Process for the preparation of dry butter flake product having high milk solid content

A process for the preparation of dry butter-based flake product for incorporation into baked goods and flour confections, wherein said dry butter-based flake product comprises from substantially 0% to 2% moisture, from about 20% to about 60% dry dairy solids, with the balance being butterfat having less than 1% moisture content;

• wherein said dry dairy solids are naturally occurring milk solids from which substantially all water has been removed;
• wherein said butterfat is derived from whole milk;
• and
• wherein said butterfat exhibits standard butterfat solid fat index and melting points;
• said process comprising the steps of:
• (a) mixing said dry dairy solids and said butterfat so as to obtain a substantially homogenous mixture, said mixing step being carried out at a temperature of 35.degree. C. to 50.degree. C.;
• (b) transferring said homogenous mixture to a holding tank, and maintaining the temperature of said homogenous mixture at about 39.degree. C. to about 45.degree. C.;
• (c) continuously agitating said homogenous mixture while it is in said holding tank;
• (d) pumping said homogenous mixture to a tempering unit, continually agitating said homogenous mixture while in said tempering unit, and slightly cooling said homogenous mixture to about 29.degree. C. to 34.degree. C.;
• (e) transferring said slightly cooled homogenous mixture and depositing the same in a substantially thin substantially even layer on a moving belt;
• (f) passing said moving belt through a cooling tunnel so that any portion of said mixture remains in said cooling tunnel until it has cooled to a temperature of from about 5.degree. C. to about 12.degree. C.;
• (g) breaking said cooled mixture into discrete dry cooled butter-based flakes as it exits said cooling tunnel on said belt;
• and
• (h) removing said discrete dry cooled butter-based flakes from said belt for further handling and/or storage and/or shipping.