Ghee Processing Plant

Ghee Processing Plant by SS Engineers

SS Engineers & Consultants, India offers you custom built GHEE Manufacturing systems which brings profits in your business.

GHEE MANUFACTURING PROCESS - SS Engineers & Consultants, India.

Ghee production is the largest segment of milk utilization in India. Most of the dairy plants have ghee production facility to meet the demand of the market as well as to utilize the excess fat at their dairy plants. The technology involved in ghee production is simple for adaption.

Method of production varies from small scale to large scale.

Ghee Processing Plant by SS Engineers

Direct Cream Method

This method involves separation of cream from milk (60 to 70% fat) by centrifugation process through Cream Separator, The Fresh cream (or) cultured cream then heated to 114±2°C in a stainless steel, triple jacketed ghee kettle. The kettle is fitted with agitator, boiling of the cream is through steam which runs in the intermediate jacket of the tank having steam control valve with respect to required pressure and temperature, the product Heating is discontinued as soon as the color of the ghee residue turns to golden yellow or light brown. The Ghee is then decanted to the Ghee settling tank having filter for collection of the Ghee residue.

Advantages of this method are

No need for butter production prior to manufacturing of ghee.

Limitations

Long heating time to remove the moisture.
High content of serum solids in the cream may also produce a highly caramelized flavour in the ghee.
4 – 6% loss of butter fat in the ghee residue & during the handling operations.
So, 70 – 80% fat cream is recommended to minimize both fat loss and steam consumption.

Creamery Butter Method

This is the standard method adopted in most of the organized dairies.

Unsalted or white butter is used as raw material.

Butter mass/butter blocks are melted at 80°C in butter melting vat.

Molten butter is then pumped to the ghee boiling vat, where the Ghee is prepared using steam as heating medium.

Ghee is filtered via oil filter into the settling tank.

Ghee Processing Plant by SS Engineers

Pre-Stratification Method

In this process Butter is produced from aged cream (38 to 40% fat) using continuous butter making machine or batch butter churn machine.

Butter is then transferred to butter melting vat heated at 80°C, This molten butter is kept (undisturbed) in a ghee kettle at a temperature of 80-85°C holding it for 30 min for stratification of mass. The product stratifies into 3 distinct layers.

1.Denatured protein particles (curd particles) and impurities stays on top layer and floats on surface. Middle layer consists of clear fat and bottom layer consists of buttermilk serum (which carry 80% of moisture and 70% of solids).

The bottom layer is then carefully removed without disturbing the top and middle layers. Middle layer is then heater upto 114±2°C along the top layer of floating curd particles/ denatured protein. This step is necessary to develop characteristic ghee aroma. Milder flavour ghee is produced.

Advantages of pre - stratification method & Continuous Method

This method was developed to meet high volume production requirement

Requires high energy, due to low heat transfer co-efficient
Cleaning and sanitation of equipment's, not satisfactory
Equipment's and process unsuitable for large volume of production
Floor becomes slippery due to ghee spillage
Handling losses are more

Benefits of continuous method of Ghee Production:

Better control on quality of the product
Only small hold-up of raw material in the plant at any time and hence no chance for whole batch getting spoiled
Contamination by handlers can be eliminated
Feasibility for CIP cleaning.
No foaming of the product during production

Butter is heated in a butter melting vat to molten state and then transferred to balance tank, further it is pumped to scraped surface heat exchanger (SSHE), having two stages flashing with vapour separator to reduce the moisture level. Ghee is then passed through centrifugal clarifier to remove the residue. Clarified ghee is stored for filling and packing.

Ghee Processing Plant by SS Engineers
Granulation and Cooling of Ghee

Granulation is important criterion of quality; higher temperature of clarification gives better grain size due to high phospholipids content.

Phenomenon

Completely melted ghee on cooling to prevailing Indian temperatures, can assume the form of large, coarse grains suspended discretely or in clusters in a liquid phase. The process of crystallization is initiated with the formation suitable nuclei. Rate of cooling strongly influences the rate nucleus formation. Stirring or agitation and seeding (at the rate of 1 – 3%) encourage the nucleus formation. For better granulation, ghee should be slowly cooled to 28°C in 2-3 hours time and agitation is required during granulation to form smaller granules.

Yield

The yield of ghee from cream or butter is influenced by fat content of raw material. Factors which influence the yield are listed below.

Following factors influence the yield of ghee,

Method of production: The fat recovery in indigenous method is lowest in range of 80-85% in creamery butter method it ranges from 88-92% and highest in direct cream method ranging from 90-95%.
The fat content of the raw material used: Higher the fat content higher will be the yield and vice versa.
Quality of milk or cream: If the acidity of milk or cream intended to use in ghee production is higher than fat, losses in ghee residue will be higher , thus it reduces the yield.
Fat recovery from ghee residue: Scientific reports suggest to extract as much as fat from ghee residue by dissolving ghee residue in hot water followed by filtration and centrifugation. By this method, it is possible to extract the fat from ghee residue and that fat can be added back to cream or butter melter.

Ghee Processing Plant by SS Engineers

Use of Substandard Milk for Ghee Production

India is a tropical country, where in ambient temperatures touches the mark of 40°C in summer. Collection system for raw milk in rural area is still carried out at ambient temperature. Especially in summer while collecting the milk cans from many places causes increase acidity in milk results in souring of milk. This acidic sour milk can't be used or sold in the market..

Therefore, there is a need to utilize, this milk for products preparation. Where in it does not affect the quality of end product. So, in commercial dairy plants such milk is diverted and collected separately based on platform tests (COB, sensory etc…). This sourced milk is collected in balance tank and circulated using high speed pump. This causes the breakdown of far globule membrane and release the fat. After a circulation of 30 minutes, the milk is kept undisturbed facilitating the separation of cream through gravity. This cream is used for ghee production directly or collected over-a-period of time and neutralized to produce butter from this cream. This butter will also be used for ghee making.

Ghee Making made easy - by SS Engineers & Consultants.

Ghee is considered a Super food with many health benefits,
# It Strengthens Your Bones
# It Promotes Healthy Weight Loss
# It Improves Digestion
#It Relieves Inflammation
#it’s Free of Lactose and Casein
# It Contains Conjugated Linoleic Acid
# It’s Loaded with Butyrate

So it has many benefits...make it at home right now.
Consumption of Ghee increases your immunity and can protect yourself from seasonal changes, diseases like cold and cough. Ghee helps better digestion.
It has antioxidant and anti inflammation properties to fight with allergies
and infections. Ghee is Rich in Fat Soluble vitamins A, D, E and omega 3.
According to Ayurveda, ghee helps in increasing your wit, age, strength and prosperity.

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Contact us today for detailed project report of making GHEE.

SS ENGINEERS & CONSULTANTS
#11-49, Morampudi Junction, Rajahmundry - 533107, Andhra Pradesh, INDIA.
Ph: (+91) 883 2426845, 46, Fax: (+91) 883 2430819
E-mail: response.ssengrindia@gmail.com, www.ssengrindia.in