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How is Condensed Milk Made?

Introduction to Condensed Milk Production

• Millions of cans of condensed milk are produced daily worldwide, commonly used in desserts, beverages, and fruits.

• The process transforms fresh milk into a concentrated, sweet, and long-lasting product, beginning from the acquisition of fresh milk to final packaging.

• Condensed milk originated in the 19th century when food preservation was challenging; Gil Borden patented the modern process in 1856.

Historical Context and Popularity

• During the American Civil War, condensed milk became a practical nutrient source for soldiers due to its stability compared to fresh milk.

• Post-war, it gained popularity among civilians and became a staple food item as production scaled up in Europe and America.

• Companies like Nestlé refined the production process and expanded distribution globally while maintaining the original formula.

Dairy Farming Practices

• The production begins on dairy farms where cows are fed balanced diets including fresh grass and mineral supplements for optimal health.

• Cows are milked using automated machines two to four times daily; each machine is designed to prevent injuries during milking.

• Freshly extracted milk is stored in refrigerated tanks at 4ºC with constant agitation to prevent cream separation.

Transportation and Quality Control

• Milk is transported in specialized tankers (28,000 L capacity), ensuring cold chain integrity within a four-hour journey to processing plants.

• Upon arrival at the plant, quality samples are taken for analysis based on fat content, density, acidity, microbiological purity, and antibiotic residues.

Processing Steps: From Reception to Pasteurization

• Only compliant batches proceed after quality checks; they move through centrifuges that remove impurities resulting in clean white milk.

• The pasteurization process involves heating at 72ºC for 15 seconds followed by rapid cooling to eliminate microorganisms without compromising nutrients.

Mixing Ingredients for Condensation

• After pasteurization, large quantities (10,000 L per batch) of milk are mixed with sugar (45 kg per 100 L), enhancing texture and sweetness characteristic of condensed milk.

Evaporation Process

• The mixture enters evaporators where water removal occurs under vacuum conditions across three connected bodies operating at different pressures.

• Approximately 60% of water is removed resulting in a thick concentrate with high density (1.28 g/mL).

Final Stages: Cooling and Packaging

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How is Condensed Milk Made?

Cooling and Preparation for Crystallization

• The cooling process takes approximately 2 minutes using double-flow heat exchangers, preventing clumping and preparing the product for controlled crystallization.

• A small amount of powdered lactose is added during this phase to serve as a nucleus for uniform sugar crystal formation, ensuring a smooth and homogeneous texture without graininess.

Stabilization and Packaging Process

• The product is kept in stainless steel tanks with slow agitators for about 40 minutes until it reaches the desired consistency before packaging.

• After stabilization, the condensed milk flows through closed pipes to aseptic filling machines that dispense precise amounts into various container sizes, from 390g packages to industrial 5kg containers.

Sealing and Sterilization

• Immediately after filling, containers undergo hermetic sealing; metal cans are sealed with double mechanical folds while plastic or flexible containers use thermal pressure sealing to prevent leaks and air entry.

• The next step involves sterilizing the containers in steam tunnels at 110ºC for 20 minutes, effectively destroying residual microorganisms and extending shelf life beyond 12 months without refrigeration.

Labeling and Storage

• Post-sterilization, jars are labeled with self-adhesive sheets at a rate of up to 120 units per minute, ensuring visual uniformity across the production line.

• Finished units are grouped into recyclable cardboard boxes containing between 12 to 24 units each. These boxes are then wrapped in plastic film for stability during transport.

Distribution Logistics

• The packaged products are moved via forklifts to storage chambers maintained at a constant temperature of 20ºC with controlled humidity, preserving texture and color until distribution.

• Condensed milk can be transported thousands of kilometers without losing quality or requiring refrigeration due to effective sealing and sterilization processes.