Development and evaluation of a processing sector model for butter manufacture using a mass balance technique at two dairy processing sites

The butter manufacturing process at two different commercial dairy processing sites in Ireland was evaluated using a mass balance approach to develop, evaluate and validate a processing sector model of the flow of milk fat from intake to final product. The mass balance was represented as a function of fat intake = fat in products + fat losses + recycled fat. Representative samples of all products, namely whole milk, cream, skim milk, butter, buttermilk and cleaning-in-place streams (cream silo flush, butter churn residue and sludge), were collected from two different sites. Milk fat levels and product quantities were measured to obtain the fat outputs. Total fat losses at the end of butter production ranged between 1.90% and 2.25% of the total fat input for both sites. Three different scenarios were examined to evaluate the model: S1 (Animal Breed) high genetic merit (Elite) and national average (NA) Holstein Friesian (HF) cows were evaluated, for their effect on the net value of milk; S2 (Product Portfolio) a mixed product portfolio of cheese, butter and skim milk powder (SMP) was compared to a product portfolio comprised of butter alone; and S3 (Process Efficiency) the impact of varying process losses on net values of milk and the quantities of products produced was simulated. The value per 1000 L of milk for S1 was €410.69 and €393.20 for Elite and NA cow’s milk, respectively. For S2, the butter-only product portfolio returned €355.10, whereas the mixed-products portfolio returned €369.60. Lastly, S3 corresponding returns for 1%, 2.2% and 5% losses was €365.90, €361.47 and €351.12, respectively.