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Butter and Its Manufacturing: A Complete Guide for Food Industry Professionals

Q: What does FSSAI require for a product to be sold as butter in India?

Under FSSAI, butter is defined as a fatty product derived exclusively from cow and/or buffalo milk. It must be a water-in-oil emulsion and free from animal body fat, vegetable oil, added flavour and mineral oil. Only salt and lactic acid bacteria may be added, as per accepted norms. Butter typically carries a fat content of 80–83%, and these limits govern both formulation and labelling compliance.

Q: Should we go for batch churning or continuous churning in a new butter line?

Batch churning uses horizontal cylindrical churns operating at roughly 6–14°C with a cycle time of about 90 minutes, making it suitable for smaller batches and specialty butter. Continuous churning works through three zones: churning, centrifugation and emulsification. It is common in Western Europe and yields a denser, matte-finished butter. The choice depends on batch size, product positioning and desired texture.

Q: What temperatures and holding times matter most in the butter process?

Key set points in butter manufacturing include preheating milk to about 63°C before cream separation, cooling cream to around 14°C for roughly 8 hours during ageing so milk fat crystallises, and pasteurising cream at about 95°C to destroy enzymes and microbes. Churning itself is carried out at approximately 6–14°C. These parameters govern butter firmness, flavour and microbiological quality.

Q: Why is cream ripening used, and how much starter culture is added?

Cream ripening involves adding starter cultures at 0.5–2.0% to develop diacetyl-rich flavours, which improves taste and extends shelf life. Ripening also determines butter classification by cream acidity: sweet cream butter from non-acidified cream at pH around 6.4, mildly acidified butter at pH 5.2–6.3, and ripened cream butter below pH 5.1 with higher acidity and greater flavour complexity.

Q: What butter variants can we plan for on the same line?

Butter can be classified by salt content as salted butter with 0–3% salt for flavour and preservation, or unsalted butter, which is preferred for ghee and butter oil production. Under BIS end-use classification there is table butter, which may contain salt and colour, and white butter with no salt or colour for traditional Indian recipes. FSSAI also recognises pasteurised cream butter and desi or cooking butter prepared from curd.

Q: What happens after churning, before the butter is packed?

After churning, butter is drained to separate it from buttermilk and washed with water to remove impurities and excess whey. Salt is then blended in at up to 3% to improve flavour, shelf life and texture. The butter is moulded into rectangular blocks, wrapped in wax paper and held in cold rooms, where further fat crystallisation takes place.

By PMG Engineering · 1 Jan 2019

Introduction to Butter

Butter is a high-fat dairy product obtained by churning milk or cream, converting it from an oil-in-water emulsion to a water-in-oil emulsion. With a fat content ranging from 80–83%, butter has been a staple in both domestic kitchens and the food processing industry.

Modern butter production saw its expansion during World War II, as industrialization surged in the dairy sector. This growth was backed by evolving standards and regulations that ensured quality and safety across the food supply chain.

As a food consultant or food manufacturing consultant, understanding butter’s production intricacies is key to ensuring product consistency and regulatory compliance.

Butter Regulations and Standards

In India, FSSAI (Food Safety and Standards Authority of India) defines butter as a fatty product derived exclusively from cow and/or buffalo milk. It must be a water-in-oil emulsion and free from animal body fat, vegetable oil, added flavor, and mineral oil. Salt and lactic acid bacteria may be added as per accepted norms.

Types of Butter

Butter is classified based on several criteria relevant to food consultants and food industry consultants advising on product development or line extensions:

1. Based on Cream Acidity

Sweet Cream Butter: From non-acidified cream; pH ~6.4
Mildly Acidified Butter: From partially acidified cream; pH 5.2–6.3
Ripened Cream Butter: pH <5.1, with higher acidity and flavor complexity

2. Based on Salt Content

Salted Butter: 0–3% salt for flavor and preservation
Unsalted Butter: Preferred for ghee or butter oil production

3. Based on End Use (as per BIS)

Table Butter: May contain salt and color
White Butter: No salt, no color, traditionally used in Indian recipes

4. Based on Manufacturing Practice (FSSAI)

Pasteurized Cream Butter: From sweet cream with milder flavor
Desi/Cooking Butter: Traditionally prepared from curd

A good food business consultancy should consider these classifications when developing region-specific dairy products.

Butter Production Process

The butter-making process involves several controlled steps—each critical for achieving the desired texture, flavor, and microbiological quality.

1. Milk Reception and Quality Check

Raw milk is sampled and tested. Upon approval, it's stored in silos.

2. Cream Separation

Milk is preheated (~63°C), then separated into cream and skim milk. Cream is sent for further processing, and skim milk is pasteurized and stored.

3. Cream Ripening

Starter cultures are added (0.5–2.0%) to develop diacetyl-rich flavors. Ripening enhances taste and shelf life.

4. Ageing and Crystallization

Cream is cooled (~14°C for ~8 hours) to crystallize milk fat—key for butter firmness.

5. Pasteurization

The cream is heated to ~95°C to eliminate enzymes and microbes.

6. Churning: The Heart of Butter Manufacturing

Butter churning converts cream from an oil-in-water emulsion to a water-in-oil emulsion.

6.1 Batch Churning

Performed in horizontal cylindrical churns
Operates at ~6–14°C
Time: ~90 minutes
Ideal for smaller batches or specialty butter

6.2 Continuous Churning

Involves three zones: Churning, centrifugation, and emulsification
Common in Western Europe
Produces denser, matte-finished butter

7. Draining and Washing

Post-churning, butter is separated from buttermilk and washed with water to remove impurities and excess whey.

8. Salting

Salt (up to 3%) is blended to enhance flavor, shelf life, and texture.

9. Packaging and Storage

Butter is molded into rectangular blocks, wrapped in wax paper, and stored in cold rooms for further fat crystallization.

Food processing consultants can guide dairy plants in optimizing this workflow with modern tech like de-aerators for improved texture and aroma.

Conclusion

Butter production is more than just churning cream—it's a controlled and regulated process that demands technical precision and understanding. Whether you're a food technology consultant, a dairy entrepreneur, or part of a consultancy for food industry ventures, mastering butter manufacturing can significantly boost your offerings in the growing dairy segment.

If you're planning to set up a butter plant or want to optimize your existing operations, consider reaching out to experienced food consultancy services. From regulatory compliance to quality assurance and process engineering, the right food industry consultant can transform your butter business into a scalable, sustainable success.

Frequently asked

What does FSSAI require for a product to be sold as butter in India?

Under FSSAI, butter is defined as a fatty product derived exclusively from cow and/or buffalo milk. It must be a water-in-oil emulsion and free from animal body fat, vegetable oil, added flavour and mineral oil. Only salt and lactic acid bacteria may be added, as per accepted norms. Butter typically carries a fat content of 80–83%, and these limits govern both formulation and labelling compliance.

Should we go for batch churning or continuous churning in a new butter line?

Batch churning uses horizontal cylindrical churns operating at roughly 6–14°C with a cycle time of about 90 minutes, making it suitable for smaller batches and specialty butter. Continuous churning works through three zones: churning, centrifugation and emulsification. It is common in Western Europe and yields a denser, matte-finished butter. The choice depends on batch size, product positioning and desired texture.

What temperatures and holding times matter most in the butter process?

Key set points in butter manufacturing include preheating milk to about 63°C before cream separation, cooling cream to around 14°C for roughly 8 hours during ageing so milk fat crystallises, and pasteurising cream at about 95°C to destroy enzymes and microbes. Churning itself is carried out at approximately 6–14°C. These parameters govern butter firmness, flavour and microbiological quality.

Why is cream ripening used, and how much starter culture is added?

Cream ripening involves adding starter cultures at 0.5–2.0% to develop diacetyl-rich flavours, which improves taste and extends shelf life. Ripening also determines butter classification by cream acidity: sweet cream butter from non-acidified cream at pH around 6.4, mildly acidified butter at pH 5.2–6.3, and ripened cream butter below pH 5.1 with higher acidity and greater flavour complexity.

What butter variants can we plan for on the same line?

Butter can be classified by salt content as salted butter with 0–3% salt for flavour and preservation, or unsalted butter, which is preferred for ghee and butter oil production. Under BIS end-use classification there is table butter, which may contain salt and colour, and white butter with no salt or colour for traditional Indian recipes. FSSAI also recognises pasteurised cream butter and desi or cooking butter prepared from curd.

What happens after churning, before the butter is packed?

After churning, butter is drained to separate it from buttermilk and washed with water to remove impurities and excess whey. Salt is then blended in at up to 3% to improve flavour, shelf life and texture. The butter is moulded into rectangular blocks, wrapped in wax paper and held in cold rooms, where further fat crystallisation takes place.

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PMG Engineering. (2019). Butter and Its Manufacturing: A Complete Guide for Food Industry Professionals. PMG Engineering. https://pmg.engineering/Presentation/1/butter-and-its-manufacturing-a-complete-guide-for-food-industry-professionals/

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