Automation of water dosing in butter production through real-time control of product moisture content

In butter production, accurate water dosing is critical — not just for compliance, but also for productivity. The legal maximum moisture content in butter is 16%, but to avoid any risk of exceeding this limit, producers typically stay conservative, operating at around 15%. However, every fraction closer to the 16% threshold—while still compliant—translates directly into higher yield.

The BUPAIC Solution

The BUPAIC (Butter Production Automation with In-line Control) project has developed an innovative real-time moisture measurement system using near-infrared (NIR) spectroscopy. Installed directly on the production line, this sensor-driven system enables automated water dosing by continuously monitoring the actual moisture content of the butter. This ensures maximum precision, improved product quality, and increased output.

Thanks to this technology, producers can confidently target a moisture content of 15.7%, significantly closer to the regulatory limit. For a plant producing 10,000 tonnes of butter annually, that 0.7% increase represents an additional 70 tonnes of butter — or €140,000 in added value per year at an average price of €2/kg.

Beyond moisture: a comprehensive quality tool

The BUPAIC system doesn't just monitor moisture. It also measures:

• Fat content with an accuracy of ±0.7%
• Salt content with an accuracy of ±0.16%
• Moisture content with an error margin below ±0.25%

This real-time insight empowers producers to fine-tune quality parameters throughout the process — not just at the end.

Looking ahead

Following the success of BUPAIC, Glaucor and Ilaçor have agreed to continue their collaboration by permanently installing the system on Ilaçor’s production line. The goal: to further refine measurement precision and drive continuous improvement in butter production.