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Design and Development of an Automated and Quality Controlled System for Traditional Butter and Ghee Production

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Design and Development of an Automated and Quality Controlled System for Traditional Butter and Ghee Production Ahmad Aljaafreh, Riadh Al-Tahiri, Ahmad Abadleh, WSEAS TRANSACTIONS on ENVIRONMENT and DEVELOPMENT Ayman M. Mansour, Murad Alaqtash Design and Development of an Automated and Quality Controlled System for Traditional Butter and Ghee Production AHMAD ALJAAFREH Department of Communication, Electronics and Computer Engineering, Tafila Technical University, Tafila, 66110, JORDAN [email protected] RIADH AL-TAHIRI Al-Tahiri and Al-Kawaleet Dairy Company, Ader, Karak, JORDAN [email protected] AHMAD ABADLEH Department of Computer Science, Mutah University, Mutah, 61710, Karak, JORDAN [email protected] AYMAN M. MANSOUR Department of Communication, Electronics and Computer Engineering, Tafila Technical University, Tafila, 66110, JORDAN [email protected] MURAD ALAQTASH Department of Communication, Electronics and Computer Engineering, Tafila Technical University, Tafila, 66110, JORDAN [email protected] Abstract: - Traditionally, Jordanian butter has always been made from yogurt. Raw milk of sheep are collected, fermented, and then churned by mechanical shaking until butter granules are formed. A fter extracting the butter, the remaining buttermilk, called Makheedh or Shaneena in Jordan, is used to produce a type of dry yogurt called Jameed, a local dairy product in Jordan. The traditional process of churn and Jameed production is primitive and time-consuming. Moreover, many challenges may affect the quality of products such as poor sanitation, lack of effective milk cooling, and absence of milk pasteurization. Observations made of traditional butter-making by smallholders have indicated that the process should be improved by increasing the efficiency of fat extraction from the yogurt and reducing the processing time, thereby improving the economic return. The main objective of this work is to automate the process of traditional Jameed and butter production, as well as improve the quality of the products. To achieve this goal and overcome all production problems of the traditional process, a system was designed and developed to churn milk and produce butter rapidly and consistently. Several experiments were performed to select the optimal churn parameters such as rotor velocity, churn temperature and time. Many experiments were also performed to select the best sensors that can be used to control the whole process including heating, cooling, fermentation, and churn. Key-Words: - Dairy Mechanization, Butter Churn, Process Automation, Quality Controlled, Jordanian Jameed. 1 Introduction made of animal materials like animal leather. Later, The butter churn process used to make butter by other materials like wood, metal or glass were used shaking up t he yogurt. The agitation of yogurt is as containers to churn butter. In a manual churn done by mechanical motion, which disrupts fat process, a human being decides to end the churning globules and changes emulsion from oil in water to process when a satisfying quantity or quality of fat water in oil. Butter grains are formed by breaking or buttermilk is collected. The local churn process is down the milk fat globules membranes [1]. The still a m anual process although there were many churn causes these grains to fuse from each other attempts toward churn automation [2], [3], [4], and and then form the butter. The liquid left out without [5]. fat is called buttermilk. Butter churns have been Locally, the raw milk of sheep is processed to varied over time. E arly local butter churns were produce buttermilk, butter, ghee, and Jameed, local E-ISSN: 2224-3496 478 Volume 15, 2019 Ahmad Aljaafreh, Riadh Al-Tahiri, Ahmad Abadleh, WSEAS TRANSACTIONS on ENVIRONMENT and DEVELOPMENT Ayman M. Mansour, Murad Alaqtash and traditional homemade products in Jordan. Fig. 1 The traditional process of Jameed and ghee illustrates the traditional process of Jameed and production in Jordan is primitive and time- ghee production from sheep milk. The process starts consuming. Moreover, many challenges may affect by collecting milk, usually using plastic or the quality of products such as poor sanitation, bad aluminum containers with very low standards of microbiological quality of milk due to bad hygiene cleaning. Workers then heat the milk to the during milking, lack of effective milk cooling, and fermentation temperature by a direct gas fire absence of milk pasteurization. Plastic and following by adding the starter (yogurt) to the aluminum containers are usually used in all heated milk for the fermentation process. Through processing steps, both of them are not suitable for the fermentation, the milk is incubated at a warm food production. Furthermore, lack of cooling in the temperature for at least three hours. Starter bacteria milk collection stage reduces the quality of milk due convert lactose to lactic acid which converts the to the growth of microorganisms which leads to liquid milk to a jelly-like yogurt. A fter acidity development and production of many fermentation, the product is cooled by adding materials that badly affect the human health and chilled water and ice to start churn. Most of the production process [6]. Enzymes activity time, churn is done using a plastic container with accelerated due to high storage temperature leads to low hygiene standards. The churn usually takes fat degradation which produces rancidity in the final about one hour to make the butterfat float on the products especially the ghee. While protein surface. Workers collect the butterfat and store it in degradation gives rise to unwanted taste in the plastic drums. The produced butter is usually Jameed. The absence of milk pasteurization leads to transformed into ghee by cooking butter with at a very dangerous health situation due to the transfer least ten different herbs to overcome the rancidity of milk-borne disease from animal to human as taste. The heat evaporates the water and shown in Table 1. Many other microorganisms can concentrates the fat in the ghee. Furthermore, contaminate the milk from the farmer, the workers, Jammed is produced from buttermilk which is called and the environment which can affect badly human Makheedh or Shaneena in Jordan. The buttermilk health and the process. There is no control produced after churn is heated without agitation to equipment for heating and cooling of the milk and allow the whey to be separated from the buttermilk. the products, fermentation process and the acidity The heated buttermilk is then filled in a cloth bags, development of the milk and churning processes. adding salt to it, and then kept for three days to Also, direct gas fire for heating can rise coked flavor remove the whey as m uch as possible. After that, and brown color to the final products. A dding the dehydrated buttermilk is mixed by hand and chilled water and ices to the products for cooling formed as balls of Jameed. Jammed balls are then increase the possibility of contamination. dried and became ready to be sold in the market. Table 1. The causative organisms of diseases from Adding Collecting Heating animal to human. Starter Milk Milk (yogurt) Disease Causative organisms Mastitus Staphylococcus aureus Incubating Streptococcus uberis Milk Streptococcus agalactiae Escherichia coli Listeria monocytogenes Churn Johne's disease Mycobacterium avium Subsp paratuberculosis Tuberculosis Mycobacterium bovis Collecting Butter Separating Buttermilk Mycobacterium tuberculosis Brucellosis Brucella abortus Producing Ghee Producing Jameed Brucella melitensis Fig. 1. The traditional process of Jameed and ghee production from sheep milk. Local butter, fat, ghee, and Jameed are all almost homemade products. C onsumers and food makers who use local products always demand to have their E-ISSN: 2224-3496 479 Volume 15, 2019 Ahmad Aljaafreh, Riadh Al-Tahiri, Ahmad Abadleh, WSEAS TRANSACTIONS on ENVIRONMENT and DEVELOPMENT Ayman M. Mansour, Murad Alaqtash foods of higher standards and better quality. refrigerator cooling system is composed of a Nutritional value, health benefits, and safety are refrigerator compressor, temperature sensor, and a essentials to food quality. water jacket layer around the tank to heat or cool the Automation is using technologies to operate product automatically. The system also contains a machines and systems without human intervention special agitator which can move in different speeds. to achieve higher operation performance than A low speed for agitating the milk and the product manual operation [7]. Sensors, actuators, and during heating and cooling and a high speed for controllers are the three main components of the churning the yogurt. The agitator has a single phase industrial automation system. electric motor 240V attached with a stainless round The ultimate goal of this work is to automate the shape shear impeller with a diameter of 15 cm and process of Jameed and butter production, as well as sharp teeth as shown in Fig. 3. The main controller improve the microbiological quality of the products consists of motor drive, inverter, to control motor to get hygienic products. Automation ensures high- speed, timer to set the timing parameters, and quality products with excellent flavors and a high temperature control keypad to set the desired churn solubility characteristic for Jameed and butter. temperature. The rest of this paper is organized as follows: The system is equipped with many sensors to Sec.2 presents the system design. Followed by the control and monitor the heating, fermentation, and Jameed manufacturing process in Sec.3. Then, Sec.4 churn processes. Conductivity is measured by describes the experimental methodology and setup. electrodeless conductivity stick meter 5JI. To The experimental results are discussed in Sec.5. automate the churn process, a proper sensor is Sec.6 presents the conclusion. needed to end the churning process when a sufficient amount of butter is collected [8] and [9]. We assumed that the conductivity, density, and 2 System Design viscosity changes according to the process. This Fig. 2 shows the system developed in this work assumption is based on the fact that when the butter to automate the churn process. It consists of a 200- is extracted from the yogurt the conductivity liter stainless tank with a drain outlet.
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