Preface   This book has been written for the under-graduate students of Dairy technology course being offered by different Dairy Science Colleges and various Agricultural and Deemed Universities across the country. The need was felt to upgrade the only existing text, on the subject, to the collegiate for the last two decades. The book has been designed to cover the principles involved in processes and products that applies to dairy industry. Attempts have been made to categorically put forth the concepts of current technologies used for manufacture of fat rich dairy products and techniques involved in their quality assurance together, in an easily understandable expressions, for dissemination of information. The topic covered under the text includes production and consumption pattern of fat rich products, about lipids specially milk lipids its composition and components and physico - chemical properties, various fat constants, processes and processing techniques for manufacturing of different fat rich produtcs, theoretical considerations, packaging, quality assurance and legal aspects including various food laws and implementation agencies involved during processing and marketing of milk products. It covers newer technologies available and being in use by different players in the dairy industry. The book is a result of considerable experience by the authors in handling theoretical and practical aspects related to different courses in the subject of dairy technology as well as dairy plant operations. It is expected to be of value to the newly trained as well as existing technocrats engaged in Indian Dairy Industry.

Several centuries ago, perhaps as early as 6000-8000 BC, ancient man learned to domesticate species of animals for obtaining milk for their consumption. These included cows, buffaloes, sheep, goats, and camels, all of which are still used in various parts of the world for the production of milk for human use. The significance of milk as the most wholesome single food available in nature has never been debated. It is as ancient as mankind itself. The role and consumption pattern of milk in the traditional diet varies widely in different regions of the world. The tropical countries have not been traditional milk consumers, whereas in Europe (especially Scandinavia) and North America, milk and milk products have been traditional parts of the diet.

Definition It is one of the important portion of milk which forms a fatty layer on top of milk when left un-disturbed. It is a prime component of milk and comprises mainly of milk fat. It may be defined as “that portion of milk which is rich in milk fat” meaning portion of milk into which larger portion of milk fat has been gathered.  According to FSSAI, 2011 Malai and Cream are defined as – Malai means the product rich in butter fat prepared by boiling and cooling cow or buffalo milk or a combination thereof. It shall contain not less than 25.0 per cent milk fat.

Introduction Makkhan (Makhan) is an indigenous(desi) butter obtained by hand churning of dahi using wooden beater (mathani). It is traditional unsalted butter characterized by its delectable and rich flavour. It is white in colour with slightly greenish tinge and has typical soft body and a smooth grainy texture with pleasant aroma. This product has been extensively used for dietary and religious practices since vedic times. The entire quantity produced forms an intermediate product for preparation of ghee (clarified butter fat). Nearly 30% of the total milk production goes for desi butter manufacture. The average yield of the product is very low ranging from 5.5-7.0% for every 100 kg milk used for the purpose. The chemical composition of the product is variable depending upon the method of manufacture. It is difficult to achieve the uniform standard of 20% moisture in the final product due to limitations in the technique adopted for its manufacture. The non fatty solids and lactic acid are derived from the method of preparation and preservation. Higher non fatty solids in makhan indicates use of self soured milk, while a high lactic acid content indicates prolonged storage and in sanitary conditions of manufacture.

Butter is one of the leading milk product in developed countries of the world. It serves as a balance wheel of dairy industry. Surplus milk is generally converted into butter to be used during the times of scarcity. It is an article of commerce and a sign if wealth. Butter is a fat concentrate, which is obtained by churning cream, gathering the fat into a compact mass and then working it for proper distribution of moisture and salt. The art of butter making has a long history. The manufacture of butter was confined to colder regions where gravity creaming was successful. The milk was allowed to stand undisturbed for 10-12 hours until layer of cream collects at the top.

Introduction The demand for butter as table spread has declined due to high cost, poor spreadability at low temperature, high saturated fat and cholesterol content, changing life style and increased demand for healthy products. Today food industry is actively involved in new product development, this includes new formulations and imitation of foods being designed to compete with or replace existing products based on their superiority in convenience, cost and quality. The wide acceptance of bread in regular diet among urban consumers (75 percent of all household) reflects around 8 percent rate of growth in bread consumption. With this increase, the requirement of a suitable spread to complement has also increased. Table spreads include a variety of spreadable semi-solid products such as fat spreads, cheese spread, peanut butter etc. Butter has also been blended with vegetable oils/fat to produce a product that retains dairy qualities of butter with enhanced spreadability.

Introduction Ghee is the pure clarified butter fat prepared chiefly from cream and/or desi butter (Makhan) to which no colouring matter is added.  Ghee manufacture has great significance and relevance to Indian masses and the dairy industry. Ghee is a very popular product since ancient time and has greater demand during festival and other ceremonial functions where use of ghee in food has been considered to delicacy due to its pleasing flavour and aroma. There are sufficient recorded evidence to prove that the manufacture of ghee originated from India and has been used extensively for religious and dietary purposes since Vedic times. Presently about 28% of total milk production is utilized for manufacture of about 1 million tones of ghee per annum. It is the traditional product with an established market. Cow ghee is golden yellow in colour, and is attributed unique therapeutic value.  The colour of buffalo ghee is greenish yellow due to presence of pigments called billirubin and billiverdin. Ghee is characterized by its pleasant, cooked and rich flavour. The preferred texture is of larger uniform size from grains having non-greasy consistency.

Introduction In the recent past there has been a great deal of questioning regarding role of milk fat in cholesterol metabolism and other body functions. The enormous wave against cholesterol containing foods has damaged the image and market growth of fat rich dairy products. This trend is due to presence of saturated fats and cholesterol that are known to increase the incidence of coronary heart diseases one of the common cause of heart attack. The educated and urban society is more health conscious about the presence of cholesterol in their diets. This has led to the greater demand of cholesterol free foods. Ghee being a saturated fat and containing little amount of cholesterol, is suspected to contribute towards coronary heart diseases. However, critically surveyed scientific literature indicates that there is no evidence of any association of milk fat with increased risk of coronary heart diseases. Age old and proven Ayurvedic system of medicine has proved the usage of ghee to induce several beneficial effects on human health and used extensively for therapeutic purpose like in treatment of skin allergy, respiratory diseases, curative for ulcers and eye diseases. This suggest that ghee is a valuable form of dietary fat.

Introduction The economic choice of any process is the criterion for efficient utilization of the by-product that is produced along side of main product. During manufacture of major dairy products, the dairy industry also ends up in producing different by-products. Various by-products of dairy industry are skim milk, butter milk , whey and ghee residue. Dairy industry is particularly confronted with the problem of economic utilization of whey and ghee residue. The techno-economical problems associated with utilization of these by-products, is now receiving considerable attention. More efficient, cost effective and sophisticated technologies have opened up new vistas for manufacture of number of derived by-products. Further more the market for dairy by-products, as an ingredients in other consumer food products like snacks, ready meals and microwavable food products, has been growing.

Over the past several years, there has been significant change in consumer perception on quality and food safety. Consumers are demanding healthy, nutritious and cost-effective products processed under controlled hygienic conditions. Food safety concern, in recent years, has become dominant and important. The requirement of food safety and quality assurance has never been so demanding as it is now. Globally food safety is being addressed independent of food quality. In anticipation of consumer demands on food safety, food sanitary standards at national and international levels are under constant review. Several inter governmental agencies/organizations are engaged in work related to quality assurance and food safety. Amongst these World Health Organization (WHO) and Codex Alimentarius Commission (CAC) play the major role in protecting public health and defining standards of quality and safety aspects of foods for regional and or world wide usage.