Fabricacin De la

Mantequilla

Definiciones y estndares
Descripcin del proceso de la fabricacin de la mantequilla

La ciencia del fondo del batido de la mantequilla

Cristalizacin de la grasa de leche durante el envejecimiento

Estructura De la Mantequilla

Fabricacin de la mantequilla Continua

Clculos De la Produccin

Mantequilla Azotada

Grasa de leche Anhidra

La mantequilla es esencialmente la grasa de la leche. Se hace de la crema dulce y se sala generalmente. Sin embargo, puede tambin ser
hecha de acidulado o la crema bacteriolgico cortada y las mantequillas (dulces) sin sal estn tambin disponibles. Bien en el diecinueveavo
siglo la mantequilla todava fue hecha de la crema que haba sido permitida estar parada y agriar naturalmente. La crema despus fue
desnatada de la tapa de la leche y vertida en una tina de madera. La fabricacin de la mantequilla fue hecha a mano en mantequeras. El
proceso natural el agriar es, sin embargo, el y una infeccin muy sensibles por los microorganismos extranjeros estrope a menudo el
resultado. La fabricacin de la mantequilla comercial de hoy es un producto del conocimiento y de la experiencia ganados sobre los aos en
las materias tales como higiene, la acidificacin bacteriana y el tratamiento de calor, as como el desarrollo tcnico rpido que ha conducido a
la maquinaria avanzada ahora usada. El separador poner crema comercial fue introducido en el final del diecinueveavo siglo, la mantequera
continua haba sido comercializado por el centro del vigsimo siglo.

Definiciones y estndares
Grasa de leche
- los componentes de lpido de la leche, segn lo producidos por la vaca, y encontrados en leche comercial y productos leche-derivados,
abarcados sobre todo del triglyceride.
Grasa de mantequilla
- casi sinnimo con grasa de leche; todos los componentes gordos en leche que son separables batiendo.

Grasa de leche Anhidra (AMF)

- la extraccin comercialmente preparada de la grasa de leche de la vaca, encontrado en el bulto o la forma concentrada (abarcada de la grasa
del 100%, pero no no necesariamente de todos los componentes de lpido de la leche).
Aceite de mantequilla
- synonomous con grasa de leche anhidra; (la terminologa convencional en el yacimiento de las grasas y de petrleos distingue un aceite de
una grasa basada encendido si es lquida en la temperatura ambiente. o slido, pero muy arbitrario).
Mantequilla
- una emulsin del agua-en-aceite , abarcada del > de grasa de leche 80%, pero tambin de contener el agua en la forma de gotitas
minsculas, quizs de algunos solids-not-fat de la leche, con o sin la sal (mantequilla dulce); la textura es un resultado de working/kneading
durante el proceso en las temperaturas apropiadas, para establecer la red cristalina gorda que da lugar a suavidad deseada (compare la
mantequilla con mantequilla derretida y recristalizada); utilizado como una extensin, una grasa el cocinar, o ingrediente de la hornada.
Los componentes principales de una mantequilla salada normal son gordos (80 - el 82%), el agua (15,6 - 17,6%), la sal (cerca de 1,2%) as
como la protena, calcio y phosphorous (cerca de 1,2%). La mantequilla tambin contiene las vitaminas solubles en la grasa A, D y E.
La mantequilla debe tener un color uniforme, ser densa y gusto limpio. El contenido en agua se debe dispersar en gotitas finas de modo que
la mantequilla parezca seca. La consistencia debe ser lisa de modo que la mantequilla sea fcil de separarse y derrite fcilmente en la
lengeta.

Descripcin del proceso de la fabricacin de la

mantequilla

El proceso de la fabricacin de la mantequilla implica absolutamente un nmero de etapas. El mantequero continuo ha hecho el tipo ms
comn de equipo usado.
La crema se puede proveer por una lechera flida de la leche o separar de la leche entera por el fabricante de la mantequilla. La crema debe
ser dulce (pH > 6,6, TA = 0,10 - 0,12%), no rancio y no oxidado.
Si la crema es separada por el fabricante de la mantequilla, la leche entera est precalentada a la temperatura requerida en un pasteurizer de la
leche antes de ser pasado a travs de un separador . La crema se refresca y se conduce a un tanque de almacenaje donde la proporcin de
grasas se analiza y se ajusta al valor deseado, en caso de necesidad. La leche desnatada del separador se pasteriza y se refresca antes de ser
bombeado al almacenaje. Es generalmente destinada para la concentracin y sequedad.
De los tanques de almacenaje intermedios, la crema va a la pasterizacin en una temperatura de 9C o ms. La temperatura alta es necesaria
de destruir las enzimas y los microorganismos que deterioraran la calidad que guarda de la mantequilla.
A si la maduracin se desea para la produccin de la mantequilla cultivada, las culturas mezcladas del S. cremoris, lactis diacetyl del lactis
del S., leuconostocs, se utilizan y la crema se madura pH 5,5 en 21oC y entonces pH 4,6 en 1C. La mayora del desarrollo del sabor ocurre
entre pH 5,5 - 4,6. Ms fra es la temperatura durante la maduracin del ms es la produccin de cido en relacin con del desarrollo del
sabor. La mantequilla madurada no se lava ni se sala generalmente.
En el tanque del envejecimiento, la crema se sujeta a un programa de refrescarse controlado diseado para dar a la grasa la estructura
cristalina requerida. El programa se elige para acordar con factores tales como la composicin de la grasa de mantequilla, expresada, por
ejemplo, en los trminos del valor del yodo que es una medida de la proporcin de grasas no saturada. El tratamiento se puede incluso
modificar para obtener la mantequilla con buena consistencia a pesar de un valor bajo del yodo, es decir cuando la proporcin no saturada de
la grasa es baja.
En general, el envejecer toma 12 - 15 horas. Del tanque del envejecimiento, la crema se bombea a la mantequera o al mantequero continuo
va un cambiador de calor de la placa que la traiga a la temperatura indispensable. En el proceso del batido la crema se agita violentamente

analiza los glbulos gordos , haciendo la grasa coagular en granos de la mantequilla, mientras que la proporcin de grasas del lquido
restante, el suero, disminuciones.
As la crema est partida en dos fracciones: granos y suero de la mantequilla. En el batido tradicional, las paradas de la mquina cuando los
granos han alcanzado cierto tamao, con lo cual se elimina el suero. Con el mantequero continuo el drenaje del suero es tambin continuo.
Despus de drenar, la mantequilla se trabaja a una fase gorda continua que contiene una fase finalmente dispersada del agua. Era prctica
comn lavar la mantequilla despus de batir para quitar cualquier slido residual del suero y de leche pero esto se hace raramente hoy.
La sal se utiliza para mejorar el sabor y el shelf-life, pues acta como preservativo. Si se va la mantequilla a ser salada, la sal (1-3%) se
extiende por su superficie, en el caso de la produccin de hornada. En el mantequero continuo, una mezcla de la sal se agrega a la
mantequilla que la sal se disuelve todo es la fase acuosa, as que la concentracin eficaz de la sal es el aproximadamente 10% en el agua.
Despus de salar, la mantequilla se debe trabajar vigoroso para asegurar la distribucin uniforme de la sal. El funcionamiento de la
mantequilla tambin influencia las caractersticas por las cuales el producto es juzgado - aroma, gusto, calidad que guarda, aspecto y color. El
funcionamiento se requiere para obtener una mezcla homogenous de los grnulos, del agua y de la sal de la mantequilla. Durante el trabajo,
la grasa se mueve desde globular a la grasa libre. Las gotitas del agua disminuyen de tamao durante el trabajo y no deben ser visibles en
mantequilla correctamente trabajada. La mantequilla con exceso de trabajo ser demasiado frgil o grasienta dependiendo de si la grasa es
dura o suave. Un poco de agua se puede agregar standarize el contenido de agua. El control exacto del compostion es esencial para la
produccin mxima.
La mantequilla acabada se descarga en la unidad de empaquetado, y de all a la conservacin en cmara frigorfica.

La ciencia del fondo del batido de la mantequilla

El glbulo gordo
La grasa de leche se abarca sobre todo de triglycerides, con cantidades pequeas de mono y de los diglycerides, de phospholipids, de
glicolpidos, y de lipoprotenas. Los trigylcerides (el 98% de grasa de leche) estn de la composicin diversa con respecto a sus cidos grasos
componentes, el aproximadamente 40% de los cuales sea no saturado firmeza gorda varan con la longitud de cadena, el grado de no
saturacin, y la posicin de los cidos grasos respecto al glicerol. Los glbulos gordos varan a partir del micon la 0,1 - 10 en dimetro. La
membrana del glbulo gordo se abarca de materiales tensoactivos: phospholipids y lipoprotenas.
Agregado de los glbulos gordos tpicamente de tres maneras:

floculacin
fusin
fusin parcial

El azotar y batido
Espuma de muchos productos lcteos fcilmente. La leche desnatada hace espuma copioso con la cantidad de espuma que es muy
dependiente en la cantidad de grasa residual - la grasa presiona hacer espuma. Los elementos espumosos son protenas, la cantidad de
protenas en la espuma son proporcionales a su contenido en leche. El hacer espuma se disminuye en leche tratada calor, posiblemente
porque denaturated producto de las protenas del suero a la capa ms frgil de la protena en el interfaz. Las grasas tienden para extender por
el interfaz del aire-agua y desestabilizan la espuma; las cantidades muy pequeas de grasas (phospholipids incluyendo) pueden desestabilizan
una espuma.
Durante la interaccin de glbulos gordos con las burbujas de aire el glbulo puede tambin ser interrumpido (sta es la nica manera que los
glbulos gordos se pueden interrumpir sin entrada de energa considerable). La interrupcin del glbulo gordo por la interaccin entre el
glbulo gordo y las burbujas de aire es rara a menos que en la caja de burbujas de aire nuevamente formadas donde todava est fina la capa
diedra del aire-agua. si la parte del glbulo gordo es slido, el batido resultar, por lo tanto el trmino "flotacin que bate" - de romper
repetido de las burbujas de aire y de la fusin que resulta de la grasa fijada por adsorcio'n.
A pesar de los comentarios antedichos sobre la desestabilizacin de hace espuma por la grasa, la grasa de leche es esencial para la formacin
de los productos azotados estables que dependen de la interaccin entre los glbulos gordos, las burbujas de aire y los componentes del
plasma (especialmente protenas).

Cuando se bate la crema las clulas del aire forman ms lentamente en parte debido a una viscosidad ms alta y en parte porque la presencia
de la grasa causa el derrumbamiento inmediato de la mayora de las burbujas ms grandes. si la mayora de la grasa es lquida (de alta
temperatura) la membrana del glbulo gordo es no pinchada fcilmente y no ocurre el batido - en la temperatura fra donde est presente la
grasa slida, el batido (el agrupar) del glbulo gordo ocurre. Los grupos de glbulos comienzan a asociarse a las burbujas de aire de modo
que una red de las burbujas de aire y de los grupos y de los glbulos gordos forme el encierro de todo el lquido y producir una espuma
estable. si el golpeo contina los grupos gordos aumentan de tamao hasta que se convierten en demasiado grandes y demasiado pocos para
incluir las clulas del aire, por lo tanto las burbujas de aire se unen, la espuma comienza "a escaparse" y untar con mantequilla en ltima
instancia y la leche de la mantequilla permanecen.

Cristalizacin de la grasa de leche durante el

envejecimiento
Antes de batir, la crema se sujeta a un programa de refrescarse diseado para controlar la cristalizacin de la grasa de modo que la
mantequilla resultante tenga la consistencia derecha. La consistencia de la mantequilla es una de sus caractersticas calidad-relacionadas ms
importantes, directamente e indirectamente, puesto que afecta las otras caractersticas - principalmente gusto y aroma. La consistencia es un
concepto complicado e implica caractersticas tales como dureza, viscosidad, plasticidad y capacidad que se separa.
Las cantidades relativas de cidos grasos con el alto punto de fusin se determinan si la grasa ser dura o suave. Suavemente la grasa tiene un
alto contenido de bajo-derretir los cidos grasos y en la temperatura ambiente esta grasa tiene una fase gorda continua grande con una fase
slida baja, grasa es decir cristalizada, de fusin elevada. Por otra parte, en una grasa dura, la fase slida de la grasa de fusin elevada es
mucho ms grande que la fase gorda continua de bajo-derretir los cidos grasos.
In buttermaking, if the cream is always subjected to the same heat treatment it will be the chemical composition of the milk fat that
determines the butter's consistency. A soft milk fat will make a soft and greasy butter, whereas butter from hard milk fat will be hard and stiff.
If, however, the heat treatment is modified to suit the iodine value of the fat, the consistency of the butter can be optimized. For the heat
treatment regulates the size of the fat crystals, and the relative amounts of solid fat and the continuous phase - the factors that determine the
consistency of the butter.
Pasteurization causes the fat in the fat globules to liquefy. And when the cream is subsequently cooled a proportion of the fat will crystallize.
If cooling is rapid, the crystals will be many and small; if gradual the yield will be fewer but larger crystals. The more violent the cooling
process, the more will be the fat that will crystallize to form the solid phase, and the less the liquid fat that can be squeezed out of the fat
globules during churning and working.
The crystals bind the liquid fat to their surface by adsorption. Since the total surface area is much greater if the crystals are many and small,
more liquid fat will be adsorbed than if the crystals were larger and fewer. In the former case, churning and working will press only a small
proportion of the liquid fat from the fat globules. The continuous fat phase will consequently be small and the butter firm. In the latter case,
the opposite applies. A larger amount of liquid fat will be pressed out; the continuous phase will be large and the butter soft.
So by modifying the cooling program for the cream, it is possible to regulate the size of the crystals in the fat globules and in this way
influence both the magnitude and the nature of the important continuous fat phase.
Treatment of hard fat
For optimum consistency where the iodine value is low, i.e. the butterfat is hard, as much as possible of the hardest fat must be converted to
as few crystals as possible, so that little of the liquid fat is bound to the crystals. The liquid fat phase in the fat globules will thereby be
maximized and much of it can be pressed out during churning and working, resulting in butter with a relatively large continuous phase of
liquid fat and with the hard fat concentrated to the solid phase.
The program of treatment necessary to achieve this result comprises the following stages:
- rapid cooling to about 8oC and storage for about 2 hours at this temperature;
- heating gently to 20 - 21oC and storage at this temperature for at least 2 hours (water at 27 - 29oC is used for heating);
- cooling to about 16oC.
Cooling to about 8oC causes the formation of a large number of small crystals that bind fat from the liquid continuous phase to their surface.
When the cream is gently heated to 20 - 21oC the bulk of the crystals melt, leaving only the hard fat crystals which, during the storage period
at 20 - 21oC, grow larger.
After 1 - 2 hours most of the hard fat has crystallized, binding little of the liquid fat. By dropping the temperature now to about 16oC, the
hardest portion of the fat will be fixed in crystal form while the rest is liquefied. During the holding period at 16oC, fat with a melting point

of 16oC or higher will be added to the crystals. The treatment has thus caused the high-melting fat to collect in large crystals with little
adsorption of the low-melting liquid fat, so that a large proportion of the butter oil can be pressed out during churning and working.
Treatment of medium-hard fat
With an increase in the iodine value, the heating temperature is accordingly reduced from 20-21oC. Consequently a larger number of fat
crystals will form and more liquid fat will be adsorbed than is the case with the hard fat program. For iodine values up to 39, the heating
temperature can be as low as 15oC.
Treatment of very soft fat
Where the iodine value is greater than 39-40 the "summer method" of treatment is used. After pasteurization the cream is cooled to 20oC. If
the iodine value is around 39 - 40 the cream is cooled to about 8oC, and if 41 or greater to 6oC. It is generally held that aging temperatures
below the 20o level will give a soft butter.

Butter structure

It should now be obvious from the discussions regarding the background science of churning and the crystallization processes that the
structure of butter is quite complicated. The size and extent of crystal networks both within the globules and within the non-globular phases
is controlled to a large extent by milkfat's variable composition and by the aging process. The extent of globular versus non-globular fat is
controlled to a large extent also by the amount of physical working applied to the butter post-churning.

Continuous Buttermaking
There are essentially four types of buttermaking processes:

traditional batch churning from 25- 35% mf. cream;

the anhydrous milkfat process whereby water, SNF, and salt are emulsified into butter oil in a process very similar to margarine
manufacture.

continuous flotation churning from 30-50% mf. cream;

the concentration process whereby "plastic" cream at 82% mf. is separated from 35% mf. cream at 55 C and then this oil-in-water
elulsion cream is inverted to a water-in-oil emulsion butter with no further draining of buttermilk;

An optimum churning temperature must be determined for each type of process but is mainly dependent on the mean melting point and
melting range of the lipids, as discussed above, i.e., 7-10 oC in summer and 10 - 13 oC in winter. If churning temperature is too warm or if
thermal cycle permits to much liquid fat than a soft greasy texture results; if too cold or too much solid fat than butter too brittle and sticky.

Continuous Flotation Churns

The cream is first fed into a churning cylinder fitted with beaters that are driven by a variable speed motor.
Rapid conversion takes place in the cylinder and, when finished, the butter grains and buttermilk pass on to a draining section. The first
washing of the butter grains sometimes takes place en route - either with water or recirculated chilled buttermilk. The working of the butter
commences in the draining section by means of a screw which also conveys it to the next stage.
On leaving the working section the butter passes through a conical channel to remove any remaining buttermilk. Immediately afterwards, the
butter may be given its second washing, this time by two rows of adjustable high-pressure nozzles. The water pressure is so high that the
ribbon of butter is broken down into grains and consequently any residual milk solids are effectively removed. Following this stage, salt may
be added through a high-pressure injector.
The third section in the working cylinder is connected to a vacuum pump. Here it is possible to reduce the air content of the butter to the
same level as conventionally churned butter.
In the final or mixing section the butter passes a series of perforated disks and star wheels. There is also an injector for final adjustment of the
water content. Once regulated, the water content of the butter deviates less than +/- 0.1%, provided the characteristics of the cream remain
the same.
The finished butter is discharged in a continuous ribbon from the end nozzle of the machine and then into the packaging unit.

Concentration Method

30% fat cream pasteurized at 90 oC

degassed in a vacuum

cooled to 45 - 70 oC
separated to 82% fat ("plastic" cream)
the concentrate, still an O/W emulsion, is cooled to 8 - 13 oC
fat crystals forming in the tightly packed globules perforate the membranes, cause liquid fat leakage and rapid phase inversion
contrast to mayonnaise, also a o/w emulsion at 82% fat but is winterized to prevent crystallization
butter from this method contains all membrane material, therefore, more phospholipids
no butter milk produced
after phase inversion the butter is worked and salted.

Phase Separation
Butter from anhydrous milkfat:

prepare "plastic" cream (>80% fat)

further worked to develop crystal structure and texture

heat with agitation to destabilize emulsion

separate oil from aqeous phase: 82 to 98% butter fat
this butter oil is then blended with water, salt and milk solids in an emulsion pump and transferred to scraped surface heat
exchanger for cooling and to initiate crystalization
process similar to margarine manufacture
margarine has advantage of fat composition control to modify physical properties
butter produced by phase separation contains few phospholipids.

Butter Yield Calculations

Technological limits to yield efficiency are defined by separation efficiency, churning efficiency, composition overrun, and package over fill.
1. Separation efficiency (Es):
- represents fat transferred from milk to cream
Es = 1 - fs/fm
where fs = skim fat as percent w/w fm = milk fat as percent w/w
Separation efficiency depends on initial milk fat content and residual fat in the skim. Assuming optimum operation of the separator, the
principal determining factor of fat loss to the skim is fat globule size. Modern separators should achieve a skim fat content of 0.04 - 0.07%.
2. Churning Efficiency (Ec):
- represents fat transferred from cream to butter
Ec = 1 - fbm/fc
where fbm = buttermilk fat as percent w/w
fc = cream fat as percent w/w
Maximum acceptable fat loss in buttermilk is about 0.7% of churned fat corresponding to a churning efficiency of 99.3% of cream fat
recovered in the butter. Churning efficiency is highest in the winter months and lowest in the summer months. Fat losses are higher in
ripened butter due to a restructuring of the FGM (possibly involving crystallization of high melting triglycerides on the surface of the
globules). If churning temperature is too high, churning occurs more quickly but fat loss in buttermilk increases. For continuous churns
assuming 45% cream, churning efficiency should be 99.61 - 99.42%.
3. Composition Overrun
% Churn Overrun
= (Kg butter made - Kg fat churned)/Kg fat churned x 100 %
% Composition Overrun
= (100 - % fat in butter)/% fat x 100 %

4. Package Fill Control

= (actual wt. - nominal wt.)/nominal wt. x 100%
An acceptable range for 25 kg butter blocks is 0.2 - 0.4% overfill. Overfill on 454 g prints is about 0.6%.
5. Other factors affecting yield
- shrinkage due to leaky butter (improperly worked).
- shrinkage due to moisture loss; avoided by aluminum wrap.
- loss of butter remnants on processing equipment; % loss minimal in large scale continuous processing.
6. Plant Overrun
-Plant efficiency or plant overrun is the sum of separation, churning, composition overrun and package fill efficiencies. In summary the
theoretical maximum efficiency values are:
Separation Efficiency 98.85
Churning Efficiency 99.60
Composition overrun (% fat) 23.30
Package overfill 0.20
-These values can be used to predict the expected yield of butter per kg of milk or kg of milk fat received.
7. Example
3.6% m.f. milk
0.05% m.f. in skim
40% m.f. in cream
0.3% m.f. in buttermilk
81.5% m.f. in butter
Es = 1 - .05/3.6 = 98.6
Ec = 1 - .3/40 = 99.25
% Overrun = (100-81.5)/81.5 = 22.7%

Whipped Butter
Whipped butter is typically used in foodservice situations. The main advantage of whipped butter is increased spreadability even at
refrigeration temperatures, thus providing great advantage for the restaurant industry. The volume increase is usually 25 - 30%. Whipping is
achieved by injecting an inert gas (nitrogen) into the butter after churning. In the phase separation process, whipping can be achieved by
injecting nitrogen in the crystalizer as is done in the production of whipped margarine.

Anhydrous Milkfat ("butter oil")

The processes for the production of anhydrous fat, using cream as the raw material, are based on the emulsion splitting principle. In brief, the
processes consist of the cream first being concentrated and the fat globules then being broken down mechanically, so that the fat is liberated.
This forms a continuous fat phase containing dispersed water droplets which can be separated from the fat phase.
Either the Clarifixator or the Centrifixator is used for mechanically liberating the fat and thus allowing for the phase conversion, and these
two process lines derive their names from the corresponding units.
The Clarifixator line has been used commercially for a number of years. One of the key machines in the system - the Clarifixator - is a
centrifugal separator equipped with a serrated disc which simultaneously homogenizes the milk. The disc normally breaks down the fat
globules into smaller globules, although in the production of anhydrous milk fat, the disc breaks down the emulsion, so that the liquid leaving
the machine is a continuous oil phase, with dispersed water droplets and buttermilk. After phase inversion, the fat is concentrated in a
hermetic separator.
Clarifixator lines with capacities between 500 and 1000 kg of butter oil per hour are available.

The Centrifixator line has an appreciably higher capacity of 1500 - 2000 kg of butter oil per hour and offers opportunities for planning
production rates of 4000 - 6000 kg of butter oil per hour. In this case, the emulsion is split in a unit of special design - known as the
Centrifixator - which contains a motor-driven serrated disc. The fat is concentrated in a hermetic solids-ejecting separator. Solids-ejecting
machines are also used in the second centrifugal separation stage, and the line is thus capable of operating for long periods and can be
cleaned in place.
Fractionation of anhydrous milk fat
Milk fat is a complicated mixture of triglycerides that contain numerous fatty acids of varying carbon chain lengths and degrees of saturation.
The proportions of the various fatty acids present will also vary depending on the conditions surrounding the production of milk.
One method of milkfat fraction in by thermal treatment. The mixture can be separated into fractions on the basis of their melting point. The
technique consists of melting the entire quantity of fat and then cooling it down to a predetermined temperature. The triglycerides with the
higher melting point will then crystallize and settle out.
In the modern thermal fractionation method, sedimentation by gravity is replaced by centrifugal separation. Since a modern separator
generates a force which is thousands of times greater than the force of gravity and since the sedimentation distances are very short, the
process is incomparably faster. The crystallizing stage can also be accelerated, since the crystals need not be large if centrifugal separation is
employed.
Fractionation of milkfat can also be accomplished by supercritical fluid extraction techniques.

Some of this material has been condensed from the Alfa-Laval Dairy Handbook, with permission.

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