Document No.
NDDB/FC/05
BUTTER Date of Issue
NDDB Version 100
Flow Chart Page No. 1 of 3
1. Flow Chart For Table Butter in Churner
Pasteurized Cream (38-42% Fat), B1
QC Checks,
B
B2
Loading of cream to churn
(40% volume), B3
RMST, B7
D Churning on for 30min, B4
Granulation on till get butter
granules of Peanut size/ view
glass is clear, B5
QC
Check
Sweet butter Milk,
B6
D
Pasteurized Washing of butter
Chilled water B8
(<5°C), B8A
Draining
B9
N
Final working of butter,
B10
Reprocess
NOT OK
QC
Check, B11
Confidential
Document No. NDDB/FC/05
BUTTER Date of Issue
NDDB Version 100
Flow Chart Page No. 2 of 3
Receiving of Primary &
secondary, tertiary packing
materials from store, B20
Collection and hardening of
Butter in trolleys for 12h @ 10°C
in butter cold room, B12
B
Primary packing
Feeding to chiplet/molding Unit, B13
material, B20A
Reprocess Chiplet/mold packing, B14
D Packed in duplex cartons, B15
NOT OK
QC Check,
B16
Secondary packing
materials & Coding,
B20B
D
Tertiary packing
Collection of Butter Chiplets in Coded Carton
materials & Coding,
box, Taping and storage in Butter cold / ante
B20C
room/24-48h, B17
Storage in deepfreeze (min. -18°C) B18 OPRP 01
N
Dispatch, B19
Confidential
Document No. NDDB/FC/05
BUTTER Date of Issue
NDDB Version 100
Flow Chart Page No. 3 of 3
2. FLOW CHART FOR WHITE BUTTER
Pasteurized Cream (38-42% Fat), W1
RMST, W3B
B
QC Check,
W2
QC
Check
Transfer to Continuous butter
making Machine, W3
Butter Milk, W3A
D
Pasteurized
Chilled water
(<5°C), W4A
Washing of butter, W4
Discharge of butter, W5
QC Check
NOT OK
Transfer to Ghee
D
W6 Section, W7
To butter trolleys for Bulk Packing (Optional)
ghee making, W8 W9
N
Confidential
Document No. NDDB/WI/05
Date of Issue
Butter Manufacturing
NDDB Version 1.00
Work instruction Page No. 1 of 3
I. Butter manufacturing in CBMM
1. Cream will be stored in cream storage tank. Before taking to production
quality control checks of cream for the quality parameters such as fat,
SNF, acidity, temperature will be carried out. If found ok issued to butter
section if not ok will be taken back for reprocessing.
B
2. Receiving of cream to the cream balance tank of CBMM (Continuous
butter making machine)
3. From cream balance tank cream will fed/transferred to CBMM.
4. Pasteurized water is used for washing of butter and sweet butter milk
which is obtained during washing of water will be a by-product and
butter milk will be tested for quality parameters and then transferred to
D
raw milk silos.
5. Butter will be removed from CBMM through kneader section.
6. During production online butter sample will be taken for testing of
quality parameters if it is not satisfactory transferred to ghee section for
ghee making.
D
7. After getting clearance from quality control section butter will be
wrapped in LDPE liners and packed in 20 / 25 kg butter cartons and
also transferred to butter trolleys for ghee making.
8. Butter box will be weighed for 20 / 25 kg net weight.
9. Online checks are done to confirm to standard weight requirement and
verification of taping and coding.
N
10. Butter box will be taped by using Bopp tape and coding is done for date,
batch no. machine number box number for traceability.
11. Butter boxes are transferred to ante room for hardening of butter for 1
day.
12. After hardening of butter, it will be transferred to deep freezer at or
below -18 degrees to ensure quality of butter till consumption
Confidential
Document No. NDDB/WI/05
Date of Issue
Butter Manufacturing
NDDB Version 1.00
Work instruction Page No. 2 of 3
13. Quality control Checks will be carried out before dispatch of butter and
also during transfer of butter during ghee production. As per
requirement the butter are packed in retail cartons.
14. Dispatch of butter.
II. Butter manufacturing in Batch process (Churner)
B
1. Receiving of pasteurized cream and check for its chemical and
biochemical requirements as per quality plan.
2. Aging of cream for min 4 hrs at 5-10°C.
3. Load the cream in to churner approximately 40% of churner capacity
and close the lid and safety gears.
D
4. Switch on the churners for 30 min and observe till get the proper
granulation of Peanut size/ view glass is clear.
5. Drain the butter milk and collect it for further processing.
6. Wash the butter with pasteurized chilled water, Drain the wash water.
D
7. Work the butter till you get desired good body & texture at 4th Gear.
8. Up on completion of working check for its chemical composition
(Moisture, salt and fat %) as per quality plan.
9. Once QA cleared the batch unload the butter in to cleaned and sanitized
butter trolleys and close the lids and keep it for hardening in cold rooms
for 12hrs @ below 10 °C.
N
10. Upon hardening, cut the butter blocks and load it in to cleaned and
sanitized chiplet/molding unit. If it’s manual loading personal and
equipment hygiene has to be taken care by the supervisor.
11. Receiving of packaging materials and coding with batch number and
date of manufacture/packed date.
12. Packing in to respective SKUs as per demand in primary packaging,
secondary cartons and tertiary CFB cartons.
Confidential
Document No. NDDB/WI/05
Date of Issue
Butter Manufacturing
NDDB Version 1.00
Work instruction Page No. 3 of 3
13. Ensure the coding, taping on packed boxes and check for its final
quality clearance.
14. Butter carton boxes are held in butter cold room / anteroom for 24 to
48 h allowing to set before shifting it to deep freezer at -18°C until
dispatch.
B
D
D
N
Confidential
