India is the largest producer and consumer of milk and dairy products. Among them, ghee holds the second-largest share in the Indian dairy market. With the expansion of the organized dairy sector and the rise of modern dairy processing plants, there is increasing emphasis on transitioning from traditional techniques to commercial-scale ghee manufacturing methods. Food processing consultant and food manufacturing consultant supports the adoption of efficient, scalable, and safe ghee production practices in line with food industry standards.
Top Methods of Ghee Processing
1. Desi Method (Traditional Household Ghee Making)
The desi method is widely used in rural households and small-scale operations. This method accounts for over 80% of ghee production in India and typically involves:
- Route 1: Lactic acid fermentation of raw or boiled milk, followed by churning curd into makkhan (butter).
- Route 2: Collection of malai (clotted cream) from boiled milk, churning it into butter, then heating it to make ghee.
Despite its popularity, this method lacks scalability and hygiene controls required in industrial setups.
2. Direct Cream Method (Commercial Ghee Production)
This food industry-grade method involves:
- Boiling cream in steam-jacketed kettles made of stainless steel.
- Monitoring via pressure and temperature gauges.
- Stopping the heating process when golden froth and browning residues appear.
Cream is separated from milk via centrifugation, making this method suitable for small and mid-sized dairies.
This food industry-grade method involves:
- Boiling cream in steam-jacketed kettles made of stainless steel.
- Monitoring via pressure and temperature gauges.
- Stopping the heating process when golden froth and browning residues appear.
Cream is separated from milk via centrifugation, making this method suitable for small and mid-sized dairies.
3. Creamery Butter Method (Industrial Ghee Production)
This is a commonly used industrial ghee production method where:
- Unsalted white butter is melted at 60°C and pumped into ghee boilers.
- Steam pressure raises temperature to 90°C to remove moisture.
- Once frothing and browning are complete, the ghee is filtered, cooled, and packed.
This method is preferred in food factories requiring hygienic, scalable ghee production with consistent quality.
4. Pre-Stratification Method
Used in automated food plants, this method involves:
- Melting cream-based butter at 80–85°C in ghee boilers.
- Allowing the product to stratify into three layers:
- Top: Curd particles and impurities
- Middle: Clarified ghee
- Bottom: Moisture-rich serum
This method minimizes residue and reduces the need for excessive heating.
5. Cream De-Emulsification Method (Continuous Process)
A modern, continuous ghee manufacturing technique that:
- Separates milk into 40% fat cream using centrifugal separation.
- Concentrates the cream and de-emulsifies fat via clarifixators and heat exchangers.
- Removes moisture using vapour separators and clarifies oil residue through filters.
This is ideal for large-scale food factories aiming for energy efficiency, hygiene, and automation.
Hazards in Ghee Processing
As an expert food safety consultant, PMG Engineering emphasizes hazard identification and control during ghee production.
1. Physical Hazards
- Foreign matter: dust, dirt, glass, stone, etc.
- Fine particles from improper settling.
2. Chemical Hazards
- Residual cleaning agents in pipelines.
- Packaging contamination due to polymer migration.
3. Biological Hazards
- Microbial risks: Coliforms, E. coli, Salmonella, Clostridium, yeasts, molds, etc.
- Poor hygiene and unclean equipment are leading causes.
Conclusion: Moving Towards Modern Ghee Processing
Ghee plays a central role in Indian diets, rituals, and even Ayurvedic medicine. While 90% of ghee is still produced via traditional methods, the future lies in industrial, hygienic, and scalable ghee processing systems. As a trusted partner in food consultancy services and engineering consulting for the food industry, PMG Engineering designs and implements turnkey manufacturing plants, ensuring safety, efficiency, and compliance with international food standards.
PMG stands for Projects Management Group. We provide state-of-the-art Engineering Services to build world-class food processing factories. 
Engineering is the difference between Chaos and Excellence. If you are going to do it, do it right. 
Explore the diverse range of Products in the Food Processing Industry. 
Explore the technologies at the heart of the the Food Processing Industry. 
Filter
