Westfalia Separator MSD 90-01-076

Westfalia Separator
Food Tec GmbH

Mechanical Separation
Division
Dipl.-Ing. Arnold Uphus
Milk fat processing

Butter and Butteroil / AMF ( Anhydrous Milk Fat )
List of contents
1
Introduction
1.1
Milk fat products using a buttermaking machine
1.2
Milk fat products using a butteroil process
Buttermaking
2.1
History
2.2
Butter processing line
2.3
Cream treatment
2.4
Cream treatment for making sour cream butter
12
2.5
Cream pre-heating
12
2.6
Buttermaking machine
13
2.7
Dosing station
15
2.8
Control
16
2.9
Butter distribution
18
2.10
CIP system
19
2.11
Reworkers
20
2.12
Special processes for the production of milk fat products
22
2.12.1
Milk fat with reduced fat content
22
2.12.2
Butter with vegetable fat additives
23
2.12.3
Butter production with reduced content of solids non fat
24
Butteroil production (AMF)
26
3.1
Introduction
26
3.2
Chemical/physical correlations
26
3.2.1
Definition and designation of milk fat
27
3.2.2
Characteristics of fatty acids
31
3.2.3
Phase inversion
32
3.2.4
Minimising the emulsion phase
37
3.2.5
Reducing the free fatty acids
38
3.2.6
Peroxide number
38
3.2.7
Phospholipid distribution
39
3.3
Processes used for production of butteroil
41
3.3.1
Standard process using buttermilk
42
3.3.2
Process using -serum and secondary skim
44
3.3.3
Processes for butter processing
46
3.3.3.1 Melting the butter blocks
47
3.3.3.2 Making butteroil from sweet cream butter
47
3.3.3.3 Processing of salted sweet cream butter
49
3.3.3.4 Production of butteroil from sour cream butter
51
3.3.3.5 Processing of Cream and Butter with a high FFA content
52
3.3.3.6 Addition of antioxidants
53
Machines used for making butteroil
54
4.1
Cream concentrators
54
4.2
Oil concentrators / oil polishing separators
55
4.3
Skimming separators
58
4.4
Three-phase decanters
59
4.5
Butter melting system BMSA 5000
61
4.6
Vacuum unit
62
Bibliography
64
1 Introduction
In the milk fat field, Westfalia Separator nowadays offers the complete range of production methods
for various end products. The methods can be classified under two main groups:
1.1 Milk fat products using a buttermaking machine

Cream 40 %
Pasteurisation
Crystallisation
Cream
pre-heating
Butter churn
BUD
Butter
distribution
Buttermilk
Separation
Butter packer
Buttermilk
Consumers
Bulk Butter
Butter reworker
Butter packer
Butter melting
Recombined
Butter
Butteroil
production
Consumers
Figure 1:
Westfalia Separator milk fat processing using the example of buttermaking
1.2 Milk fat products using a butteroil process
Cream 40 %
Pasteurization
Cream
concentration
Phase
inversion
Buttermilk
separation
Cooling
system
Oil
concentration
Buttermilk
Oil polishing
Pin worker
Vacuum
treatment
Resting tube
Butter
(GoldenFlow)
Butteroil
Consumers
Crystallization
Separation/
Filtration
Stearin
Olein
Soft butter
Figure 2:
Westfalia Separator milk fat processing using the example of butteroil production
2 Buttermaking
2.1 History
Westfalia Separator has been involved with manufacturing and delivering buttermaking equipment
since the 1920s.
Production of the first timber butter vat with a capacity of 25 l cream started in 1929. Production of
butter vats was closed down only in 1950.
In 1941, a contract was signed between Westfalia Separator AG and Dr. Fritz, the inventor of the continuously operating buttermaking machine; this enabled us to use the Fritz system on an industrial
basis.
In the same year, the first prototypes of the continuously operating buttermaking machine appeared
on the market. This was followed immediately by series production of the type BUA with a capacity of
500 kg/h. Then followed the types BUB 1500 with a capacity of 750 kg/h and the type BUA with a capacity of 400 kg/h, and these were built approximately until 1960/1963.
In response to higher production levels in the field of sour cream butter, development of the type series BUC commenced at the end of the 1950s. The BUC 800 with a capacity of 800 kg/h butter was
built between 1960 and 1972.
The BUC 1500 was also developed in 1964 for a capacity of 1,500 kg/h.
Higher capacities were reflected in 1969 with the type BUC 3000 with a capacity of 3,000 kg/h. In
1974, the sales program was extended to include the type BUC 4000 with a capacity of 4,000 kg/h.
Development of the new BUD generation was commenced at the end of the 1970s.
2.2 Butter processing line
The following is a schematic representation of a butter processing line.
Cream 40 %
Cream treatment
Cream storage
CIP System
Cream pre - heating
Culture treatment
BDSB Dosing System
Butter distribution
Salt brine preparation
Butter packaging
Figure 3:
Flow chart of buttermaking
2.3 Cream treatment
The primary aim of cream treatment is crystallisation of the fat globules in order to achieve adequate
phase inversion.
H2O
Water
protein
fat nucleus
( Triglycerids
solid or
liquid )
lecithin
H2O
Figure 4:
Cross-section through a fat globule, according to Kiermeier
The crystallisation or cream treatment process depends on the conditions or regulations which obtain
in the specific country.
In the past, central Europe mainly saw the production of sour cream butter, whereas nowadays sweet
cream is now virtually used exclusively for churning into butter.
Slightly cultured butter can be achieved by adding suitable cultures, e.g. using the NIZO method.
When butter is made from sweet cream, sweet buttermilk is obtained, and this can be used very efficiently in subsequent processing.
Legal requirements, relating to texture for instance, continue to result in differentiated cream treatment
in Germany.
Sweet cream butter is generally made in other countries. In line with the national laws in a particular
country, the cream is pasteurised and then cooled to approx. 5 - 6 C.
Mechanism of butter formation (Kiermeier)
intact milkfat
globule
H2 O
protein
fat
globule
lecithin
H2 O
air
H2 O
air
fat
fat
foam
air
air
air
H2 O
breaking of foam
butter grain
fat
fat
fat
Figure 5:
Foam theory of butter granule formation
The cooled cream is stored in isolated tanks. The crystallisation heat (latent heat) which is released
during the crystallisation process generally raises the temperature of the cream by 1 - 2 C. When the
tank has been filled, the cream should be allowed to stand for 8 - 12 hours (crystallisation time).
When the tank is being filled and when the cream is allowed to stand during the crystallisation time,
agitators should not be operated; this avoids the fat globules being damaged and also avoids hindering crystal growth.
Pasteurisation
[ C ]
churning tempearture
10
Crystallisation temperature
5
Crystallisation time
Figure 6:
time [ h ]
Temperature-time curve for making traditional sweet cream butter
Shortly before the churning process, the contents of the tank are mixed gently. On the other hand, the
agitator should only operate at selected intervals during the discharge phase. During the pasteurisation process, vacuum treatment can be used in order to remove negative flavours. These methods are
used in New Zealand and in the USA. The buttermilk fat content is around 0.2 to 0.3% higher due to
the unavoidable destruction of fat globules.
Special conditioning of the cream is necessary in order to improve the spreadability of the butter. A
special temperature-time program is used depending on the melting and solidification points of the fat.
After the pasteurisation process, the temperature of the cream is lowered to 5 - 6 C. The cream is
then allowed to stand for at least two hours, and its temperature is raised to approx. 18 - 21 C (depending on the melting and solidification characteristics). This can be achieved by pumping the product from the storage tank to the preheating tank via a plate heat exchanger. The cream is allowed to
stand for approx. 2 hours after the preheating process, and the temperature is then reduced to approx.
6 C in a plate heat exchanger.
10
The cream is allowed to stand for at least 12 hours in the tank before the churning process can be
commenced.
Pasteurisation
T
[ C ]
min 2 h
min 2 h
min 12 h
20
10
5
Figure 7:
time [ h ]
Temperature-time curve for cold-warm-cold crystallisation
11
2.4 Cream treatment for making sour cream butter

In the process used for making traditional sour cream butter, the creamery culture is added to the ripening tanks.
Pasteurisation
T
[ C ]
min 12 h
20
churning tempearture
10
5
Figure 8:
Temperature-time curve for making sour cream butter
When it has been pasteurised, the cream is pumped to the ripening tanks with a temperature of approx. 18 - 20 C. The pH value is checked after the cultures have been added.
At a pH value of approx. 4.8 - 5.0, the acidification process is stopped by cooling the cream. The
cream tank is equipped with a corresponding heating and cooling device, a special agitator and a device for measuring the pH value.
2.5 Cream pre-heating

The crystallised cream is pre-heated to the appropriate temperature ahead of the buttermaking machine. In order to ensure that buttermaking processes are as efficient as possible, it is necessary to
avoid fluctuations of whatever nature.
Tests have shown that temperature fluctuations upstream of the buttermaking machine affect the water content in the butter, even if all other parameters remain constant (fat content, speeds, butter texture, etc.).
12
The feed quantity to the buttermaking machine is maintained constant by means of a speed-controlled
displacement pump with a downstream inductive flow meter. Pressure-influencing factors from the
cream tank or gradually changing resistance levels at the cream pre-heater are compensated.
FIC
TI
Cream 40 %
Cream 40%
Icewater
Icewater
Condensate
Steam 1,5 bar
TIC
TIC
Buttermilk
Buttermilk
Figure 9:
Westfalia Separator cream pre-heater system
By integrating a cooling section, the pre-heating water can be set to and maintained at the desired
temperature at the start of production and during any interruptions of production. A cooling device for
recirculating the buttermilk is also integrated in the pre-heater.
2.6 Buttermaking machine

The WS buttermaking machine type BUD consists of the following main components:
Primary churning cylinder with adjustable drive
Secondary churning cylinder with adjustable drive
Primary blender with adjustable drive
Secondary blender with adjustable drive and vacuum section
Vacuum unit
Buttermilk recirculation and buttermilk cooling
Butter granule recovery system
13
Dosing unit for culture, salt and water

Control system for production and cleaning
The treated cream is pumped from the cream tank to the primary churning cylinder via the cream preheater at a constant rate. The rotating dasher shaft breaks down the fat globules, and so-called butter
granules form. The speed of the dasher shaft depends on the capacity, cream treatment, temperature,
etc., and can be adjusted by the operator.
Cream feed
Annular weir
Butter granule
recovery
Rotary screen
Butter
Buttermilk cooler
Buttermilk
Figure 10: Butter granule recovery system

The mixture consisting of butter granules and buttermilk enters the secondary churning cylinder. The
mixture consisting of butter granules and buttermilk is cooled intensively by the addition of cooled
buttermilk (approx. 2 C). The cooling effect is intensified by a weir in the secondary churning cylinder
(WS patent).
The buttermilk is then separated in the secondary churning cylinder, and is then conveyed directly to
the buffer tank.
The butter granules enter the texturizer and are conveyed to the blending section with augers. Buttermilk is removed and recycled to the secondary churning cylinder via a centrifugal pump. Fine butter
granules from the texturizer can thus be directly recycled into the process.
The additive components such as cultures, salt or water are added in the blending section.
14
A vacuum section installed between the primary blending section and the secondary blending section
reduces the air content to less than 0.5%.
The integrated displacement pump in the secondary blender (WS patent) produces a high vacuum
which removes almost all of the air enclosed in the butter.
The butter is blended intensively in the second blending section. Fine water distribution of 3 - 5 m
can be achieved in this way, and the butter is subsequently conveyed to a butter tank.
2.7 Dosing station

Depending on the particular capacity and task involved, the dosing station consists of two or three
dosing pumps. Each dosing pump is monitored and controlled by an inductive flow meter.
water
culture 2 / saltbrine
culture 1 / saltbrine
CIP
FIC
FIC
FIC
Figure 11: BDSB dosing station

A calculation program integrated in the operating monitor calculates the dosing quantities on the basis
of the capacity of the buttermaking machine, and uses these quantities as the preset data for the
pumps. The dosing quantity is automatically changed if the capacity is increased or reduced. This is
particularly important in the case of cultures, as any analysis will only produce useful results several
days later.
15
The tanks are equipped with agitators and level sensors so that the addition of culture, saline solution
or water can be automatically requested.
Cream flow
to BUD
Computer
Buttermilk fat content
Cream fat content
Dosing quantity per pump
BUD
Butter capacity in kg/h
Dosing pump 1
Flow meter
Dosing pump 2
Flow meter
Dosing pump 3
Flow meter
Culture I
Culture II
Water
Salt brine
Salt brine
Water
Figure 12: Functional diagram of the dosing station
2.8 Control
The buttermaking machine is adjusted to meet the various process parameters via frequencycontrolled drives.
In addition to the external motor control, the machine has a control system consisting of the following:
Siemens S5 135U programmable logic controller
16
Equipped with:
CPU 528 / communication processor CP 527
Digital inputs / digital outputs
Analog inputs / analog outputs
Colour graphic display

Operator interface
Option:
Printer
Monitoring
and
Control
CP 527 / CP 528
Control unit
Siemens S 5
DA / DE
AA / AE
Drives
Modulating valves
24 DC
Flow meter, etc.
4-20 mA
AC
Temperature probe,
Feedback
Process
Automatic valves
230 V
M
3~
MCC
Figure 13: Structure of control system

Operating monitor
Siemens MP 14
Equipped with the following:
Colour monitor 14 inch
Function keys F1 - F16
Operating keyboard for selecting images and entering data, etc.
17
The screen installed in the front of the buttermaking machine enables the process to be displayed in a
clear manner.
The system provides process automation functions for measuring, controlling and regulating data as
well as screen-oriented operating and monitoring functions.
The entire process is observed with the aid of process-related flow diagrams. The operator can thus
monitor the process, obtain an overview of the system status at all times and thus identify the occurrance of any problems. Simple user guidance and function keys permit rapid operator intervention in
the event of any problems.
2.9 Butter distribution

The butter is generally distributed to the packing machines from a butter tank with attached butter
pumps.
Packing machines usually operate with a direct feed facility, which then require a directly assigned
butter pump.
In order to prevent product damage, Westfalia Separator has developed a system for reducing butter
overworking in butter tanks (WS patent).
The handling capacity of the packaging machines determines the speed of the butter pumps, and the
speed of the pumps in turn controls the speed of the screws in the butter tank.
This arrangement achieves optimum pressing ahead of the butter pump as well as gentle product
handling.
18
CIP- Return
CIP- Feed
steam
Butter silo
Butter pump
Packaging machine
Water
Figure 14: Installation diagram of a butter silo
2.10 CIP system

The process concepts of Westfalia Separator AG include not only the buttermaking systems but also
cleaning systems whereby the cleaning lye is recycled.
Larger quantities of CIP liquid are required when butter distribution systems are integrated.
The CIP system features a hot water tank for the necessary rinsing processes, a lye tank for the special cleaning liquid, the necessary valves, the heating system with the corresponding pumps.
A storage tank can be used for treating residual fat. The storage tank then collects and decants the
residual fats from the melting process and the initial rinsing stage. The concentrated fat is used in
other processing processes.
19
CIP- Return
CIP
M
Butteroil
Water
Steam
Caustic
Steam
Water
Condensate
CIP-Feed
Steam
Figure 15: CIP system
2.11 Reworkers
Westfalia Separator has developed a reworker for treating block butter.
This machine has been designed for reworking block butter. Intensive blending is necessary before
the butter is packaged in consumer packagings. The reworker type BMB 2500 enables salt, water and
other soluble additives to be added to the butter.
The block butter is stored in cold rooms at -10C to -20C. A subsequent controlled conditioning process raises the temperature of the butter to approx. +2C to +4C before the butter is conveyed to the
reworker type BMB 2500.
The packaging material is removed, and the butter blocks are pushed onto the elevator.
20
Figure 16: Reworker

The main cylinder conveys the block to the inlet of the reworker. The swivel cylinder tips the block
onto the inlet chute.
There is a conveyor screw with adjustable drive in the hood or inlet chute. The supply speed of the
screw determines the capacity of the reworker type BMB 2500.
The cutter drum is equipped with replaceable cutters, and cuts the block into small pieces.
The conveyor screws in the reworker convey the butter pieces to the blending section, where the butter is intensively blended. The mechanical work raises the temperature of the butter to approx. 8 C to
10C.
Salt, water or soluble additives can be added in the blending section. The blended butter is discharged
from the machine via an extension tube, and can be conveyed to a butter tank for distribution to several packaging machines or to a directly connected packaging machine.
21
2.12 Special processes for the production of milk fat products

This buttermaking machine can be used for making milk fat products with different compositions.
The production of fat-reduced milk and mixed fats has been started in response to consumer demand.
2.12.1 Milk fat with reduced fat content

The buttermaking machine can be used for making milk fats with a fat content of max. 60%.
Suitable additives can be used for reducing the fat content. These additives and products are added in
the blending section of the texturizer.
The production and composition of the additives for so-called half-fat butter are of vital importance for
successfully marketing these products.
Cream 40 %
CIP - System
Cream treatment
Dosing media treatment
Cream storage
Pasteurisation
Cream preheating
Storage
BDSB Dosing system
Butterdistribution
Butter packaging
Butter with
60 % Fat
Figure 17: Production of butter with reduced fat content
22
2.12.2 Butter with vegetable fat additives

Improved spreadability can be achieved by the addition of vegetable oils.
The buttermaking machines can be used for this process without the need for major inversion. The
vegetable fat content in relation to the total fat content is generally 25%. The vegetable fat is added to
the cream before the cream treatment process.
Cream 40 %
Vegetable oil
Pasteurisation
Crystallisation
Cream preheating
Primary churning cylinder
Buttermilk Separator
Butter milk
Secondary Churningcylinder
Texturiser I
Dosing system
Texturiser II
Butter distribution
Packaging machine
Butter with vegetable oil
Figure 18: Production of butter with the addition of vegetable fat
23
2.12.3 Butter production with reduced content of solids non fat

Certain regions require butter to be made with a reduced content of solids non fat (SNF).
Cream 40 %
Cream treatment
Cream storage
CIP - System
Cream pre - heating
Cooling water
Primary churning cylinder
Salt brine preparation

Secondary churning cylinder
Texturiser I
BDSB Dosing system
Texturiser II
Butterdistribution
Butter with < 1 % SNF
Figure 19: Butter production with reduced SNF content

Washing is necessary in order to achieve an SNF content of less than 1%. Whereas this did not present any problems in the past when butter vats were used, the current use of continuous buttermaking
machines means that SNF reduction can only be achieved at the expense of certain compromises.
Westfalia Separator has developed a special process for making "table butter" in India. The special
washing process used in this system achieves an adequate reduction in the SNF content.
24
The washing effect is influenced by the way in which the wash water is added to the system. The temperature of the wash water is also very important.
25
3 Butteroil production (AMF)
3.1 Introduction
Westfalia Separator has been manufacturing separators for more than 100 years and decanters since
1959 for the most diverse processes in the dairy industry. These separators and decanters are often
the very heart of the process.
The product, anhydrous milk fat (AMF), butteroil or dry butter fat, which is known in Asia under the
name "Ghee", is widely used for the recombination of milk and milk products, as a frying fat and as a
raw material for other food factories, for example in the baking industry.
Increasing industrialisation in many countries on the one hand and the population explosion, for example in third-world countries on the other have given this product a new dimension. Its many uses
and excellent storage characteristics have lent impetus to the development of new processes for the
production of anhydrous milk fat.
Many years of experience in the design of separators and decanters as well as fundamental knowledge of the technologies involved are the corner stones of the expertise and knowhow of Westfalia
Separator AG. The supply of complete plants for the production of anhydrous milk fat (AMF) is a logical consequence of this development.
3.2 Chemical/physical correlations

For the sake of simplicity, only the production of AMF (AMF = Anhydrous Milk Fat) is described here,
whereby the general collective term "butteroil" is used as a rule for the end product.
Definition:
Butteroil is a product which is obtained exclusively from milk, cream or butter by the almost complete
removal of water and fat-free dry matter. (1)
26
The current international specifications are set out in the following:

Definition of product
Water-free milk fat (anhydrous
Water-free butter fat (anhydrous
Dry butter fat (butteroil) made
milk fat) AMF made from top
butteroil) made from cream or
from cream or butter of any age.
quality milk, cream or butter and
butter of any age.
to which no neutralising substances are added.
Composition
Milk fat
99.8 % minimum
99.8 % minimum
99.3 % minimum
Water
0.1 % maximum
0.1 % maximum
0.5 % maximum
Free fatty acids
0.3 % maximum
0.3 % maximum
0.3 % maximum
Copper
0.05 p.p.m. maximum
0.05 p.p.m. maximum
0.05 p.p.m. maximum
Iron
0.2 p.p.m. maximum
0.2 p.p.m. maximum
0.2 p.p.m. maximum
Peroxide
0.2 milliequivalent O2/kg
fat
fat
fat
Coliforms
Negative/ g
Negative/ g
Negative/ g
Taste and texture
Pure and mild
No pronounced impure or
No pronounced impure or
(at 20 - 25 C)
in any other way imperfect
in any other way imper-
taste or aroma
fect taste or aroma
Traces
Traces
Neutralising substances
None
Table 1
3.2.1 Definition and designation of milk fat

As a substance of biological origin, milk fat is a complex mixture of several components which differ
only slightly in terms of their characteristics. Triglycerides are the main component in milk fat.
Triglycerides are esters of the three-valent alcohol glycerine with monocarboxylic acids.
A uniform designation of fats is not always encountered in literature. The designations fats, lipids, lipines or fatty oils are used for the same group of substances.
For this reason, it is necessary to define some concepts. Lipids is the term used to describe the entire
group of substances.
In general, we distinguish between the following:
simple lipids
compound lipids (also known as lipoids ) and
lipid derivatives.
Simple lipids are esters of fatty acids with alcohols.
27
Milk fat
Simple lipids
Compound lipids
Lipid derivatives
Fat escort substances
Glycerides
Phospholipids
Free fatty acids
Stearins
Table 2:
Overview of components in the milk fat complex
These include fats as esters of the monocarboxylic acids with glycerine and waxes as esters of monocarboxylic acids with high molecular alcohols. Compound lipids contain alcohol and monocarboxylic
acids as well as other components. These include the phospholipids and glucolipids. Lipid derivatives
are substances which are obtained from simple and compound lipids in the course of chemical processes and which feature the general characteristics of the lipids.
Depending on the particular origin, we distinguish between animal and vegetable fats. However, a
useful method is to classify food fats into vegetable fats, animal deposit fats and milk fats. The distinction drawn between milk fat and animal deposit fats emphasises the particularly nutritional value as
milk fat is the only natural fat which is formed in the milk glands and used exclusively for nourishing
the young. The term oils is used to describe simple lipids which are liquid at room temperature. As
however solid fats liquefy when their temperature is raised, the term oil is not justified. Every fat can
be an oil, and every oil can be a fat.
The term oil is also used to describe liquid hydrocarbon mixtures. In order to make a distinction, liquid
lipids are described as fatty oils. We also speak of etherl oils, such as rose oil and orange oil, which
are used as scents. Fats can be recognised by the fact that they leave a permanent mark on paper,
whereas the marks of ethere oils evaporate after a certain amount of time. They produce watersoluble soaps with potassium lye. On the other hand, crude oil components do not react and remain
insoluble in water. When heated to more than 300 C, fats give off acrolein, which is a pungent substance which irritates the eyes. Various designations are used for milk lipids, e.g. milk fat, butter fat,
whey fat or cheese fat, and the designation is based on the particular product which is contained in
the fat or from which it is isolated. Although milk is the starting substance for all products, this distinction may be appropriate. The designations are used for describing the possible effect which the processing method may exert on the characteristics and the composition of the milk fat in the products, as
there are differences in the composition in comparison with the fat contained in raw milk.
Pure fat is a mixture of triglycerides.
Milk fat occurs in milk in the form of small fat globules with a diameter of 3 ... 6 m, and forms an
emulsion with water of the type oil in water. In order to stabilise the emulsion, the fat globule is sur-
28
rounded with an adsorbent envelope consisting of phospholipids and proteins. The envelope contains
fat escort substances.
The components of the milk fat are contained in various phases, namely the fat globule and the envelope; there are also traces in the milk serum.
Table 3 sets out the components of milk fat and their quantities in the individual phases of milk.
Lipid
Contents
Quantities
Occurance
Simple lipids
Triglycerides
98...99 %
Fat globules
Diglycerides
0.2... 0.6 %
Monoglycerides
0.02 %
Waxes
Traces
Fat globules
Phospholipids
0.2...1.0 %
Fat globule envelope and
Lecithin
35...40 %
serum
Kephaline
29...38 %
Sphingomyceline
19...24 %
Fatty acids
Traces
Sterines
0.25 ... 0.40%
Cholesterol
0.2 ... 0.4%
Lanosterine
Traces
7-dehydro-
Traces
Compound lipids
Lipid derivatives
Fat globules and serum
Fat escort substances

Aqueous phase
cholesterol
Fat globules
Squalene
Traces
Fat-soluble
Fat globules and envelope
Vitamins
Traces
Vitamin A
7.0 ... 8.5 g

per 1 g Fat
Carotinoides
8.0 ... 10.0 g

per 1 g Fat
Vitamin E
2.0 ... 50 g
per 1 g Fat
Table 3:
Vitamin D
Traces
Vitamin K
Traces
Components of milk fat (according to Jenness-Patton
..[..])
The data concerning the content of individual phospholipids are calculated in the form of lecithin on
the basis of phosphorus content.
29
The milk fat components are also classified on the basis of a typical reaction for esters, namely
saponification.
Saponification is the process whereby esters are split by alkalis into alcohol components and the alkali
salts of monocarboxylic acid.
Milk fat components are classified into saponifiable substances and non-saponifiable substances (table 4).
Milk fat
Saponifiable substances
Non-saponifiable substances
Triglycerides
Cholesterol
Mono- and diglycerides
Lanosterin
Lecithin
Fat-soluble vitamins
Cephalin
Squalene
Sphingomyelin
Free fatty acids
Table 4:
Saponifiable and non-saponifiable substances in milk fat
Although free fatty acids are not subject to saponification according to the above definition, they bind
alkalis and are considered to belong to the saponifiable components of milk fat.
Under certain conditions, the non-saponifiable substances do not react with the alkalis. During the
saponification process, substances which are soluble in water and insoluble in etherl oils are obtained
from the saponifiable components. The aqueous soap solution which is obtained is extracted under
specific conditions with diethyl ether (ethoxyethane).
The non-saponifiable components of the milk fat are the dried ether extract obtained from boiling the
0.5 N aqueous soap solution containing KOH for one hour. The content is 0.30 ... 0.45% of total fat.
As illustrated by the table, triglycerides make up 99 % of the mass of the milk fat. Their
characteristics primarily determine the reaction of the milk fat and the characteristics of
fatty products.
30
3.2.2 Characteristics of fatty acids

Saturated fatty acids
The saturated fatty acids contained in milk fat are significant for the following:
Melting behaviour and thus consistency
Characterisation of the milk fat and
Taste and aroma.
Saturated fatty acids with up to eight carbon atoms in their molecules are liquid at room temperature.
The higher molecular acids are white, crystalline compounds.
The melting points increase in line with rising relative molecular mass. The fatty acids with an odd
number of carbon atoms have a lower melting point than fatty acids with one carbon atom less. If the
melting points of the even-number fatty acids and the odd-number fatty acids are set out separately
against the number of carbon atoms, we achieve two almost parallel curves, as can be seen in the
diagram. The abnormally high melting points of the acids of C1 to C5 can be explained by the association to dimers as a result of hydrogen bridge binding. The chain length also has an effect on the
other physical characteristics. The effect of the chain length is greater with the saturated fatty acids
than with the unsaturated fatty acids. As the chain length increases, the melting points and density
rise, whereas dissociation and acid strength decline. Unlike all other fatty acids of milk fat, butyric acid
is completely soluble in water, and capronic acid is partially soluble in water. Both acids can thus be
titrated with bases in aqueous solution. This property is the basis for determining a fat coefficient,
namely the Reichert-Meil coefficient. The lower molecular fatty acids, including the caprinic acids,
are volatile with steam. The number of fatty acids which are volatile in steam but insoluble in water
produces another fat coefficient, namely the Polenske coefficient. All fatty acids are soluble in the typical organic solvents alcohol, ether, petroleum ether and benzene. They are thus also detected with
the fat determining methods which are based on extraction.
Free low molecular fatty acids have the greatest effect on the taste and aroma of milk fat. The lower
volatile fatty acids have an unpleasant rancid and sweaty taste and aroma which are still perceptible in
concentrations of 0.009 mg acid per 1 kg fat. Every violation of this limit concentration has a negative
effect on the taste of the milk fat, and thus diminishes the quality of the product. In quantities below the
limit concentration, the low molecular fatty acids however contribute to the aroma of certain dairy
products. Fatty acids with more than 12 carbon atoms are virtually without taste and without aroma.
The chemical reactions concentrate on the functional carboxyl group and, under special conditions,
also on the carbon chain.
The ability to bind bases is used to determine specific quantities for calculating the degree of acidity in
butter fat. The carbon chain is stable with respect to oxidation effects to which it is exposed under the
normal processing and storage conditions of milk and dairy products. The stability is comparable to
31
that of alkanes. Pyrolysis phenomena do not occur. However, enzymes formed by the catalytic influence of fungi may be less efficient than saturated fatty acids due to the air oxygen of -oxidation.
-oxidation is defined as the process whereby fatty acids oxidise to methylketone which has one carbon atom less at carbon atom 3 via a -keto acid as intermediate product.
3.2.3 Phase inversion

In its normal state, milk fat forms a stable emulsion with water of the oil-in-water variety. To stabilise
the emulsion, the fat is enveloped in an adsorptive covering of phospholipids and proteins.
The break-down of this emulsion and separation of all non-milk-fat components is the aim of butteroil
production.
= crystalliszed triglyceride layer

MI Fe++
Fe++
2
= liquid fat nucleus
3
MI
= water
Cu++
= Euglobolin layer
MI
Cu++
= Lipoid layer ( lecithin )
Cu++
MI
= Membranlipase
( 1 ) = triglyceride molecules
lipo
ph
il
hyd
rop
hil
( 2 ) = Phosphatide molecules
4
( 3 ) = Euglobulin molecules
( 4 ) = Microsomes
Cu++
MI
Cu++ = adsorbed copper ions

Fe++ = adsorbed iron ions
Figure 20: Diagram of the structure of a fat globule and its envelope
It is possible to break down the membrane by means of mechanical energy or a chemical reaction.
Mechanical energy (e.g. homogenisation) is used to break open the membranes. Smaller fat globules
are formed by the newly created membranes, which themselves were created by the fragmentation of
the original membranes and from the proteins in the milk serum.
32
Reduction of the fat globules is also employed, for example, in the processing of drinking milk, in order
to prevent the so-called "creaming" effect.
Figure 21 attempts to illustrate the principle of homogenisation.
d2
Fat globule formed from

the available envelope
material
d1
fat globule formed

from the envelope
material of the serum
Figure 21: Graphic representation of the principle of homogenisation

The following calculation contains a key statement for the production of butteroil.
Assumption:
Existing fat globule size
d1 = 3 m
Desired fat globule size
d2 = 1 m
33
Calculation of the volume:
V1 =
V2 =
3
d1 33 27
=
=
6
6
6
3
d2 13 1
=
=
6
6
6
V1 =
n V2
n =
27
27 fat globules with a diameter of 1 m can be formed from one fat globule with a diameter of 3 m .
Surface calculation:
O1 =
d12 = 32 =9
O2 =
d22 = 12 =1
O1 =
n O2
n =
Theoretically, the surface of a fat globule with a diameter of 3 m can only cover 9 fat globules with a
diameter of 1 m. Therefore, for 18 further fat globules of the same size, the membranous material
must be taken from the serum.
However, the aim in the production of butteroil is not to reduce the size of the fat globules; on the contrary, the aim is to destroy the membranes or envelopes so that the fat can be recovered. It is therefore important to prevent the formation of fat globules with intact new membranes.
An initial conclusion from the above is that the amount of serum should be minimised before the start
of actual production of the oil, so as to minimise the amount of available membrane building blocks.
In order therefore to achieve adequate release of fat, a cream fat content of greater than 75% is required. The release of the fat, and the phase inversion brought about by this, take place by mechanical fragmentation of the intact fat globules in a homogeniser.
Figure 22 illustrates the principle of phase inversion.
34
d2
Fat globule formed from

the available envelope
material
d1
Free fat resulting from

the absence of envelope
material
Figure 22: Graphic representation of the principle of phase inversion

The graphic representation itself illustrates that there is still a part with intact fat globules.
= 78 % initial
fat content
Phase inversion ( % )
100
80
= 74 % initial
fat content
60
= 70 % initial
fat content
Pressure
: 70 bar
Temperature : 55 C
40
20
10
20
30
40
ATF ( % )
Figure 23: Phase inversion as a function of the homogenisation pressure (bar)

Steps for optimisation of phase inversion can be derived from figures 23 and 24 (3).
35
Complete phase inversion is therefore not possible with this process. Furthermore, a relatively stable
emulsion layer is formed from the existing amount of cream and part of the serum; this impedes
separation as a third layer between the oil and serum phases.
Special measures are necessary if the reversible process of formation of new, intact fat globules is to
be minimised.
= 78% initial
fat content
Phase inversion ( % )
100
= 74% initial
fat content
80
= 70% initial
fat content
60
ATF
: 30 %
Temperature : 58 C
40
20
35
90
140
Homogenisation pressure ( bar )
Figure 24: Phase inversion as a function of the initial ATF

(ATF = Amount of free fat in the total fat)
36
from Cream concentrate
Figure 25:
Recirculation
to Oil concentrator
Phase inversion
The optimum parameters for homogenisation pressure shown in figures 23 and 24 and the initial fat
content and ATF (4), when applied to phase inversion give a degree of inversion of 80 - 95 %.
The ATF, which contributes considerably to the efficiency of phase inversion, is increased en-route to
the homogeniser by means of recirculating a partial stream of the product leaving the homogeniser.
Accordingly, the capacity of the homogeniser must be designed for third the capacity of the oil
throughput of the butteroil plant.
3.2.4 Minimising the emulsion phase

The following applies for minimising the emulsion content:
The three fractions, namely fat, phospholipids and proteins, are largely responsible for a stable emulsion. If one of the three fractions is removed, or is changed to such an extent that it can no longer be
used as a building block for the membranes, then the formation of intact fat globules is prevented and
the formation of emulsion is not possible.
If, for example, the proteins are converted from their natural state into a denaturated state, then they
are no longer suitable as a building block for the envelope.
For example, with acid (product pH value: 4.5 - 4.7) or lye (pH value 10 - 11), the hydrate envelope of
the protein is weakened. This allows the approach of various protein molecules. By means of so37
called hydrogen bridge formation, they join together and form high-volume groups of protein molecules. These flocculant-like solids can be separated out because their specific weight is greater than
that of the oil.
3.2.5 Reducing the free fatty acids

FFA (= Free Fatty Acids) in the end product oil results as a rule in a loss of quality. Furthermore, IDF
standards place a limit on the FFA content (figure 1). If the FFA content is to be reduced, e.g. because
the initial values are too high, this can be achieved by physical and chemical means.
Free fatty acids are short-chain fats, such as butyric acids, caproic acids and carpinic acids. There are
problems of taste (rancidity) and/or aroma if the above are present in sufficient concentrations.
Free fatty acids result from the process whereby lipase enzymes adhere to the fat globule membrane
and break down free fat over a period. It is necessary to consider that the activity of the enzyme is
very slow at low temperatures. Its maximum activity is at about 37 C. Above 50 C, its activity is
minimal, and its activity stops completely at higher temperatures (> 60 C) (4). Assuming that there
may be a relatively high FFA content in the initial product, namely cream and butter, it may be necessary to take special measures in order to remove the free fatty acids from the product.
A saponification process can be used to reduce the FFA content.
Addition of lye (product-pH-value > 11) causes the free fatty acids to "saponify".
The resulting flocculate can then be separated out in the centrifuge.
3.2.6 Peroxide number

The quality of the butteroil is also determined by the peroxide number which expresses the milliequivalents of oxygen O2 bound by peroxide in one kilogram of oil.
Oxidation of fat that has already occurred cannot be reduced as a rule; however, it can be suppressed
or kept constant for a certain length of time. This is achieved by the addition of so-called antioxidants.
38
3.2.7 Phospholipid distribution

During centrifugal separation of the product, most of the free phospholipids migrate into the serum.
For this reason, it is necessary to calculate the content of phospholipids in order to determine the yield
of the "heavy phase" from a butteroil process.
An important criterion during the production of butteroil from cream is the heavy phase or buttermilk. In
addition to the familiar process, Westfalia Separator has now developed a new process and has
launched this new process on the market. The requirement that as much secondary skim has also to
be produced when butteroil is being manufactured means that, during cream concentration, it is possible to produce a milk which is similar to normal skim milk and which guarantees a higher yield when
mixed with other products.
The phospholipid content in this skim milk coming from the cream concentrator is slightly higher in
comparison with the content in normal skim milk. This higher phospholipid content also has an effect
on the yield and suitability for skimming.
The buttermilk in this process is known as -serum.
The following section details the phospholipid distribution in the processes butteroil production from
cream (standard process) and butteroil production from cream with secondary skim and -serum.
39
Phospholipid distribution in butteroil/AMF production
Raw milk 4 % Fat

0,035 % Phospholipids
Rahm 35 %Fat
Skim milk 0,06 % Fat

Standard process with Buttermilk

Cream concentrate 75 %Fat
0,8-1,0 % Phospholipids
Butteroil 99,9 % Fat
Buttermilk 0,5 % Fat

Process with Secondary skim and -Serum

Rahmkonzentrat 75 %Fat
Secondary skim 0,2 % Fat

Butteroil 99,9 % Fat
-Serum 1,5 % Fat

Figure 26: Phospholipid distribution

Because of its high phospholipid content, the -serum is very appropriate for emulsion processes or
other special products.
40
3.3 Processes used for production of butteroil

Butteroil can be made from butter and from cream. Whereas in the past, butteroil used to be made
almost exclusively from butter, the situation nowadays has changed, and cream is used instead of
butter.
It is now necessary to design installations which are capable of processing all raw products.
The following diagram illustrates the spin samples of various butter types and phase-converted cream.
100
90
80
70
60
50
40
30
20
10
5
Clear Oil
Emulsion
Serum
0,1
Sediment
Cream 80 %
pH 6,8
phase inverted
100
90
80
70
60
50
40
30
20
10
100
90
80
70
60
50
40
30
20
10
100
90
80
70
60
50
40
30
20
10
0,1
0,1
0,1
Sweet cream butter

pH 6,5
Sour cream butter

pH 4,5
Sweet cream butter

adjusted to
pH 4,5 with acid
Figure 27: Spin samples of various raw products

As can be seen in figure 27, processing of sour cream butter is the easiest at first glance, and can be
carried out with minimum fat losses as a clear separating line occurs between the oil and serum
phases.
The separation of oil, emulsion and serum from one another rarely takes place in static sedimentation
tanks. As a rule, separation is far more efficient in high-capacity self-cleaning separators and/or continuously operating three-phase decanters. The emulsion phase is an intermediate layer, and poses
major problems during the separation procedure; the problems can only be solved by modifying the
design of the centrifuges.
Planned losses can be minimised by using suitable separators and decanters adjusted for the particular separation function required.
Extremely precise designs can be achieved nowadays by means of computer-aided volume controls.
41
3.3.1 Standard process using buttermilk

Pasteurised cream in which the lipase enzyme has been inactivated should be used for producing
butteroil from sweet cream. This is achieved by the application of a recognised cream heating process.
Cream 40 %
Pasteurisation
Cream concentration
Skimming
Phase inversion
Butter milk
Oil concentration
Washwater
Washwater
Oil polishing
Vacuum treatment
Butteroil > 99,8 %
Figure 28: Block diagram for making butteroil from cream with buttermilk
In the case of the process version illustrated in figure 28, butteroil is produced from cream of about
40%. "Buttermilk" is also produced in this process. The "buttermilk" discharging from the process,
namely about 60% of the cream feed, contains all the phospholipids which are to some extent only
released during phase inversion.
42
Cream 40 %
Buttermilk
Butteroil (AMF)
Figure 28.1:
Cream balance tank
Buttermilk separator
Cream concentrator
Buttermilk balance tank
Homogeniser
Polishing separator
Oil concentrator
Vacuum dryer
Flow diagram for butteroil production from cream with buttermilk
Sweet cream of approx. 40% is heated to approx. 55 - 60 C in a plate heat exchanger. This temperature is necessary to ensure that the cream to be concentrated remains liquid in the separator
bowl.
The cream is concentrated to 75 - 78 % in the cream concentrator and conveyed to the buffer tank of
the homogeniser.
The phase inversion process takes place under high pressure. The temperature, cream concentration,
recirculation quantity, pressure and aspects such as the design of the buffer tank are very important
aspects in this respect.
The emulsion and serum phase (heavy phase) is separated from the oil (light phase) in the downstream oil concentrator.
The oil with a concentration of 99.5% is heated in the plate heat exchanger to 90 - 95 C.
Oil washing or FFA reduction can be achieved by integrating an oil polishing separator.
The remaining moisture is evaporated in the vacuum evaporator, and the butteroil leaving the vacuum
evaporator has an oil content of more than 99.8%. The "heavy phase" discharging from the oil concentrator is recycled back into the buffer tank of the cream concentrator; it is then separated again and
concentrated.
43
The heavy phase from the cream concentrator is skimmed in the skimming separator. The cream recovered from the skimming separator is also recycled back into the process. The heavy phase leaving
the skimming separator must be described as buttermilk as it contains all the phospholipids.
3.3.2 Process using -serum and secondary skim

As already described above in the standard process, pasteurised cream is normally used.
The main difference with respect to the standard process is to be seen in the fact that the serum
phases are recycled, as the phospholipids are released from the fat globule membranes during the
phase inversion process.
Cream 40 %
Pasteurisation
Cream concentration
Separation
Phase inversion
Secondary skim
Oil concentration
Separation
Washwater
Washwater
Oil polishing
- Serum
Vacuum drying
Butteroil > 99,8 %
Figure 29:
Block diagram making butteroil from cream with -serum and secondary skim
Sweet cream of approx. 40% is heated to approx. 55 - 60 C in a plate heat exchanger. This temperature is necessary to ensure that the cream to be concentrated remains liquid in the separator
bowl.
44
The cream is concentrated to 75 - 78% in the cream concentrator and conveyed to the buffer tank of
the homogeniser. The discharged skim milk (secondary skim) can be separated again if it is required.
Cream 40 %
Skimmilk
Butteroil (AMF)
Buttermilk
Figure 29.1:
Cream balance tank
Cream concentrator
Homogeniser
Polishing separator
Oil concentrator
Vacuum dryer
Flow diagram for butteroil production from cream with -serum and
secondary skim
The phase inversion process takes place under high pressure. The temperature, cream concentration,
recirculation quantity, pressure and aspects such as the design of the buffer tank are very important
aspects in this respect.
The emulsion and -serum (heavy phase) is separated from the oil (light phase) in the downstream oil
concentrator.
The oil with a concentration of 99.5% is heated in the plate heat exchanger to 90 - 95 C .
Oil washing or FFA reduction can be achieved by integrating an oil polishing separator.
The remaining moisture is evaporated in the vacuum evaporator, and the butteroil leaving the vacuum
evaporator has an oil content of more than 99.8%.
The "heavy phase" discharged from the oil concentrator is pumped to a separate buffer tank. The
"heavy phase" is now concentrated in a separator to approx. 65% to 75% fat content, and is recycled
to the buffer tank of the homogeniser.
45
The -serum discharging from this separator contains the remaining phospholipids.
3.3.3 Processes for butter processing

With butter as the initial product, the emulsion of water in oil is already present. Phase inversion will
have taken place during the churning process.
The initial product is of decisive importance for the design of the installation. Basically, an installation
for processing cream is also suitable for the separation of melted butter.
When sweet cream butter with a pH of around 6.5 is to be processed and no "chemical agents" (e.g.
citric acid) are allowed to be used for denaturating the proteins, the emulsion layer has to be taken
into account. Centrifugation and destruction of this layer can only be carried out by specially designed
separators and phase inversion. The operating method of the separator has a decisive influence on
the process, the required additional equipment and the efficiency of the installation. For processing
sweet cream butter, it is necessary to use a separator which allows concentration to 99.5% fat. The
emulsion has to be discharged with the serum phase.
When sour cream butter with a pH of 4.6 to 4.5 and with an increased protein content is to be processed, a decanter can be used. Separate concentration of the solids is possible.
In any case, a separator (polishing separator) has to be installed downstream of the decanter to increase the fat concentration to 99.5%.
A polishing separator is necessary for butter processing and for FFA reduction. High solids contents
can reduce the capacity and efficiency of the installation as frequent partial solids ejections of the
separator bowl are required.
46
3.3.3.1 Melting the butter blocks

The raw product, namely butter, will usually have been kept in cold storage at -18 to -20 C in 20 or 25
kg blocks, before being further processed into butteroil. Frequently, the butter coming from cold storage is intermediately stored in order to raise the temperature by ambient air to >0 C. The butter is
then melted in one of a variety of steam-heated systems on the market. In order to eliminate costly
conditioning and the disadvantages of the steam-heated melting system, Westfalia Separator has developed the BMSA 5000 butter melting system.
The main advantages of the described system are very efficient use of energy and the very gentle
melting process. This also results in the fact that the protein in the butter is not locally overheated, and
protein burning also does not occur. The protein obtained in this oil production method has a higher
quality for subsequent use.
3.3.3.2 Making butteroil from sweet cream butter

The butter blocks are taken from cold storage at, for instance -20 C, and are melted in the melting
system. The product temperature in the buffer tank, depending on the design of the plant, is between
45 and 65C. The temperature of the product is raised to 70 - 75 C in a plate heat exchanger.
Phase inversion by means of a homogeniser is required to minimise the emulsion phase. The oil concentrator, a separator with disc type bowl, achieves separation of 99% to 99.5% fat. The heavy phase,
a mixture of buttermilk and residual emulsion particles, is fed to a skimming separator.
The oil phase (light phase) is heated to about 90 C and then separated again in a further separator.
Before the oil is fed to the polishing separator, wash water is added to improve the quality of the oil.
47
Butter
Butter melting
Phase inversion
Skimming
Oil concentration
Washwater
Washwater
Oil polishing
Buttermilk
Vacuum drying
Butteroil > 99,8 %
Figure 30: Block digram for making butteroil from sweet cream butter
In the downstream vacuum evaporator the residual moisture content is adjusted to less than 0.1%.
The efficiency of the installation depends on the degree of skimming of the heavy phase discharging
from the oil concentrator and the oil polishing separator. The cream should have a fat content of 65%
to 70% for optimum phase inversion in the homogeniser.
48
3
Butteroil (AMF)
Buttermilk
Butter melting system
Homogeniser
Polishing separator
Oil concentrator
Vacuum dryer
Figure 30.1: Flow diagram for butteroil production from sweet cream butter
3.3.3.3 Processing of salted sweet cream butter

The amount of salted butter used as a raw material for the production of butteroil in recent years has
risen steadily. The salt content is removed together with the buttermilk during centrifugal separation.
The salt concentration in the buttermilk increases to approx. 10% if the original salt content of the
butter was 2% for example. Further processing of the salted buttermilk is limited.
For this reason, the emulsion phase in salted sweet cream butter can also be "broken" by the addition
of citric acid. At the same time, the protein in the butter is denaturated. The treated raw material then
behaves in the same way as sour cream butter.
49
Butter
Butter melting
Addition of Acid
Reaction tube
Serum
Oil concentration
Washwater
Oil polishing
Washwater
Vacuum drying
Butteroil > 99,8 %
Figure 31: Diagram of the processing of salted sweet cream butter

The melted butter is brought to a pH of 4.5 - 4.6 by the addition of acid. At this pH, not only the free
protein is denaturated; in addition, due to the alteration in the intact fat-globule membrane protein, the
membrane is broken open and the emulsion is destroyed. An easily decantible sediment is then obtained in addition to a clear water and oil phase. In contrast with "real" sour cream butter, this sediment content is significantly lower. One reason is that the fat-free dry matter (part of which consists of
protein) is less in the case of sweet cream butter than is the case with sour cream butter.
Acid is added, and the product is heated to a temperature of 70 - 75C; an adequate reaction time is
then allowed.
The oil is then concentrated in the oil concentrator to approx. 99%. The oil is heated to 90 - 95 C for
instance in the following plate heat exchanger, and it is then concentrated to 99.5% in the oil polishing
separator. It is necessary to add wash water upstream of the separator so that residual salt particles in
solution can be washed out.
Care must be taken to ensure that the pH does not rise again when the wash water is added. The
wash water should thus be adjusted to a pH of 4.5 - 4.6 with acid before it is added to the product.
50
The final value of the oil of 99.8% is adjusted in the downstream vacuum evaporator. For processing
salted butter, it is extremely important to ensure that all parts of the installation which come into contact with the product are made of special corrosion-proof materials.
A three-phase decanter is to be recommended as an oil concentrator because of the high decantible
sediment content.
3.3.3.4 Production of butteroil from sour cream butter

Sour cream butter is produced from biologically acidified cream. The pH value of the butter is between 4.5 and 5.2 depending on the country of origin.
Processing of sour cream butter into butteroil is generally the least expensive method. This is however
only partly true when the pH is between 4.7 and 5.2.
Butter
Butter melting
Serum
Oil concentration
Washwater
Oil polishing
Washwater
Vacuum drying
Butteroil > 99,8 %
Figure 32: Diagram of butteroil made from sour cream butter

When sour cream butter is processed, a third liquid phase (emulsion phase) is not present, as has already been stated. The most important for the design of the plant is that the separable solids (denatu-
51
rated protein because of the low pH value) can amount to as much as 2% absolute. In general, the
value is between 1.3 and 1.5% DS.
For processing sour cream, it is particularly important to ensure that the melting process in the melting
system is gentle, as localised over-heating will relatively quickly lead to protein burning. The product
leaving the butter melting system at a temperature of 45 - 55 C is heated in the plate heat exchanger
to 70 - 75 C, and is then pumped to the three-phase decanter. The oil is concentrated in the decanter
to 97 - 99%, and is heated to 90 - 95 C; it is then brought to a concentration of 99.5% in the oil polishing separator. The residual moisture content is reduced to less than 0.1% by evaporation in the
vacuum evaporator. The serum phase generally has a fat content of less than 0.8%; accordingly, if we
consider the amount obtained (10 - 12% of the amount of raw product), fat recovery is only worth
while if daily quantities are high. The decantible solids are concentrated in the decanter to 20 - 45%
DS as required, and are then fed from the decanter discharge to the tank. The solids consist mainly of
denaturated protein. In addition, a fat in DS of 2-5% must be expected. The oil-enriched heavy phase
from the oil polisher is recycled back into the process.
It is necessary to add water upstream of the oil polishing separator in order to ensure optimum
"washing out" of the residual protein, and also at the same time to stabilise the separation zone in the
bowl of the oil polishing separator in the required position. It is good policy to adjust the pH of the
wash water beforehand.
For further utilisation, the denaturated protein discharged by the decanter can be converted into a stable soluble state. In this form, the protein itself can be used to enrich liquid milk end products.
3.3.3.5 Processing of Cream and Butter with a high FFA content

As already mentioned, when butter with high initial FFA values is processed, perfect butteroil can still
be obtained by saponification of the short-chain fatty acids, followed by separation of the resulting
flocculate.
A suitably prepared wash water (pH > 11) is added to the flow of oil upstream of the oil polishing separator. The free fatty acids come into contact with the basic water, are saponified and are simultaneously washed out. The wash water with the free fatty acids is separated from the oil in the oil polishing
separator. The oil leaving the oil polisher then meets IDF standards with respect to FFA values.
Before "Wash water with caustic" is added, the oil must have a concentration of more than 99 % fat.
52
3.3.3.6 Addition of antioxidants

Antioxidants are additive substances which prevent an increase in the peroxide number of the oil, and
to some extent reduce the peroxide values already present.
The following can for instance be used:
Tocopherol
The final concentration of tocopherol in the butteroil must be less than 200 ppm.
Westfalia Separator AG has the knowhow for preparing and adding substances of this nature.
53
4 Machines used for making butteroil
4.1 Cream concentrators

The special design features of cream concentrators are directed towards the following:
Attainment of a high cream fat content
Maximum separating efficiency to achieve the lowest residual fat content in the discharging heavy
phase
Fast and precise partial solids ejection from the bowl in order to minimise fat losses.
1. Feed
2
3
2. Cream discharge
4
3. Skim milk discharge

4. Skim milk pump
5. Cream pump
6
7
6. Discs
7. Soft-stream inlet
9
8
8. Sediment holding space

9. Sediment ejection ports
Figure 33: Bowl cross-section of cream concentrator MSD 200-01-076

The 40% cream to be concentrated is fed through the central feed tube (1) with a certain flow velocity
into the inlet chamber (7) which rotates at the same speed as the bowl.
The energy of flow in the stationary feed tube is converted into pressure energy in the optimally widened inlet chamber (principle of the soft-stream system).
54
The feed to the disc set (6) is throttled, thus ensuring that there is always liquid in the lower part of the
central distributor bore. Other throttles are arranged after the first throttle in such a way that there is an
uninterrupted flow of liquid right into the disc set. Vacuum (flow interruption) and shear forces are thus
avoided. The soft-stream system guarantees optimum separation efficiency and a high level of concentration.
The cream is separated into skim milk and cream in the disc set.
Both components are conveyed foam-free and under pressure by means of centripetal pumps (4 and
5) to the outlets (2 and 3). The separated solids collect in the sediment holding space (8) and are periodically ejected through ports (9). The solids ejection process is initiated automatically. The cream
centripetal pump (5) and the centripetal pump for the heavy phase (4) must be precisely adjusted to
the throughput conditions of the cream concentrator.
All centrifuges in the MSD series can be used for cream concentration. The throughput capacity for
40% cream is 30 to 50% of normal milk separation capacity.
Type of machine
Feed capacity l/h
MSD 50-01-076
up to 2500 l/h
MSD 90-01-076
up to 6500 l/h
MSD 170-01-076
up to 11000 l/h
MSD 250-01-076
up to 16000 l/h
The stated feed capacities are mean values and can vary depending on
the plant design.
Table 5:
Feed capacities for cream concentrators
4.2 Oil concentrators / oil polishing separators

Westfalia Separator now offers two different types of separator for oil concentration. Whereas type
RSA separators were mainly used in the past, these are now increasingly being replaced by semihermetic separators.
A semi-hermetic separator has been developed in response to specific customer requests and also in
order to achieve maximum concentration of the oil phase. Concentrations of between 99.6 and 99.8%
can be achieved with this separator. Particularly when AMF with a reduced FFA content is being
made, high oil concentrations during separation reduce the residual soap content in the oil.
55
1. Feed
1
2. Heavy phase discharge
3. Light phase discharge

4
4. Heavy phase pump

5. Distributor
6
6. Disc set

9. Sliding piston
7
8
Figure 34: Bowl
cross-
section of the MSD 90-97-076

These new separators with the model designation MSD 90-97-076 and MSD 170-97-076 have a hermetic seal in the oil feed and the oil discharge. The heavy phase is discharged via a centripetal pump.
Special design features on the disc stack and separating disc enable the emulsion phase to be discharged separately.
Rapid and precise partial solids ejections minimise losses. The specially designed disc set permits
high ejection frequencies such as are required occasionally for processing butter.
56
1. Feed
4. Heavy phase pump
5. Light phase pump
4
5
6
7
11
6. Distributor
7. Discs
10.Sliding piston
11.Rising channels
8
9
10
Figure 35 : Bowl cross section of an oil separator type RSA 60-01-076

For oil concentration and oil polishing, the separating zone inside the centrifuge bowl is displaced to
the periphery of the disc set because of the high oil concentration. For this reason, the product to be
treated is guided into rising channels (11) located towards the periphery of the disc set.
A constant pressure valve is fitted in the oil discharge line (3) in order to maintain a constant separating zone. Special valve switching has been developed in order to reduce oil losses after partial solids
ejections as a result of the peripheral position of the separating zone. The necessary valves are controlled by a timing unit. The product flowing into the centrifuge is separated into an oil phase and "serum phase" (heavy phase) in the disc set (7). At the same time, the solids are removed and collect in
the sediment holding space (8). The oil phase flows inwards and is conveyed foam-free and under
pressure to the outlet (3) by means of the centripetal pump (5).
The heavy liquid phase flows outwards and is conveyed by centripetal pump (4) under pressure to
outlet (2).
The separated solids are instantly ejected at periodic intervals through ports (9) by movement of the
hydraulically operated sliding piston (10).
The separators listed in table 6 are available for concentrating and polishing the oil.
57
Separator type
Oil concentration in kg/h
Oil polishing in kg/h
MSD 50-01-076
1200
1500
RSA 40-01-076
2000
2500
RSA 60-01-076
3000
5000
RSB 100-01-776
4000
7000
RSB 150-01-776
7000
10000
RSB 200-01-776
10000
14000
MSD 90-97-076
3500
6500
MSD 170-97-076
9000
13000
The stated feed capacities can be varied slightly depending on the design of the plant.
Table 6:
Feed capacities for oil concentration and oil polishing
4.3 Skimming separators

Warm milk separators available in the sales program are used for skimming; however, their disc sets
have to be modified to meet the specific application (5). Precise knowledge concerning the butteroil
process is required for designing the machine. Skimming separators have to solve different tasks in
relation to the raw product used and the system concept.
58
4.4 Three-phase decanters

The three-phase separating decanter is a horizontally arranged centrifuge with a cylindrical/conical
solid-wall bowl containing a conveyor screw.
6
8
1. Feed tube
5. Conveyor screw
2. Distributor
6. Solids discharge
3. Separation space
4. Bowl
Figure 36: Cross-section of the three-phase decanter type CA 450

The field of application of the three-phase decanter is the continuous separation and clarification of
liquid-liquid-solid suspensions.
For making butteroil, the decanter is used as a machine for pre-concentrating products with a high
solids content. So-called Nizo butter is processed into butteroil in Europe. Special cultures are added
to the butter during the buttermaking process. This reduces the pH value to approx. 5.2. Aroma cultures are required in order to achieve a different taste. The process of adding the cultures increases
the solids content and thus increases the load on the oil concentrator during the oil separation process, as large quantities of denaturated solids occur as a result of the low pH value.
The continuous method of operation means that decanters offer higher system capacity for processing
butter into butteroil.
59
An oil concentration of 95-98% is achieved.

The solids can be concentrated to approx. 35-40% DS .
The product to be separated flows through the centrally located feed tube (1) into the inlet chamber of
the distributor (2), and from there through channels into the separation space (3) of the bowl (4) in
which it is accelerated to bowl speed. Under the influence of the centrifugal field, the solid particles in
the clarifying zone settle outwards on the wall of the bowl.
The conveyer screw (5), which rotates at a slightly higher speed than the bowl shell, continuously delivers the centrifugally removed solids to the small diameter end of the bowl, where they are lifted out
of the liquid due to the conical shape of the bowl. Liquid is removed by centrifugal force when the
product passes through the drying zone. The solids are then discharged through openings at the end
of the bowl into the catch chamber of the frame, where they are seized by the vanes of a scraper ring
and ejected from the housing (6). The liquids flow between the spirals of the conveyor screw towards
the cylindrical end of the bowl. When they pass through the separating zone, they are separated into
light and heavy liquid phases. The light phase flows inwards radially to the bowl axis, while the heavy
phase moves outwards radially to the bowl wall. The two separated and clarified liquid phases discharge by gravity via regulating rings and tubes (7 and 8).
The throughput capacity of the decanter depends on the separating and clarifying characteristics of
the feed product, on the concentration of solids in the product and on the maximum permissible solids
content of the clarified liquid. It can be adapted to a large extent to the conditions and requirements of
the plant.
The throughput capacity of the CA 450 is between 5000 and 10,000 l/h depending on the plant concept.
60
4.5 Butter melting system BMSA 5000
Block Cutter
Elevator
Melting tank
Figure 37:
Plate heat
exchanger
Functional diagram of the butter melting system BMSA 5000
Butter blocks with a product temperature of up to -20 C are fed to a block cutter via the block feed
device. An adjustable block conveyor in the feed shaft ahead of the cutter drum ensures a constant
product feed into the melting tank. The rotating cutter drum cuts the butter block evenly into butter
pieces each weighing 2 - 4 g.
The cut pieces of butter fall into the enclosed melting tank. The melting tank holds approx. 1500 l
product at a temperature of 45 - 65 C. The product circulation pump conveys 2 to 4 times the quantity
in relation to the butter feed quantity through the plate heat exchanger back to the melting tank. The
product temperature achieved in the plate heat exchanger is between 65 - 85 C. A product discharge
pump conveys the melted product to the butteroil system. The built-in agitator ensures adequate turbulence in the melting tank. Any pieces of paper are retained by the sieve in the tank.
Tubular screens can be installed downstream of the pumps for safety reasons.
The melting system must be started up with product. If water is used for the start-up phase and if
product to be melted is then added, a very stable emulsion forms relatively quickly in the melting tank;
this poses problems for continuous production.
61
Performance data:
Butter capacity:
3 - 7 t/h
Butter temperature:
+ 10 C to - 20 C
Product temperatures:
a) in the buffer tank
45 - 65 C
b) in the return-flow product:
65 - 85 C
c) in the product stream to the butteroil system:
45 - 65 C
Product temperatures also depend on the type of butter used.

The hourly capacity of the system can be regulated smoothly.
4.6 Vacuum unit

A vacuum unit is required for removing residual moisture from the butteroil. The permissible residual
moisture content must not exceed 0.1% according to IDF regulations. The moisture in the oil evaporates at a vacuum pressure of 50 - 100 mbar.
The necessary vacuum is produced by means of a liquid-ring vacuum pump (3). A surface condenser
(4) is installed upstream of the vacuum pump in order to reduce the pump capacity. The amount of
vapour is reduced in the surface condenser by means of condensation. Fat mist, which is drawn off
from the vacuum tank with the vapour, crystallises in the vacuum pump and can be drawn off in the
downstream tank (5).
62
4
1
Cooling
water
PI
LSH
to
Packaging
1. Vacuum tank
2. Pressure maintaining valve
3. Vacuum pump
4. Surface condenser
5. Tank
6. Pump
Figure 38: Illustration of a vacuum unit

Pump (6) conveys the finished butteroil to the packaging line. Valve (2) closes if the feed is interrupted, so that the vacuum in tank (1) cannot collapse.
63
5 Bibliography
1.
Das groe Molkerei-Lexikon
M.E. Schulz
(The large dairy encyclopaedia)

2.
Chemie und Physik der Milch
A. Tpel
(Chemistry and physics of milk)

3.
The phase inversion of high fat cream
G.N. Watt
Dissertation, 1982
Massey University, New Zealand
4.
Rahm- und Fettkugelschdigung,
H.R. Lehmann
ein Report aus der Praxis

Deutsche Molkereizeitung
Edition 21, 22, 23 - 1988
(Cream and fat-globule damage; a report from practice)
5.
Entrahmungs-Separatoren fr die Molkereiwirtschaft
H.R. Lehmann
Technisch-wissenschaftliche Dokumentation Nr. 7
K.H. Zettier
Westfalia Separator AG, Oelde

(Separators for the dairy industry)
6.
Maschinen und Prozesse fr der Butterei
H.R. Lehmann
J. Kreimer
W. Hoffmann
7.
Prozelinien fr die Herstellung von Butterl
H.R.Lehmann
E. Dolle
A. Uphus
Printed:
30.Jan. 1996
64
65
66
Westfalia Separator
Food Tec GmbH
Mechanical Separation
Division
A company of mg technologies group

Westfalia Separator Food Tec GmbH Werner-Habig-Strasse 1 D-59302 Oelde (F. R. Germany)
Tel. ++49 / 2522 / 77-0 Fax ++49 / 2522 / 77-2089, -2821 Internet: www.westfalia-separator.com
E-mail: info@gea-westfalia.de

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Dipl.-Ing. Arnold Uphus

Milk fat processing

Milk fat products using a buttermaking machine

Milk fat products using a butteroil process

Butter processing line

Cream treatment for making sour cream butter

Special processes for the production of milk fat products

Milk fat with reduced fat content

Butter with vegetable fat additives

Butter production with reduced content of solids non fat

Butteroil production (AMF)

Definition and designation of milk fat

Characteristics of fatty acids

Minimising the emulsion phase

Reducing the free fatty acids

Processes used for production of butteroil

Standard process using buttermilk

Process using -serum and secondary skim

Processes for butter processing

3.3.3.1 Melting the butter blocks

3.3.3.2 Making butteroil from sweet cream butter

3.3.3.3 Processing of salted sweet cream butter

3.3.3.4 Production of butteroil from sour cream butter

3.3.3.5 Processing of Cream and Butter with a high FFA content

3.3.3.6 Addition of antioxidants

Machines used for making butteroil

Oil concentrators / oil polishing separators

Butter melting system BMSA 5000

1.1 Milk fat products using a buttermaking machine

Westfalia Separator milk fat processing using the example of buttermaking

1.2 Milk fat products using a butteroil process

2.2 Butter processing line

The following is a schematic representation of a butter processing line.

Cream pre - heating

BDSB Dosing System

Salt brine preparation

Flow chart of buttermaking

2.3 Cream treatment

Cross-section through a fat globule, according to Kiermeier

Mechanism of butter formation (Kiermeier)

Foam theory of butter granule formation

Temperature-time curve for making traditional sweet cream butter

Temperature-time curve for cold-warm-cold crystallisation

2.4 Cream treatment for making sour cream butter

Temperature-time curve for making sour cream butter

2.5 Cream pre-heating

Westfalia Separator cream pre-heater system

2.6 Buttermaking machine

Dosing unit for culture, salt and water

Figure 10: Butter granule recovery system

2.7 Dosing station

Figure 11: BDSB dosing station

Butter capacity in kg/h

Figure 12: Functional diagram of the dosing station

Colour graphic display

Flow meter, etc.

Figure 13: Structure of control system

2.9 Butter distribution

Figure 14: Installation diagram of a butter silo

2.10 CIP system

Figure 15: CIP system

Figure 16: Reworker