Ghee Manufacturing Process in Plant
Ghee Manufacturing Process in Plant
Ghee Manufacturing Purpose: To manufacture and pack Ghee
Scope: Respective product sectionResponsibility: Production and Quality Assurance department
1. Ingredients:-
1.1 White butter :Butter shall be prepared from fresh sweet cream which have no off taste / flavour.2. Equipment & Utilities Required
2.1 Butter churn / CBM
2.2 Butter melting vat
2.3 Pre-stratification vat
2.4 Ghee boiler / Ghee cooking Vat.
2.5 Ghee settling vat / Tank.
2.6 Ghee clarifier
2.7 Ghee filling vat / tank (buffer vat / tank).
2.8 Ghee pouch / Cekatainer filling / sealing machine.
2.9 Ghee Tin filling and seaming machine
2.10 Ghee granulation room.
2.11 Store room which should be maintained below 30 °C
2.12 Steam (2-3 Kg / cm )
2.13 Tap water
2.14 C.I.P system
2.15 Electricity (415 V 3-phase & 230V single phase)
3. Packaging Requirements:-
3.1 Primary packing: Tins with lids ; Polyfilm Cekatainer
3.2 Secondary packing :CBX with separator
4. Procedure:
4.1 Controls and measuring instruments should be calibrated in fixed interval.
4.2 All the CCP should be strictly maintained by production department and certified by the quality assurance at fortnightly.
4.3 Weighing scale should be calibrated with the standard weights in every shift by the operator and will be certified by the supervisor / in-charge.
4.4 Hygienic conditions of equipment and filling area should be maintained.
4.5 Operator will check all operational parameters and working of the machine as per the checklist displayed and supervisor / in-charge will certify.
4.6 Complete pipe line, cream vat, butter churn ,CBM ,melting vat ,pre-stratification tank, ghee boiler, settling tank ,clarifier ,filling tank / vat and filling machine should be properly cleaned and sanitized. Quality assurance staff will certify its cleanliness before its use.
4.7 The quality of the pasteurized white butter shall be tested by QA for its sensory, chemical and
microbiological tests as per the specifications.
4.8 The white butter shall be stored in the deep-freezer at < -16 ºC after packing in bulk for making ghee when required.
4.9 The white butter should be melted in butter melting vat and then transferred to pre-stratification tank for about 1.5 to 2 hours.
4.10 After stratification and removal of the butter milk ,melted fat should be taken in the ghee kettle (boiler) for cooking .The flash point shall be 110 ± 2ºC.
4.11 Ghee should be taken in settling tank after filtration and should be kept for minimum 4 hours.
4.12 Filtration / Clarification should be done at 65 to 70 ºC.
4.13 The ghee should be transferred to ghee storage tank.
4.14 The product should be filled at max. 45 ºC with slow agitation in the Ghee filling vat / tank. The quality of ghee shall be certified by QA before filling.
4.15 After packing the product, cartooning should be done and it should be transferred to cold store at 20 ± 3 ºC for 48 hours.
4.16 The product should be stored at less than 30 ºC till dispatch.
4.17 The samples should be tested to confirm the final composition by QA. The final product shall also be tested by QA for its body, texture and organoleptic test before dispatch.
4.18 Guidelines of GMP (as per IS 16021:2012) should always be applied during manufacturing, packing and dispatch.
5. Clearance Procedure:
5.1 Raw Materials: Butter quality shall be checked and certified by QA Section before Ghee making.
5.2 Final product: The final product shall be tested for each lot to ascertain the product meeting the specifications. The colour of cow milk fat should be checked with tintometer for uniformity of
product.
5.3 The final product should be dispatched for market only after verifying its quality by QA Section.
6. Transportation requirement: It should be transported at ambient temperature.
7. Shelf life:12 months for tin packing & 9 months for cekatainers / mono cartons / pouch packing from the date of manufacturing.
Post a Comment