit is mutual, your client will get what they are looking for, and you will not give your consumer to competitors.
The second way to attract a buyer is to give your product a shape that differs from the standard one, increase the weight of the briquette, while other manufacturers reduce the packing weight to “keep the price down”.
The sale of perishable products, such as butter, must be carried out not only through retail chains, but also bypassing them. The main consumers are public catering points, culinary shops selling semi-finished dough products, station cafes, schools, kindergartens, and medical hospitals. The main marketing hook is timely delivery by the supplier's cars.
franchise business
In large dairy concerns, one should see not only strong competitors, but also real assistants in business development. Many of the companies with their own trademark, a recognizable sonorous name, are franchisors for many small businesses in their field.
Investors, banks and government authorities have more confidence in a large company than in a novice entrepreneur. Supporting such a company, especially at the start of a business, is a good start. Help is:
- selection of equipment or its provision for rent;
- conducting marketing campaigns;
- verification of potential suppliers of raw materials;
- registration of the first contractual obligations with sales organizations.
Business costs and payback
Starting an oil production business on an industrial scale requires serious financial investments. The optimal location of the dairy plant is the outskirts of the city, near the forest, parkland and bypass road. Such placement of industrial facilities is usually provided for in the design of cities.
This means that in order to comply with all the requirements of the sanitary services, the fire inspectorate and other departments, it is more expedient to find a non-functioning plant that was previously used for the manufacture of food products. It's easier to sort it out. The location of workshops on the territory of a previously operating facility, as a rule, meets the requirements. Sample list of expenses for the preparatory period preceding the launch of the line:
| Item of expenses | Amount, rub. |
|---|---|
| Premises for rent | 50 000 |
| Purchase of building materials | 70 000 |
| Carrying out repairs | 40 000 |
| Delivery and installation of equipment | 20 000 |
| LLC registration | 4 500 |
| Obtaining certificates | 35 000 |
| Recruitment | 3 000 |
| Conclusion of contracts for the supply of raw materials | 5 000 |
| Procurement of office equipment and consumables | 65 000 |
| Total | 292 500 |
Purchase of equipment for the workshop with the release of 150 kg of oil per day
| Name | price, rub. |
|---|---|
| Separator | 220 000 |
| Raw material standardization bath | 80 000 |
| Vacuum deodorizer | 430 000 |
| Long pasteurization bath | 350 000 |
| Filling machine | 520 000 |
| Homogenizer-plasticizer | 310 000 |
| Tank with remote control | 350 000 |
| Pumps - 2 pcs | 70 000 |
| Total: 2,330,000 rubles. |
Monthly costs
| Name | Amount, rub. |
|---|---|
| Car rent | 30 000 |
| Wage | 120 000 |
| Communal payments | 15 000 |
| Paying taxes | 12 000 |
| Payment of loans | 20 000 |
| Purchase of HS | 60 000 rub. |
| Purchase of packaging material | 5 000 |
| Consumables | 3 500 |
| Unexpected expenses | 15 000 |
| 280 500 |
With the stable operation of the workshop in three shifts, the planned payback of the project is 1.5 years.
Characteristics of products, raw materials and semi-finished products. Butter is a food product made from cow's milk, consisting mainly of milk fat and having a specific, characteristic taste, smell and plastic texture. In addition to fat, oil contains water, proteins, milk sugar, phosphatides, vitamins, minerals, etc.
The low melting point (27…34 °С) and solidification (18…23 °С) of milk fat contributes to its transition in the digestive tract to the most convenient liquid state for assimilation (digestibility of milk fat is 91.0%, dry matter is 94.1 %). The nutritional value of butter is increased by the phospholipids contained in it, especially lecithin, which enters the butter along with the shells of fat globules.
Butter is the richest in fat-soluble provitamin A, from which the human body synthesizes vitamin A. Due to the high concentration of provitamin A (carotene), butter turns yellow.
The structure, quality, stability of the oil during storage is affected by the uniformity of distribution and the size of water droplets, the size of air bubbles, etc.
The range of butter (animal cow) butter is determined by the type of feedstock, the conditions for its processing and the composition of the finished product. Sweet cream butter is produced from fresh pasteurized cream, and sour cream butter is produced from fermented pasteurized cream. According to the method of processing raw materials, butter obtained by churning medium-fat cream or converting high-fat cream is distinguished.
In our country, the following types of butter are produced: butter containing 82.5% fat; amateur (78%); peasant (72.5%) and sandwich (61.5%). Butter can be unsalted or salted. Vologda butter (82.5% fat) is also produced from cream processed at a high temperature (105–110 °C) so that the product has a specific taste and smell.
Each type of oil has a unique taste and aroma. Butter is divided into two grades: the highest and the first. In terms of taste, nutritional value and digestibility, butter is the best fat, intended mainly for consumption in its natural form. By taste and smell, butter goes well with many foods and is widely used for making sandwiches and culinary seasonings.
The range of animal oils also includes ghee, obtained by separating plasma from free fat in molten raw butter. Melted butter contains up to 99% fat and about 1% moisture. The remaining substances (a small part of proteins, organic acids, water-soluble vitamins and minerals) are separated together with the plasma. Ghee is used for frying culinary semi-finished products.
Features of production and consumption of finished products. butter production belongs to the group of physical and biochemical technologies for the formation of a product from a stable fat emulsion of milk fat - cream. The main processes are the concentration of the fat phase of the cream, the destruction of the emulsion and the formation of the structure of the product with desired properties. There are two ways to produce butter: churning medium-fat cream (30...40%) and converting high-fat cream (up to 80...82%).
When butter is produced by the churning method, the concentration of the fat phase is achieved by separating milk and subsequent destruction of the milk fat emulsion with the formation of butter grains and a liquid fraction - buttermilk. Butter grain is a concentrated slurry emulsion consisting of dilapidated aggregates of fat globules. Grain is formed as a result of aggregation (fusion) of fat globules contained in cream under conditions of intensive mixing. The texture of the finished product is formed by removing excess moisture by pressing, and sometimes by working in (adding) the missing amount of water and dispersing it. Moisture control is carried out during oil processing. The crystallization of milk fat glycerides is completed during the physical ripening of the cream before the mechanical processing of the butter.
Upon receipt of butter by the method of converting high-fat cream, the concentration of the fatty phase of milk is carried out by separation. High fat cream is a highly concentrated emulsion of milk fat in plasma. Obtaining high-fat cream is reduced to mechanical separation of cream in the centrifugal field of the separator into high-fat cream and cream plasma - buttermilk. Normalization of high-fat cream by moisture is carried out before the start of thermomechanical processing. The breakdown of the cream fat emulsion and the crystallization of the milk fat glycerides occurs mainly during the thermomechanical treatment. At the final stage of the process, due to mechanical action, the product acquires a fine-grained structure and a plastic consistency.
Stages of the technological process. The production of butter by the method of churning cream consists of the following stages and main operations:
– acceptance of milk and cream, sorting by quality and measurement of the quantity of milk and cream received;
– heating and separation of milk;
– heating and ripening of cream;
– pasteurization, deodorization and cooling of cream;
- churning cream and separation of buttermilk;
– oil grain washing and water separation;
– evacuation of oil;
- salting oil;
– mechanical processing: normalization and distribution of moisture, plasticization and formation of an oil layer;
– packaging of oil in consumer and transport containers.
Characteristics of equipment complexes. The butter production line 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 the heat treatment of cream and its maturation, which includes a plate heat exchanger, a pasteurization and cooling unit, a vacuum deodorization unit and tanks for storing and maturing cream.
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 machines for packing oil into boxes or into consumer containers.
On fig. 2.20. the machine-hardware diagram of the butter line is shown by the method of cream churning (traditional).
The device and principle of operation of the line. Accepted milk with pumps 1 goes to container 2 , heated in a plate pasteurization and cooling unit 3 and separated in a cream separator 4 .
The received milk is separated at a temperature of 35 ... 40 ° C to obtain cream with the desired mass fraction of fat. To produce butter by the churning method in continuous butter makers, cream with a mass fraction of fat of 36 ... 50% is used. When butter is produced by the churning method in batch butter makers, cream of medium fat content with a mass fraction of fat of 32..37% is used.
Skimmed milk after separation is sent to unit 3 for pasteurization and cooling, and then for processing or for return to deliverers.
The accepted cream from the separator compartments is weighed on the scales 5 and through the bath 6 are sent for heating to a plate heat exchanger 7 .
Cream from the separator and separator compartments enters the tank 8 for intermediate storage, from where they are sent to a plate pasteurization and cooling unit 9 , where it is heated to a pasteurization temperature of 85...90 °C, and then cooled to a ripening temperature of 2...8 °C.
Pasteurized cream enters (if necessary) a vacuum deodorizer 11 equipped with a vacuum pump 10 . After removal in installation 11 extraneous odors and tastes, the cream is pumped into the cream ripening apparatus 12 . In it, with the slow development of lactic acid microflora, there is a change in the physico-chemical properties of cream, providing favorable conditions for oil formation.
Cream after maturation with a screw pump 13 either sent to a batch butter manufacturer 14 , or into a continuous oil maker 17 , where cream is churned, butter grains are washed, salted and oil is processed.
Cream in batch butter maker 14 supplied by a dosing pump 13 and are knocked down to obtain an oil grain 3 ... 5 mm in size. After that, the buttermilk is released, the oil grain is washed, and the oil is salted with dry salt or brine.
Rice. 2.20. Machine-hardware scheme of the butter production line
The oil is then mechanically treated to separate moisture and form an oil layer. To improve the consistency and distribution of moisture, the oil is processed in a homogenizer-plasticizer 15 . The finished oil is unloaded into the filling machine 16 .
In a continuous oil maker 17 cream from the creamer 12 pumped by dosing pump 13 through the surge tank. Butter manufacturer 17 consists of sequentially placed components: a beater having a cylindrical cooling body and a paddle mixer, and a screw texturer.
In the beater, the cream processing process is carried out under conditions of vigorous mixing. As a result of churning, an oil grain is formed, which, after leaving the churner, is separated from the buttermilk.
In the texturizer, the processing of the oil grain first, and then the oil layer consists in pressing out moisture: removing excess, and sometimes also working in the missing amount of water and dispersing it. The texturator consists of three screw chambers (the first is for processing butter and separating buttermilk into a tank 18 , the second - for washing the oil grain and separating water into the tank 19 , the third is a vacuum chamber for evacuating oil), a salting unit with a dosing device 20 and oil machining unit. The moisture content in the oil is adjusted by adding the missing amount of water by means of a dosing pump. 21 .
Finished oil conveyor 22 goes to the filling machine 23 for packing in the form of briquettes in parchment packs.
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