UNIT 2 METHODS OF MANUFACTURE

AND FACTORS AFFECTING

QUALITY OF PRODUCTS
Structure
2.0 Objectives
2.1 Introduction
2.2 Principle of Manufacture of Khoa, Rabri & Basundi
2.3 Preparation of Khoa
• Traditional Method
• Improved Traditional Method

2.4 Factors affecting Quality and Yield of Khoa

• Quality of Milk
• Speed of Stirring
• Temperature of Desiccation
• Homogenization of Milk

2.5 Mechanized and Continuous Methods of Manufacture of Khoa

• Mechanized Methods
• Continuous Methods

2.6 Preparation of Rabri

2.7 Preparation of Basundi
2.8 Let Us Sum Up
2.9 Key Words
2.10 Some Useful Books
2.11 Answers to Check Your Progress Exercises

2.0 OBJECTIVES
After reading this unit we should be able to:
• understand the principle involved in the manufacture of khoa, rabri and basundi.
• prepare khoa, rabri and basundi by conventional methods.
• acquaint with the design and operation of continuous khoa making machine.
• control the factors that affect the quality and yield of khoa, rabri and basundi.

2.1 INTRODUCTION
The manufacture of khoa, rabri and basundi is largely in the hands of private traders
(halwais). They use highly primitive techniques essentially based on their experience.
The scale of production is too small, each batch comprising of about 4-5 litres of
milk. The equipment used for manufacture of these heat-desiccated dairy products
18 are made up of iron or cast iron or mild steel. The conventional methods used by
halwais for the manufacture of khoa, rabri and basundi though are simple and cost Methods of Manufacture
and Factors Affecting
affective, they suffer from several inherent limitations. Some of these are given as Quality of Products
below:
• Wide variations in chemical, microbial and sensory qualities from batch to batch.
• Small scale batch processes unsuitable for commercial adoption
• Low heat transfer coefficients causing equipment to be bulky
• Unsanitary operation due to open atmospheric desiccation
• Excessive strain and fatigue on the operator
• Poor packaging
• Limited shelf life of the product
Now, the technology of these products has been standardized. In case of khoa,
continuous khoa making units have also been developed, and are presently being
used by many organized dairies as well as by some large private traders.

2.2 PRINCIPLE OF MANUFACTURE OF KHOA,

RABRI AND BASUNDI
The general principle of manufacture of khoa, rabri and basundi involves desiccation
or removal of moisture by heating (mainly boiling) of milk in a vessel. The vessel is
either a traditional Karahi or improved double jacketed stainless steel kettle (Fig.
2.1) with tilting mechanism, and source of heat are wood/coal fire, LPG and steam.
Milk is continuously boiled till desired concentration of solids is achieved, and more
importantly till typical characteristic flavour and desired texture characteristics are
developed in the final product. The proper agitation of milk and scraping of heating
surface, where milk comes in contact with, are very important steps involved in
manufacture of khoa, rabri and basundi.

2.3 PREPARATION OF KHOA

i. Traditional Method
Pindi Khoa: Milk in small lots (not more than 5 litres), preferably buffalo milk is
taken in an open pan (karahi) and boiled over brisk non-smoky fire. While boiling,
milk is continuously and vigorously stirred with a circular motion by a ladle (khunti)
to avoid burning of milk solids on the surface of the pan. Milk thickens progressively
as the evaporation of moisture takes place constantly. When concentration reaches
to about 2.8 times in cow milk and 2.5 times in case of buffalo milk, the thickened
mass shows abrupt change of colour and consistency indicating that heat coagulation
of milk proteins has started taking place. Vigorous stirring and desiccation is continued
till the viscous product reaches a pasty consistency and begins to dry up. Very close
attention is given at this stage. The final product is ready when it shows signs of
leaving the sides of the pan and collecting in the form of a bolus. This stage is called
as pat formation and invariably should be achieved after moving the pan off the fire
and by working the contents up and down. The finished product is transferred to the
aluminium containers of normally one kg size for molding/shaping. One batch of
khoa requires about 20 minutes of complete.
There are several limitations of the traditional method. Some undesirable flavours,
such as smoky and burnt may also develop in khoa made by this method. 19
Heat Desiccated Products Danedar Khoa: For making danedar khoa, an acidulant (preferably citric acid @
0.01 – 0.02%) is added to milk during boiling stage. It will result into earlier
coagulation of milk proteins and development of large size grains needed for the
manufacture of milk cake and kalakand. The rest of the method is same as for Pindi
khoa.
Dhap khoa: When milk reaches to semi solid state or starts leaving the of heating
surface of the kettle, heating is stopped and product is immediately taken out of the
kettle. At this stage khoa is slightly loose due to higher moisture retention.
ii. Improved Method
It makes use of improved equipment (Fig. 2.1). A stainless steel jacketed kettle with
steam supply is used for boiling milk. It has provision of controlling the heating by
regulating steam valve, tilting mechanism, pressure valves, etc.
Buffalo milk is standardized to desired fat (about 5.5 per cent) and SNF (9 per
cent) level so that the composition of final product does not vary. The quality of milk
is also evaluated in respect of colour, flavour (sourness in particular), acidity/pH and
presence of adulterants/neutralizers. Desiccation conditions in respect of temperature,
speed of stirring and scraping and level of desiccation are controlled. Khoa from
the heating kettle is immediately packaged and stored under sanitary conditions to
prevent contamination, surface evaporation and delay spoilage.

Fig 2.1 Double Jacketed Stainless Steel Kettle for Preparation of Khoa/Basundi

2.4 FACTORS AFFECTING QUALITY AND YIELD

OF KHOA
Fresh milk is usually preferred for production of good quality khoa, which has desirable
organoleptic attributes and is suitable for making different types of sweets. The average
yield of pindi khoa from standardized cow milk (fat 4.0% and SNF 8.6%) should
be 18.5% and from buffalo milk (fat 6% and SNF 9%) 23%. The yield of other two
types viz. Danedar and Dhap made from buffalo milk are usually 24% and 25%
20
respectively. The various factors that affect the quality (here referred to organoleptic Methods of Manufacture
and Factors Affecting
quality and suitability for sweets making) and yield of khoa are discussed as below: Quality of Products

i. Quality of Milk
Species of animal: Buffalo milk is preferred for preparation of khoa over cow
milk due to following reasons:
Organoleptic quality of buffalo milk khoa is much superior than cow milk khoa,
because of its pleasantly sweet and creamy taste, soft body and texture with uniform
grains. The colour of buffalo khoa is also whitish or creamy white, which is more
attractive. On the contrary, cow khoa has salty taste because of presence of higher
amounts of chloride (0.10% in cow milk as against 0.07% in buffalo milk) and its
body is hard and dry due to low fat content. The free fat content, which provides
some greasy appearance to the khoa and considered desirable attribute for sweet
making, is also higher in buffalo khoa (about 60% of total fat) than cow khoa (less
than 50% of total fat). The yield of buffalo khoa is also more as mentioned earlier
because of higher total solids in it. Buffalo khoa is more suitable for making sweets
than cow khoa.
The organized dairy sector normally receives mixed milk. The quality and yield of
khoa prepared from mixed milk falls in between that of buffalo milk khoa and cow
milk khoa.
Use of colostrums: Colostrums milk has extremely poor heat stability and its
chemical composition is different from normal milk. Khoa made from such milk has
deep yellow colour and very big size clotted lumps unsuitable for sweets making.
Use of concentrated milk: The use of concentrated milk having more total solids
requires less moisture removal for khoa making and thus exposed to heat treatment
for less time. This results into lesser heat denaturation of milk proteins and under
development of typical heated/cooked flavour in khoa. Therefore, khoa made from
concentrated milk has somewhat bland flavour.
Fat content in milk: A minimum of 4% fat in cow milk and 5% fat in buffalo milk
is essential to prepare khoa conforming to legal (PFA) rules. The most pleasing
aroma and taste in dairy products including khoa is attributed to butterfat. Therefore,
the higher fat content in milk produces khoa of better quality not only in terms of
flavour, but also the desirable body and texture. Khoa made from low fat milk
possesses flat flavour and hard and dry body that lacks typical soft and mellowing
characteristic.
Milk Acidity: The fresh milk produces khoa with good flavour and texture. Pindi
khoa can only be made from fresh milk having acidity in the range of 0.14 to 0.16%
as lactic acid. More than 0.17% acidity in milk produces khoa of grainy texture. The
size and hardness of grains increases with the increase in acidity. However, for the
manufacture of Danedar khoa, acidity upto 0.18% developed by addition of an
acidulant is optimum. In addition to grainy texture, khoa prepared from high acidity
milk, developed due to natural sourcing, has acidic/sour flavour. Such khoa is
unsuitable for making of good quality sweets.
Presence of adulterants/neutralizers: Adulteration of milk with water reduces
the total solids contents of milk, thereby requiring more time for evaporation of this
extra moisture to obtain khoa of desired solids. This is possible by exposure of milk
to heat treatment for longer duration, resulting into development of brown colour in
khoa. The yield of khoa will also be lowered in proportion to the amount of water
added for adulteration of milk. 21
Heat Desiccated Products • Starch is added to milk to increase its total solids, particularly when adulterated
with water. Khoa made from such milk is normally pasty with doughy taste.
The yield however is higher in this case.
• Neutralization of high acid/sour milk is a regular practice in India. Use of
neutralized milk produces khoa with improved texture having grains of very
small size or no grains at all. But the flavour cannot be improved. Khoa made
from neutralized milk has either salty or soapy or sour flavour, depending on
the extent of neutralizer used and the level of souring (acidity) in milk before
neutralization. The moisture retention in khoa made from neutralized milk is
higher and so also the yield.
ii. Speed of Stirring
The speed of stirring should be optimum. It depends on the type of machine/method.
In case of traditional method, the optimum speed is about 100 rpm, whereas, in
continuous system, it is slightly more (upto 200 rpm). The optimum speed of stirring
prevents burning of milk solids and helps developing desirable body and texture in
khoa. Low speed results into burning of khoa, whereas, the higher speed makes the
product pasty and sticky.
iii. Temperature of Desiccation
To obtain good quality khoa, milk should be maintained at the boiling temperature
till it reaches a pasty consistency and then lowered to about 95oC. Normally at this
stage, the heating is discontinued. Continued heating at higher temperature at advanced
stage of khoa making results in undesirable flavour (cooked) and texture (hard and
dry). The colour of such product is also brown. Slow heating is not only more time
consuming but also produces sandy texture and brown colour.
iv. Homogenization of Milk
Normally milk is not homogenized for khoa making. But under certain circumstances,
such as use of recombined milk or for increasing the fat by adding butter oil or
butter, homogenization of milk becomes essential. Khoa prepared from homogenized
milk is brittle and lack cohesiveness. The moisture retention in such khoa is also
more, which results into softness and higher yield.
Check Your Progress I
1) State the limitations of traditional methods of making heat desiccated dairy
products.
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2) a) At what concentration of milk solids during khoa making, the coagulation of
milk proteins start? b) How desirable grains are developed in danedar khoa?
and c) How much milk is taken in each batch for khoa making in a traditional
method?
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22
3) a) What is the average yield of khoa made from cow and buffalo milks? b) Methods of Manufacture
and Factors Affecting
Which type of milk produces better quality khoa in terms of flavour and Quality of Products
texture? and c) What are the characteristics of khoa made from cow
milk?
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4) Discuss the effects of neutralization/adulteration and vigorous scraping of milk
on the quality of khoa?
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2.5 MECHANIZED AND CONTINUOUS METHODS

OF KHOA MAKING
i. Mechanized Methods
As discussed in preceding sections, traditional method of khoa making causes
excessive strain and fatigue on the worker because milk has to be manually scraped
and stirred continuously for long time by the worker standing near the heating source.
The evaporation of moisture from milk and its subsequent condensing makes the
surrounding hot and humid. To overcome these drawbacks, several mechanized
systems have been developed from time to time. Most of these are broadly based
on following two principles:
• In the first concept the agitator and scraping blades assembly is mechanically
operated and the body of kettle is fixed/stationary.
• In the second principle, the mechanical scraping and agitation of milk is done
indirectly by rotating the body of khoa making unit around the fixed agitator
and scraper assembly.
The drawbacks of both the mechanized systems are a) they are batch type methods
and b) cannot directly provide final desiccation to the khoa stage. When milk is
thickened sufficiently (pasty stage), the mechanical agitation is not as efficient and
some burning of milk solids occurs on heating surface. Hence, final product of desired
texture is obtained by manual scraping. Out of the above two systems the one based
on the principle of rotative body of the unit with fixed scraper assembly is more
common among small traders in many parts of the country.
ii. Continuous Methods
Several types of prototype machines have been designed for continuous manufacture
of khoa in the past. Many of these units could not be commercially adopted by dairy
industry because of some drawbacks. The most successful and presently being used
are inclined scraped surface heat exchanger (ISSHE) and thin film scraped surface
heat exchanger (TSSHE).
Inclined scraped surface heat exchanger: ISSHE unit was developed at the
National Dairy Development Board, Anand for continuous manufacture of khoa.
The unit comprises of a feed balance tank, a positive displacement pump and a 23
Heat Desiccated Products scraped surface heat exchanger in inclined configuration (0-30o). The feed tank is
made up of stainless steel and has a capacity of 50 litres. A variable capacity feed
pump is used to provide the milk concentrate to the ISSHE at the desired flow rate.
The heat exchanger comprises of inner cylinder, rotor and drive, and outer steam
jacket. The inner cylinder is in S.S. construction and forms the main body. It is
provided with steam jacket and split into three separate compartments. The steam
jacket is insulated and cladded. The design of rotor is the key factor in this innovation.
It combines the functions of scraping and conveying the product. The rotor is driven
by a variable speed drive. The constructional features of ISSHE are shown in
A. Feed balance tank
B. Feed pump
C. Feed inlet
D. Drain
E. Scraper assembly
F. Steam inlet
G. Condensate outlet
H. Steam jacket
J. Vapour outlet
K. Khoa outlet
DR = Drive
ISSHE = Inclined scraped
surface heat
exchanger
V = Valve
Fig. 2.2: ISSHE Continuous Khoa Making Plant

Concentrated milk having 40-45% total solids is pumped into the inlet of the ISSHE
at the desired flow rate by adjusting the capacity of the feed pump. At the start of the
operation, the inclination of ISSHE permits formation of a pool of boiling milk,
critical for development of desired heated or slightly cooked flavour in khoa.
Subsequently, fresh concentrated feed enters the pool of boiling concentrates, while
an equivalent mass continuously leaves the pool as semi-solid mass (khoa). The
scraper repeats the process of removing coagulated particles from the heat transfer
surface and mixing them back into the pool of heated milk. The coagulated particles
absorb milk resulting in the agglomeration and formation of characteristic khoa texture.
The inclination of the scraper provides interface between metal, milk and air, which
enhances the heat coagulation of proteins which is essential for simulating desired
flavour and texture in khoa. The process of khoa making as it takes place in a
karahi is replicated in the ISSHE. The wet coagulated particles are pushed ahead
by the screw conveyer. At the end of the process run, supply of concentrated milk is
stopped and warm water is circulated. It can produce about 40 kg khoa per hour,
but installing more such units can increase the capacity.
Thin film scraped surface heat exchanges: TSSHE unit for continuous
manufacture of khoa was developed at National Dairy Research Institute, Karnal.
The constructional features of this unit have been shown in Fig. 2.3. In this unit, the
two SSHEs are arranged in a cascade fashion. The rotor of the first SSHE is provided
with four variable clearance blades and operated at 200 rpm. Standardized buffalo
milk is concentrated in this SSHE in the range of 40-45 per cent T.S. This concentrated
milk then enters the second SSHE, which has a different kind of rotor arrangement.
It has two variable clearance blades and two helical blades, which operate at a
speed of 150 rpm. Both the SSHEs are double jacketed and fitted with steam
supply line, pressure gauze and vapour outlet. Contrary to the ISSHE, the cylinders
in this unit are placed horizontally, one after the other. Milk is fed into first SSHE
with a centrifugal pump, whereas, the concentrated milk from first SSHE to second
24 SSHE moves by gravity. It can produce about 50 kg of khoa per hour
 Methods of Manufacture
and Factors Affecting
Quality of Products

1. Balance tank
2. Milk pump
3. Rotameter
4. Thin film SSHE
5. Scraper assembly
6. Milk inlet
7. Steam in
8. Vapour outlet
9. Khoa outlet
10. Rotor drive
11. Control panel
12. Condensate out
V – Valve

Fig 2.3: Thin Film Scraped Surface Heat Exchanger for Continuous Khoa Manufacture

Advantages of continuous khoa making plants

• As the process is continuous, the product of uniform quality with low operation
losses is produced throughout the run.
• Higher heat transfer coefficient, so fuel consumption is considerably less.
• It is easy to go in for automation.
• The plant is suitable for cleaning-in-place (CIP).
• Only one man can handle the unit without much fatigue.
• Sanitary operation as process takes place in a completely closed environment.
Disadvantages
• Unsuitable for small entrepreneurs
• The initial cost is high.
• Trained operator is required to run the plant.
• The ISSHE unit requires concentrated milk, having 40-45% TS as feed, hence
cannot be adopted where concentrated milk is not available.
Check your Progress - 2
1) Write the concept of developing mechanized units for khoa making. What are
the benefits and drawback of mechanized method?
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Heat Desiccated Products 2) Name the continuous khoa making plants, which are presently used by dairy
industry. What types of feed are used for these units and how much khoa can
be produced?
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3) Write the names of major parts of inclined scraped surface heat exchanger.
What is its specific constructional feature, which resembles to the conventional
kettle used for khoa making?
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4) Briefly describe the main advantages of continuous khoa making units?
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2.6 PREPARATION OF RABRI

i. Traditional Method
Traditionally rabri is prepared from milk by private traders (Halwais) at a very
small scale by simmering whole milk for a prolonged period and adding sugar after
achieving the desired concentration. The manufacture of rabri, in fact, started by
halwais (tea walla) who sit in small localities and sell milk in small lots to the nearby
residents. They keep the milk in hot condition (near to boiling temperature) in a
shallow karahi with heavy bottom to avoid spoilage. The formation of a thin skin
(malai) on the hot milk and air interface repeatedly takes place in this undisturbed
condition. When a customer comes to buy milk, halwai removes malai from the
surface with a ladle to the cooler side of the karahi and sell the bottom portion of
milk. This practice is continued for a long time (several hours). When the amount of
milk is considerably reduced, it is boiled and concentrated to about 3-4 folds. Then
sugar is added and finally the malai, which was collected on cooler side of the
karahi is remixed with concentrated sweetened milk. This product is sold at an
exorbitant price. Since the process is time consuming and labour and energy intensive,
a very few halwais prefer to prepare rabri. Rabri prepared in this way is stored in
open and shallow type of container, which leads to enormous contamination from
surroundings. Because of lack of refrigeration facilities and very high cost of raw
milk during summer months, many halwais refrain from preparing rabri during this
season resulting in very high cost.
ii. Improved Method of Rabri Making
The consumers are increasingly becoming conscious about the quality and safety of
milk based sweets. This awareness is influencing the consumer to purchase the
products from the organized establishments even at higher price. These facts underline
the need for standardization and mechanization of rabri to produce high and uniform
quality product at large scale and to reduce the post manufacturing contamination
26 (Fig 2.4).
 Buffalo milk Methods of Manufacture
and Factors Affecting
Quality of Products

Standardization (6% fat) - 5 litres

Jacketed kettle (shallow type)

Heating at simmering temperature (85o – 90oC)

Removal of malai on cooler part

Formation of malai or to a separate vessel

Removal of about 500 g malai

Partially skimmed milk

Concentration to 3 fold by boiling

Sugar addition (@6% of milk)

Addition of malai
Sweetened concentrated milk

Rabri

Packaging
Fig 2.4. Flow diagram of a improved method of rabri making

Buffalo milk is preferred for preparation of rabri because it contains higher fat content
that is responsible for the formation of a thick layer of malai. Steam heating of milk
is recommended because it will enable better control of temperature and prevent
development of flavour defects, like smoky and burnt. After adding malai to
sweetened concentrated milk, the flavouring ingredients (cardamom) and dry fruits
(almond, cashew nut etc.) can be added. Rabri prepared by this method should be
immediately chilled and packaged under hygienic conditions to prevent post-
manufacturing contamination.
iii. Large Scale method of rabri making
Scraped surface heat exchangers (SSHE) are presently used for the continuous
manufacture of khoa. Since rabri is also a heat-desiccated product like khoa, though
to lesser extent, SSHE can be used for pre-concentration of milk to the solids level
as of rabri. The flaky texture, which is an integral and desirable attribute of rabri and
produced by adding malai, can be simulated by incorporating similar fibrous and
flaky material in from of shredded chhana/paneer to this concentrated milk. The
method developed on this concept has been shown in flow diagram (Fig.2.5). 27
Heat Desiccated Products Buffalo milk

SSHE

Concentration (about 2.5 fold)

Addition of sugar @ 6% of milk
Sweetened concentrated milk

Shredded chhana/paneer @ 5% of
final product Rabri
Fig. 2.5. Flow diagram of a large-scale method for preparation of rabri

2.7 PREPARATION OF BASUNDI

Basundi is a region specific product; hence its quality attributes vary from region to
region. Product with a complete homogenous consistency (like sweetened condensed
milk) to slightly granular with soft flakes is preferred in different regions. Accordingly
the method of manufacturing of basundi differs from place to place. The general
method involves open pan (shallow kettle) concentration of sweetened milk till a
desired concentration (about 2 fold) is achieved. The heat treatment in presence of
sugar imparts slight caramel flavour and brownish colour in the final product. A
standard method has been developed for basundi preparation (Fig. 2.6).
Buffalo milk

Standardization

Fore warming (90oC/10 min)

Open pan concentration

Partial concentration (2.0 folds)

Sugar addition (5% w/w of milk)
Final concentration (2.5 fold including sugar)

Homogenization (Optional, depending on type of product required)

Cooling (<10oC)

Packaging

Refrigerated storage
28 Fig. 2.6 Flow diagram of the manufacture of basundi
Though both types of milk can be used for basundi making, buffalo milk is preferred Methods of Manufacture
and Factors Affecting
over cow milk. The initial quality of milk should be good. It is desirable to adjust fat Quality of Products
and SNF ratio of 0.50 for cow milk and 0.70 for buffalo milk for producing basundi
of same composition throughout the year. Open pan evaporation with vigorous
scraping produces basundi with granular consistency (due to denaturation of protein).
However, if a homogenous and smooth consistency product is needed, the
concentrated product should be homogenized at a pressure of 75 kg/cm2 and at
65oC. The product is stored under refrigerated conditions.
Check your Progress 3
1) Name the ingredient responsible for typical flaky texture. Which processing
step is responsible for developing this ingredient?
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2) a) To which level milk is concentrated in rabri making? b) How much sugar is
added in rabri? c) Which type of milk is preferred for rabri making? and d)
Which type of kettle is desirable for preparation of rabri by traditional method?
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3) Name the unit that can be used for large-scale production of rabri. How the
typical flaky texture can be simulated in this method?
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4) a) What should be fat and SNF ratio for making basundi?; b) What should
be the final concentration of solids for basundi making? and c) How
much and at what stage sugar is added for basundi making?
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2.8 LET US SUM UP

The principle behind manufacture of heat-desiccated products is evaporation of
moisture by continuous boiling of milk in shallow pan (karahi) along with vigorous
agitation and scraping till desired consistency/texture and flavour is achieved. Most
of the production of heat desiccated products, viz. khoa, rabri and basundi is in the
hands of milk confectioners (Halwais) who adopt small scale batch methods. Lately
some large scale/mechanized methods have also been developed.
Khoa is traditionally prepared from buffalo milk having more than 5% fat. Small
scale batch method using 4-5 kgs of milk in each batch is generally adopted. Each
29
batch requires about 20-25 min. For khoa making milk is continuously boiled till it
Heat Desiccated Products reaches to pasty consistency. At this stage kettle is taken away from fire and contents
are spread on the hot surface of kettle for further evaporation. Finally, contents are
worked to make a cohesive mass (bolus) and transferred to some mould. By this
technique Pindi khoa is obtained. Danedar khoa is prepared from using milk with
adding acidulant to milk at boiling stage. Dhap khoa is obtained by taking out khoa
at pat stage. The factors that affect the quality and yield of khoa are: quality of milk
(species of animal, fat content and acidity in milk, presence of adulterants/neutralizers,
etc.), speed of stirring, temperature of desiccation and homogenization of milk.
The mechanized systems used for khoa making are based on either a) mechanically
operated scraper assembly in the fixed kettle or b) fixed scraper assembly in the
mechanically rotating body of the kettle. The system ‘b’ is more commonly used by
private traders. Some organized dairies are also adopting continuous khoa making
machines, viz., inclined scraped surface heat exchanger and thin film scraped surface
heat exchanger.
The method of preparation of rabri is more complicated and time consuming than
that of khoa and basundi. In rabri making, malai (clotted cream) is obtained by
simmering milk at 85-90oC in a shallow pan, which takes very long time. After
obtaining sufficient quantity of malai, remaining milk is concentrated to about 3 fold,
sugar @ 6% of milk is added and after cooling to room temperature malai is remixed.
The product obtained is known as rabri. In case of manufacture of basundi malai is
not separated and sugar @ 5% is added at the start of boiling of milk. The level of
milk concentration including sugar in basundi is above 2.5 times.

2.9 KEY WORDS

Acidulant: Any substance that help reducing the acidity of a food system like lactic
acid, citric acid, tartaric acid, etc.
Bolus: A soft mass in rounded form.
Caramel: Heating of milk along with sugar or sugar alone under controlled conditions
to develop typical burnt flavour and brown colour in dairy products.
Confectioners: Persons engaged in the business of making sweets from milk or
milk products.
Homogenization: The process of breaking the fat globules by forcing milk or other
liquid product through minute opening under pressure.
Khunti (Ladle): Scraper made of iron with one side flattened and other having
wooden handle.
Organoleptic quality: The quality of a food determined by sensory organs, such
as smell, taste, colour, appearance, body and texture.
SSHE: Scraped surface heat exchanger, a mechanized unit for evaporation of
moisture from fluids by spreading on hot surface in form of a thin layer and its
vigorous scraping by scraping blades.
Standardization: Adjustment of fat and SNF ratio (or protein) individually or both
to a pre-decided level.

2.10 SOME USEFUL BOOKS

Anantakrishnan, C.P. and Srinivasan, M.R. (1964). Milk Products of India, ICAR
30
Publications.
Aneja, R.P., Mathur, B.N., Chandan, R.C. and Bajerjee, A.K. (2002). Technology Methods of Manufacture
and Factors Affecting
of Indian Milk Products. A Dairy India Publication, Delhi. Quality of Products

De, S. (1980). Outlines of Dairy Technology. Oxford University Press, New Delhi.
IS: 4883 (1980). Specification for khoa. Bureau of Indian Standards, Manak Bhavan,
New Delhi.
Rangappa, K.S. and Acharya, K.T. (1974). Indian Dairy Products. Asia Publishing
House, New Delhi.

2.11 ANSWERS TO CHECK YOUR PROGRESS

Your answer should include the following points.
Check Your Progress - 1
1. i. Wide variations in chemical, microbial and sensory qualities.
ii. Small-scale method.
iii. Energy intensive process
iv. Poor packaging and
v. Limited shelf life
2. i. Coagulation of milk proteins during khoa making starts when total solids
concentration reaches to about 2.8 times in case of cow milk and 2.5
times in case of buffalo milk, or total solids levels of about 35-36%
irrespective of type of milk is achieved.
ii. Grains formation in Danedar khoa is obtained by either using slightly
acidic milk (0.17–0.18% acidity) or adding 0.02% acidulant (citric acid)
to fresh milk.
iii. About 4-5 litres of milk in each batch can be most easily handled for
making good quality khoa.
3. i. Average yield of khoa from buffalo milk should be 23% and in case of
cow milk 18.5%.
ii. Buffalo milk is preferred for khoa making because it produces khoa with
most desirable flavour and texture.
iii. Khoa made from cow milk has yellowish colour, salty taste, slightly pasty
texture and dry body.
4. i. Use of neutralized milk produces khoa with slightly salty taste, acidic smell
if made from sour milk, and absence of grains.
ii. Milk adulterated with water has less total solids. Use of such milk requires
longer time for preparation of khoa. This can result in slight browning of
product due to prolonged heating. The yield of khoa is also low.
iii. Lower than optimum speed of scraper during khoa making results into
burning of milk solids on the surface of heating kettle that imparts burnt
flavour and brown colour to khoa. Scraping at much higher speed make
the product pasty.

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Heat Desiccated Products Check Your Progress - 2
1. i. Mechanization means exclusion of manual operation from the process. In
conventional khoa making scraping and agitation of milk is done manually.
In mechanized khoa making it can be achieved by either fixing power
operated scraper or rotating the body of kettle having fixed scraper
assembly. In this way manual scraping of milk is replaced by mechanized
scraping.
ii. The benefits of mechanized system are the convenience in operation,
hygienic production and consistent quality of khoa. The only draw back is
that proper scraping, when milk is excessively thickened (pat-formation
stage), is not achieved and manual scraping at that stage has to be adopted
for obtaining quality product.
2. i. Continuous khoa making units that are adopted by dairy industry are:
inclined scraped surface heat exchanger (ISSHE) and thin film scraped
surface heat exchanger (TSSHE).
ii. The feed for ISSHE is concentrated milk having 40-45% total solids (fat:
SNF ratio of 0.56-0.6 : 1) whereas in case of TSSHE both buffalo milk
and concentration milks can be used as feeds.
iii. About 50 kgs khoa per hour can be prepared on each continuous khoa
making units.
3. i. The main parts of ISSHE are: Feed balance tank, positive displacement
pump, scraped surface heat exchanger assembly, rotor assembly, drive
mechanism, vapour outlet, steam inlet valves, steam trap, etc.
ii. The inclined configuration is the specific constructional feature of ISSHE
machine. This position makes a pool of concentrated milk at the inlet
(base) and its boiling as in case of conventional karahi.
4. - We can produce khoa of uniform quality
- Low operational losses
- Low energy consumption
- Automation possible
- CIP possible
Check Your Progress - 3
1. i. Malai (clotted cream) is responsible for imparting typical flaky texture in
rabri.
i Malai can be obtained by following step:

Milk (preferably) Taken in a shallow Heating to simmering Leave

buffalo kettle temperature (85-90oC) undisturbed

Malai Process continued till about 10% of the Removal of this skin on Formation of a skin
initial volume of milk removed cooler side of kettle on the surface

2. i. Milk is concentrated to about 3 fold for rabri making.

32 ii. Sugar is added at rate of 6% of milk.
 iii. Buffalo milk, because of high fat, is preferred for rabri making. Methods of Manufacture
and Factors Affecting
iv. Shallow type kettle with heavy bottom is more desirable for making rabri. Quality of Products

3. i. TSSHE can be used for large-scale production of rabri.

ii. In the large-scale method, flaky texture can be simulated by adding
shredded paneer/chhana.
4. i. The fat and SNF ratio for making basundi should be 0.50 for cow milk
and 0.70 for buffalo milk.
ii. Final concentration of solids including sugar should be 2.5 times (about
45% TS) for basundi making.
iii. Sugar is added at rate of 5% and at the time of first boiling of milk for
preparation of basundi.

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