How to Make Chhana: Traditional and Modern Methods Explained

Chhana is one of the most important traditional dairy products in India, forming the base for beloved sweets like rasgulla, sandesh, rasmalai, and cham-cham. It is a soft, cottage cheese-like product made by acid coagulation of hot milk followed by whey drainage. While the basic principle behind chhana making has remained the same for centuries, the methods of production have evolved significantly – from open-fire karahi heating in small halwai shops to fully automated continuous systems in modern dairy plants. This post walks you through every major method of chhana manufacture, from the traditional batch process to the latest mechanized systems.

The science behind chhana making 🔗

Before looking at individual methods, it helps to understand the core science. Chhana production relies on destabilizing casein particles in milk through a combination of heat and acid. When milk is heated to a high temperature and an acidulant (such as citric acid, lactic acid, or sour whey) is added, the casein micelles lose their electrical charge stability. This causes them to aggregate into large clumps, forming a mass called a coagulum. During this aggregation, milk fat, whey proteins, lactose, and minerals get trapped within the protein network. The liquid that separates out is called whey.

The quality of chhana depends on several factors: the type of milk used, the coagulation temperature, the type and strength of the acid, and the speed and method of stirring. Cow milk is preferred for chhana production because it yields a softer, spongier product with a smooth texture – ideal for sweets like rasgulla. Buffalo milk, on the other hand, tends to produce harder, coarser chhana due to its higher casein and calcium content.

The traditional (batch) method 🔗

The traditional method is still widely used by halwais and small sweet shops across eastern India, particularly in West Bengal, Bihar, and Odisha. It is a batch process that handles small quantities of milk at a time.

Step-by-step process 🔗

In this method, all the milk meant for chhana making is brought to a boil in a large iron karahi over an open fire. The milk must be stirred continuously with a khunti (flat stirring ladle) to prevent scorching. Once boiling, the hot milk is ladled out in small batches of about 0.5 to 1.5 litres into a separate coagulation vessel. The required quantity of coagulant – traditionally cleansed sour chhana-whey stored in an earthen vessel from day to day – is then added to each batch. The mixture is gently stirred until complete coagulation occurs and the whey turns clear and greenish-yellow.

After coagulation, the contents are poured over a piece of clean muslin cloth stretched across another vessel to collect the whey. This process is repeated until all the milk is used up. The muslin cloth containing the collected curd is then tied into a bundle and hung up so that the whey drains out completely under gravity – no external pressure is applied. The resulting chhana is soft, moist, and ready for immediate use in sweet-making or for sale.

Key characteristics of the traditional method 🔗

The traditional method works well for small-scale production but has some clear limitations. Heating over open fire gives uneven temperature distribution, which can lead to inconsistent curd quality. The strength of sour whey varies from batch to batch depending on its age and storage conditions, making standardization difficult. There is also a high dependency on the skill and experience of the operator, and the process is labour-intensive. Despite these drawbacks, many artisan sweet-makers prefer this method because they believe the iron karahi and sour whey impart a distinctive flavour and texture to the chhana that modern methods cannot fully replicate.

The bulk method 🔗

The bulk method follows the same fundamental principles as the traditional batch method, but it is designed to handle larger volumes of milk – typically 5 to 20 litres – in a single coagulation step instead of processing small batches of 1-1.5 litres at a time.

How it differs from the batch method 🔗

In the bulk method, all the milk is boiled and then coagulated in one go in a larger vessel. The coagulant solution – often standardized citric acid or lactic acid rather than sour whey – is added slowly with uniform, constant stirring until clear whey separates out. Large stainless steel vessels or vats replace the traditional karahi, and steam jackets or electric heating elements provide more controlled and even heat distribution. Mechanical agitators may be used for stirring instead of manual ladles.

This method is suitable for commercial dairies and larger sweet shops that need to produce chhana in significant quantities while maintaining reasonable consistency. The use of standardized acid concentrations ensures more predictable results batch after batch. However, handling larger volumes of milk means that any error in coagulation temperature or acid quantity can affect a bigger batch, making careful monitoring essential.

The improved method 🔗

The improved method incorporates modern dairy equipment and controlled processing parameters to produce chhana of consistent quality. It represents a bridge between traditional practices and full-scale industrial production.

Equipment and process 🔗

The defining feature of this method is the use of a steam-jacketed stainless steel kettle. This single piece of equipment handles boiling, cooling, and coagulation of milk. Steam circulating between the double walls of the kettle heats the milk evenly, and when cooling is needed, tap water replaces the steam. This eliminates the problems of scorching and uneven heating associated with open-fire methods.

Coagulation is carried out at 80°C using a 1-2% citric acid solution, maintaining a coagulation pH of around 5.4. The acid is added within 30-60 seconds while slow, gentle stirring is applied. Slow stirring is important because vigorous agitation can cause excessive foam formation and break the curd into fine particles, which reduces yield and produces a grainy texture. Once complete coagulation is achieved, the mass is strained through muslin cloth just like in the traditional method.

Advantages over traditional methods 🔗

The improved method offers several clear benefits. The precise temperature control at 80°C ensures optimal protein denaturation without overcooking, which would make chhana tough. Citric acid is preferred as the coagulant because its strength is consistent and its flavour profile is neutral, unlike sour whey which varies in acidity. The stainless steel equipment is also easier to clean and sanitize, improving overall hygiene. This method is well-suited for medium-scale operations that want better quality control without investing in fully automated systems.

The continuous method 🔗

For large-scale industrial production, the continuous method represents the most advanced approach to chhana manufacturing. It was developed to address the limitations of batch processing – mainly inconsistency, high labour costs, and limited throughput.

How the continuous system works 🔗

A prototype continuous chhana-making machine with a capacity of about 40 kg per hour was developed at the National Dairy Research Institute (NDRI), Karnal. The system consists of several interconnected components: a balance tank, an injection chamber, a tubular heat exchanger, a cooling chamber, a mechanized strainer, and a whey collection tank.

In this process, standardized cow milk is pumped from the balance tank at a rate of approximately 250 litres per hour to the injection chamber. Here, culinary live steam is directly injected into the milk, rapidly raising its temperature to 90-95°C. The heated milk then comes into contact with the coagulant solution, whose flow rate is regulated in proportion to the milk flow. The milk-coagulant mixture passes through a holding coil that provides enough residence time for complete coagulation to occur.

After coagulation, the product is pumped to a double-jacketed cooling tank where it is brought down to room temperature. The cooled coagulated mass is then directed to a mechanical strainer – a double-jacketed inclined sieve – where whey is drained off efficiently. The finished chhana, with a moisture content of about 55-65%, is collected through the outlet, packaged, and stored in a cold room. The separated whey goes to a separate tank for further use or processing.

Benefits of continuous production 🔗

The continuous method offers several significant advantages for industrial-scale operations. It provides uniform product quality because processing parameters like temperature, acid dosage, and contact time are precisely controlled and remain constant throughout production. Labour requirements are drastically reduced since the system operates with minimal manual intervention. Throughput is much higher compared to batch methods, making it economical for large dairy plants. The enclosed system also improves hygiene and sanitation, reducing the risk of contamination. Additionally, recent research into technologies like centrifugal whey removal has shown that the spin speed and centrifugation time can be optimized to produce chhana with specific softness and moisture levels, further enhancing product consistency.

Comparing all four methods 🔗

Each method has its place depending on the scale, investment capacity, and quality requirements of the producer. The traditional batch method is ideal for artisanal sweet shops producing small quantities where the unique character of handmade chhana is valued. The bulk method suits medium-sized commercial operations that need higher throughput without major equipment investment. The improved method is the best fit for producers seeking consistent quality through better temperature and acid control at a moderate scale. The continuous method is designed for large dairy plants that need high-volume, round-the-clock production with minimal labour and maximum consistency.

A key consideration across all methods is the type of milk. As noted earlier, cow milk is preferred for most chhana-based sweets because of its softer coagulum. When buffalo milk must be used, modifications such as standardizing the fat content to 5%, adding 0.05% sodium citrate, and homogenizing the milk can help produce chhana with acceptable quality for sweet-making.

Quality factors that matter across all methods 🔗

Regardless of the production method, certain factors consistently influence the quality of the final chhana.

Coagulation temperature 🔗

The temperature at which acid is added to milk is critical. A temperature of around 80°C is generally considered optimal for cow milk chhana. Too-high temperatures can cause the protein to over-denature, making the chhana tough and rubbery. Too-low temperatures may result in incomplete coagulation and excessive moisture retention.

Type and concentration of coagulant 🔗

Citric acid and lactic acid at concentrations of 1-2% are the most commonly used coagulants in modern production. Sour whey is still popular in traditional settings but gives less predictable results. Research has shown that organic acid coagulants at 1% concentration can effectively substitute sour whey, though the resulting chhana may be slightly firmer – better suited for dry sweets like sandesh rather than spongy sweets like rasgulla.

Stirring and draining 🔗

Gentle stirring during acid addition is essential. Aggressive stirring breaks the coagulum into fine particles, leading to higher solids loss in the whey and a lower yield. Similarly, the draining method matters – the chhana should be allowed to drain naturally through muslin cloth without excessive pressing, which would make it dry and hard.

Freshness of milk 🔗

Milk with developed acidity (not fresh) produces chhana with a sour smell and bitter taste, making it unsuitable for sweet-making. Only fresh, sweet milk with a minimum fat level of 4-5% is considered appropriate for producing good quality chhana.

The road ahead for chhana production 🔗

The mechanization of chhana production is still an evolving field. While the continuous method addresses many issues of scale and consistency, researchers have emphasized that further work is needed to develop affordable, small-scale mechanized systems suitable for the thousands of small producers who currently make chhana manually. Innovations like centrifuge-based whey removal, automated kneading machines, and real-time pH monitoring systems are making production more precise and efficient. As demand for chhana-based sweets grows both domestically and in export markets, the ability to produce consistent, safe, and high-quality chhana at scale will become increasingly important.

What do you think? Can fully mechanized chhana ever match the flavour and texture that experienced halwais achieve through traditional methods? And as Indian sweets gain popularity worldwide, how important will standardized production methods become for meeting international food safety requirements?

References

1. https://ebooks.inflibnet.ac.in/ftp04/chapter/traditional-indian-dairy-products-chhana-based-sweetmeats/
2. http://dairy-technology.blogspot.com/2014/01/methods-of-manufacture-of-chhana.html
3. https://www.agricultureinindia.net/dairy-science/chhana/chhana-composition-production-storage-and-uses-dairy-technology/20410
4. https://fmtmagazine.in/mechanization-of-traditional-indian-dairy-products/
5. https://www.researchgate.net/publication/339759153_An_overview_of_mechanization_in_chhana_production
6. https://egyankosh.ac.in/bitstream/123456789/9526/1/Unit-6.pdf
7. https://www.researchgate.net/publication/314637194_Modernization_of_Manufacturing_Process_for_Traditional_Indian_Dairy_Products