Table Butter Manufacturing process in Plant

Table Butter Manufacturing

Purpose: To manufacture and pack Table Butter
Scope: Respective product section

Responsibility: Production and Quality Assurance department

1. Ingredients Specifications:-
1.1 Fresh sweet cream (acidity as L.A max.0.09% which have no off taste / flavour).
1.2 Food grade annatto colour
1.3 Food grade edible common salt without iodine
2. Equipment & utilities Required
2.1 Cream vat / tank
2.2 Butter churn
2.3 Butter trolley
2.4 Butter packing machine
2.5 Butter cold store
2.6 Chilled water
2.7 C.I.P system
2.8 Electricity (415 V 3-phase & 230V single phase)
2.9 Compressed Air (6 Kg / cm )
3. Packaging Requirements:-
3.1 Primary packing: Parchment paper & 10 g blister
3.2 Secondary Packing: Mono-carton & CBX
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 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, trolleys, butter churn, and filling machine should be properly
cleaned and sanitized before starting and after completion of operations. Quality assurance staff
will certify its cleanliness before its use.
4.7 Cream should be pasteurized at 88±2ºC for 15 seconds and should be transferred to cream
ageing tank at 8-9 ºC for 8-10 hours.
4.8 The cream should be loaded in the butter churn (40% of the churn capacity)
4.9 Annatto colour should be added to cream @ 0.10% of the total fat in cream.
st 4.10 Churning should be started with 1 gear (about 30 to 32 rpm) till butter granules are formed. The butter milk should be removed from the churn.
4.11 Pasteurized chilled Soft water (hardness < 10 ppm) (10 to 12ºC) should be added in the churn for st nd rd.
1 washing followed by 2 washing in 3 gear (speed 7 to 8 rpm) for 8 to 10 minutes each.
nd 4.12 After removing the washed water, pre-working should be done in 2 gear at 15 to 16 rpm. During this working, chilled water (10 to 12ºC) should be sprinkled on the outer shell.
4.13 Salt solution should be prepared with pasteurized chilled Soft water (hardness < 10 ppm) and
should be filtered through muslin cloth.
4.14 Edible common salt should be added @ 1.5% of the expected yield of the butter.
nd nd 4.15 After addition of salt solution, 2 working should be done in 2 gear (15 to 16 rpm) for 12 to 15 minutes. and 4.16 After 2 working, moisture content should be tested and the calculated pasteurized chilled Soft water (hardness < 10 ppm) should be then added. and 4.17 The final working should be done at 15 to 16 rpm in 2 gear continuing sprinkling of chilled water on the outer shell of the churn and moisture content should be tested by QA.
4.18 The butter should be then unloaded in butter trolleys. The temperature of the butter shall be
about 14 to 16ºC.
4.19 The testing of butter should be done to confirm its specifications by QA.
4.20 The butter should be then packed and quality should be checked again.
4.21 The packed butter should be stored in the Butter cold-store at (-) 18 ± 2 ºC.
4.22 The samples should be tested to confirm the final composition and shelf life by QA. The final
product shall also be tested by QA for its body ,texture and organoleptic test before dispatch.
4.23 Guidelines of GMP (as per IS 16021:2012) should always be applied during manufacturing, packing and dispatch.
5. Clearance Procedure:-
5.1 Raw Materials: Quality of cream shall be checked and certified by QA section before making
butter.
5.2 Final product:The final product shall be sampled and tested for each lot to ascertain the product
meeting the specifications of the product.The colour of the product should be checked with
colorimeter for uniformity in 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 in refrigerated condition.
7. Shelf life: 8 months for 100 and 500 g pack & 5 months for 10 g blister pack from the date of
packing when stored under refrigeration below 4 ºC