The Bilona Process: Why This Ancient Method Preserves More Nutrition
Your great-grandmother didn't have a food science degree.
She didn't understand fatty acid profiles, fat-soluble vitamin degradation, or the molecular structure of butyric acid.
But she knew something that industrial food manufacturers have forgotten: the way you make something matters as much as what you make it from.
The Bilona method—the traditional process of making ghee that has been practiced in Indian villages for over 5,000 years—isn't just a cultural artifact. It's a sophisticated nutritional preservation system, developed through generations of observation and refinement.
This guide explains exactly what the Bilona process is, how each step contributes to nutritional preservation, and why modern science is validating what traditional wisdom always knew.
What Does "Bilona" Actually Mean?
The word "Bilona" comes from Hindi, referring to the traditional wooden churning tool used in Indian households for centuries.
But Bilona isn't just a tool. It's an entire philosophy of ghee-making.
The Bilona (also spelled "Bilona" or "Valona" in different regions) is a wooden churner—typically made from neem, mango, or other hardwoods—with a long handle and a disc-shaped or bulbous bottom. It's operated using a rope wrapped around the handle, pulled alternately from both sides to create a rhythmic, bi-directional churning motion.
This motion isn't random. It's precisely calibrated by tradition to:
- Extract butter from cultured curd at optimal temperature
- Preserve the delicate structure of fat molecules
- Maintain the integrity of heat-sensitive nutrients
- Create the distinctive texture and flavor of authentic ghee
When we talk about "Bilona ghee," we're not just talking about ghee made with a particular tool. We're talking about an entire process—from milk collection to final product—that prioritizes nutrition and quality over speed and cost.
The Complete Bilona Process: Step by Step
Understanding why Bilona preserves nutrition requires understanding each step of the process. Let's walk through the traditional method in detail.
Step 1: Whole Milk Collection
What happens:
Fresh, full-fat milk is collected from buffalo or cows—ideally from animals that graze freely on natural pastures. The milk is collected in clean vessels, typically early in the morning when it's freshest.
Critical details:
- The milk is NOT skimmed or separated at this stage
- Milk should be processed within hours of collection
- Animals should be free from synthetic hormones and routine antibiotics
- Traditional practice favors indigenous breeds over hybrid varieties
Why it matters for nutrition:
Whole milk contains fat-soluble vitamins (A, D, E, K) integrated within its natural fat globules. These globules also contain phospholipids, CLA (conjugated linoleic acid), and other beneficial compounds. When you start with whole milk—rather than separated cream—you preserve this complete nutritional matrix.
The health of the animal directly impacts milk quality. Grass-fed, free-grazing animals produce milk with:
- 3-5 times more CLA than grain-fed animals
- Higher omega-3 fatty acid content
- More beta-carotene and vitamin E
- Greater vitamin K2 concentration
Starting with nutritionally rich milk is the foundation everything else builds upon.
Step 2: Boiling and Cooling
What happens:
The whole milk is gently boiled once, then allowed to cool naturally to room temperature (approximately 35-40°C).
Critical details:
- Single boiling, not repeated heating
- Natural cooling, not rapid refrigeration
- Temperature must be warm enough for culture to activate but not hot enough to kill it
Why it matters for nutrition:
Gentle, single-stage boiling serves multiple purposes:
Pathogen elimination: Boiling eliminates harmful bacteria without the extended high-heat exposure of ultra-pasteurization, which can denature proteins and damage heat-sensitive vitamins.
Enzyme preservation: Unlike ultra-high-temperature (UHT) processing used commercially, traditional boiling preserves more of the milk's natural enzymes that aid digestion.
Vitamin protection: While some vitamin C is lost during boiling (milk isn't a significant source anyway), the fat-soluble vitamins A, D, E, and K remain largely protected within the fat globules.
The cooling phase is equally important. Rapid cooling (refrigeration) can shock the milk and affect its structure. Natural cooling allows for gradual temperature reduction, keeping the milk in optimal condition for the next critical step.
Step 3: Curd Formation (Fermentation)
What happens:
Once cooled to the right temperature, a small amount of natural culture (called "jaman" or "starter") from a previous batch of curd is added. The milk is then left undisturbed for 8-12 hours to ferment into thick, creamy curd (dahi).
Critical details:
- Natural culture only—no commercial bacterial strains
- Fermentation time of 8-12 hours (varies slightly with ambient temperature)
- Curd should be thick but not sour
- The entire vessel is covered and kept in a warm place
Why it matters for nutrition:
This fermentation step is perhaps the most significant difference between Bilona and industrial ghee-making. It's also the step that commercial producers skip entirely.
Here's what fermentation accomplishes:
Probiotic development: The culturing process develops beneficial lactic acid bacteria (Lactobacillus species). While most probiotics don't survive the final heating process, their metabolic byproducts remain and contribute to ghee's nutritional profile.
Fatty acid transformation: Fermentation modifies the fatty acid profile of milk fat. Research published in the Journal of Dairy Science has shown that fermented dairy products contain higher levels of conjugated linoleic acid (CLA) than non-fermented equivalents. The bacterial cultures actually synthesize additional CLA during fermentation.
Pre-digestion of lactose: Bacterial cultures consume much of the milk's lactose during fermentation, resulting in a lower-lactose final product. This is why traditionally made ghee is often tolerated by people with lactose sensitivity.
Vitamin B synthesis: Certain bacteria produce B vitamins during fermentation, adding to the nutritional value of the curd.
Flavor compound development: Fermentation creates the distinctive flavor precursors that give Bilona ghee its complex, nutty taste—compounds that simply don't exist in cream-based ghee.
The industrial alternative skips all of this. Commercial ghee production uses mechanical cream separators to extract cream directly from fresh milk. No fermentation. No probiotic development. No fatty acid transformation. No enhanced CLA. The cream goes straight to heating.
This single difference—fermentation versus no fermentation—accounts for much of the nutritional gap between Bilona and commercial ghee.
Step 4: Bilona Churning
What happens:
The cultured curd is churned using the traditional wooden bilona in a bi-directional motion. This rhythmic churning gradually separates cultured butter (makkhan) from buttermilk (chaas).
Critical details:
- Wooden bilona, not metal blades or industrial separators
- Bi-directional motion (alternating clockwise and counter-clockwise)
- Slow, rhythmic churning—not high-speed agitation
- Churning done at cool temperature (not refrigerated, not heated)
- Motor-powered bilonas replicate the exact traditional motion with greater consistency
Why it matters for nutrition:
Gentle extraction: The bi-directional motion of the bilona extracts butter without generating significant heat or mechanical stress. Industrial cream separators spin at thousands of RPM, generating friction heat and potentially damaging delicate fat structures.
Fat globule preservation: Milk fat exists in spherical globules surrounded by a membrane of phospholipids and proteins. Gentle bilona churning preserves these structures better than high-speed mechanical separation. These membranes contain nutritionally valuable compounds including phosphatidylcholine and sphingomyelin.
Temperature control: Traditional churning is done at ambient temperature (cooler in morning hours). This prevents the premature melting of butter and maintains the structural integrity of fat-soluble vitamins embedded within the fat.
Complete extraction: Because the bilona churns fermented whole-milk curd (not just cream), it extracts butter that contains the full spectrum of fat-soluble nutrients. Cream separation, by contrast, captures only the fat that rises to the top—missing nutrients integrated throughout the milk.
The wooden bilona itself matters. Wood doesn't conduct heat like metal, preventing temperature spikes during churning. Traditional bilonas made from neem wood may also impart subtle antimicrobial properties, though this requires more research.
Hand-churning vs. motor-powered bilona:
A common question is whether motor-powered churning is "authentic." Here's the truth: the magic of Bilona lies in:
- Churning curd (not cream)
- Using the bi-directional bilona motion (not industrial separator spinning)
- Maintaining controlled, cool temperatures
Whether the bilona is powered by human hands or a motor doesn't change the fundamental process. Motors provide consistency; the bilona provides authenticity. At 24 Karat Manthan, we use motor-powered wooden bilonas that replicate the exact traditional motion, ensuring every batch meets the same standard.
Step 5: Makkhan Collection
What happens:
After churning, cultured butter (makkhan) floats to the surface and is carefully collected by hand. The remaining liquid is buttermilk (chaas)—itself a nutritious, probiotic-rich beverage.
Critical details:
- Makkhan is collected without squeezing or pressing
- It has a distinctive cultured aroma—different from commercial butter
- Color is naturally white to pale cream (for buffalo) or light yellow (for cow)
- Texture is soft, slightly grainy, not uniformly smooth
Why it matters for nutrition:
The makkhan produced from cultured curd is nutritionally distinct from butter made directly from cream:
- Higher butyric acid content: Fermentation enhances short-chain fatty acid development
- Greater CLA concentration: Bacterial transformation during culturing increases CLA
- Richer flavor compounds: Diacetyl, acetoin, and other flavor molecules develop during fermentation
- Retained milk solids: Unlike commercial butter that's often "washed" to remove milk solids, traditional makkhan retains these nutritious components until the final heating stage
This makkhan is the raw material for ghee—and its quality directly determines the final product's nutritional value.
Step 6: Slow-Cooking (Ghee Clarification)
What happens:
The collected makkhan is placed in a heavy-bottomed vessel and heated slowly over controlled flame. As it heats, water evaporates, milk solids separate and sink, and pure golden ghee emerges.
Critical details:
- Low to medium flame—never high heat
- Constant monitoring (traditional method relies on sight, sound, and smell)
- Heating continues until water fully evaporates (bubbling stops)
- Milk solids turn light brown and sink to bottom
- Characteristic nutty aroma develops
- Ghee turns clear and golden when held to light
- Small-batch production ensures consistent quality and attention
Why it matters for nutrition:
The slow-cooking phase is where the most damage can occur—or be prevented.
Temperature control is everything. Ghee's smoke point is approximately 250°C (482°F). As long as cooking temperature stays well below this (which slow-cooking ensures), the ghee's fatty acids remain stable and unoxidized.
What slow-cooking accomplishes:
Complete moisture removal: Water must be fully evaporated for ghee to be shelf-stable. Rushing this process with high heat can cause uneven evaporation and potential burning. Slow cooking ensures thorough, gentle moisture removal.
Maillard reaction development: The gentle browning of milk solids creates the complex flavor compounds that distinguish quality ghee. This reaction also produces antioxidant compounds. Rushed cooking can burn these solids, creating off-flavors and potentially harmful compounds.
Vitamin preservation: Fat-soluble vitamins (A, D, E, K) are stable at the temperatures used in slow-cooking (typically 100-120°C during water evaporation, rising to about 150°C at the end). Industrial high-heat processing can reach temperatures that degrade these vitamins.
Butyric acid retention: Butyric acid has a relatively low boiling point (164°C). Slow-cooking at controlled temperatures minimizes butyric acid volatilization, while rapid high-heat processing can cause significant losses.
The artisan's skill:
Traditional ghee-making relies on sensory expertise, not timers:
- Sight: The ghee becomes progressively clearer; milk solids sink and turn golden-brown (not dark brown or black)
- Sound: Vigorous bubbling (water evaporating) gradually becomes a gentle crackling (final moisture leaving)
- Smell: Raw butter smell transforms into a distinctive nutty, caramelized aroma
- Touch: A drop of ghee between fingers feels smooth, not gritty
This expertise, developed over generations, ensures the ghee is perfectly cooked—not under-cooked (residual moisture leads to spoilage) or over-cooked (damaged nutrients and burnt flavor).
Step 7: Filtering and Storage
What happens:
Once cooking is complete, the ghee is allowed to cool slightly, then filtered through clean cotton cloth to remove any remaining milk solids. The clear ghee is stored in glass or food-grade containers.
Critical details:
- Filtering while ghee is still warm (but not hot) for easy flow
- Clean, dry cotton cloth—no synthetic materials
- Glass containers preferred for long-term storage
- Stored away from light and heat
- Clean, dry spoon used for every serving
Why it matters for nutrition:
Proper filtering and storage protect the nutritional investment made throughout the process:
Removal of milk solids: While milk solids contribute flavor during cooking, their presence in the final product would cause faster spoilage and potential burning during cooking use. Complete removal ensures purity and stability.
Container choice: Glass doesn't react with ghee's fatty acids, preventing any chemical leaching. Plastic containers, especially when exposed to heat, may leach compounds into the ghee.
Light protection: Light accelerates the oxidation of unsaturated fatty acids and degrades fat-soluble vitamins. Proper storage preserves these nutrients for the ghee's full shelf life.
Moisture prevention: Even small amounts of moisture can promote microbial growth and rancidity. Using dry utensils and keeping containers properly sealed maintains ghee's natural stability.
Properly made and stored Bilona ghee remains nutritious and fresh for 12+ months without refrigeration—a testament to the method's inherent preservation properties.
The Science of Preservation: Why Bilona Outperforms Industrial Methods
Now that we understand the complete process, let's examine the specific nutritional differences between Bilona and industrial ghee production.
Industrial Ghee: The Modern Shortcut
Commercial ghee production typically follows this abbreviated process:
- Milk is collected (often pooled from multiple sources)
- Cream is mechanically separated from milk using centrifugal separators
- Cream is heated directly to make butter
- Butter is heated at high temperature to make ghee
- Product is filtered and packaged
Time from milk to ghee: 2-4 hours
No fermentation. No culturing. No traditional churning.
The Milk-to-Ghee Ratio: What It Reveals
One of the clearest indicators of processing method is the milk-to-ghee ratio:
| Method | Milk Required per Litre of Ghee |
|---|---|
| Bilona Method | 17-20 litres |
| Commercial Method | 15-18 litres |
Why does Bilona require more milk? Because it extracts butter from cultured whole-milk curd—not just cream. The commercial method separates cream first, capturing more fat per litre of milk but missing the nutritional benefits of fermentation and whole-milk processing.
This difference in yield directly impacts cost. Authentic Bilona ghee will always be more expensive than industrial ghee—because it genuinely requires more raw material and more time.
Comparative Nutrient Analysis
| Nutrient/Compound | Bilona Method | Industrial Method | Why the Difference |
|---|---|---|---|
| CLA (Conjugated Linoleic Acid) | Higher | Lower | Fermentation enhances CLA synthesis |
| Butyric Acid | Preserved | Partially lost | Slow cooking prevents volatilization |
| Vitamin A | Well-preserved | Variable | Gentle heat protects carotenoids |
| Vitamin D | Preserved | Variable | Fat-soluble, stable in slow-cook |
| Vitamin E | Preserved | Reduced | Antioxidant vulnerable to high heat |
| Vitamin K2 | Preserved | Reduced | Heat-sensitive above 180°C |
| Omega-3 Fatty Acids | Preserved | Often oxidized | Slow processing prevents oxidation |
| Phospholipids | Retained | Often discarded | Cream separation loses milk membrane |
| Flavor Compounds | Complex, developed | Simple, flat | Fermentation creates flavor precursors |
The Fermentation Factor
Let's examine fermentation's impact more closely, since this is the step industrial producers eliminate entirely.
Study evidence: Research published in the International Dairy Journal found that fermented dairy products showed significantly higher levels of bioactive compounds compared to their non-fermented equivalents. The fermentation process:
- Increased CLA content by 40-60% in some studies
- Enhanced vitamin B12 levels
- Improved mineral bioavailability
- Created bioactive peptides with potential health benefits
The implication: By skipping fermentation, industrial ghee production forfeits these enhancements entirely. The cream used for industrial ghee has the same nutritional profile as fresh cream—none of the fermentation benefits are captured.
The Heat Factor
The temperature at which ghee is made significantly impacts its final nutritional profile.
Slow-cooking temperatures (Bilona):
- Water evaporation phase: 100-110°C
- Clarification phase: 110-130°C
- Final phase: 130-150°C
- Small batches allow for precise control
Industrial high-heat processing:
- Often uses steam-jacketed kettles at 160-180°C
- May use vacuum drying at elevated temperatures
- Optimized for speed, not nutrient preservation
- Large batches make temperature control difficult
What's lost at higher temperatures:
- Vitamin E: Begins degrading above 170°C
- Vitamin K2: Sensitive to temperatures above 180°C
- Butyric acid: Volatilizes progressively above 160°C
- Flavor compounds: Delicate aromatics destroyed by high heat
- Antioxidants: Carotenoids degrade at elevated temperatures
The 20-40°C temperature difference between traditional and industrial processing may not sound significant, but nutrient degradation isn't linear—it accelerates rapidly as temperature increases.
The Mechanical Factor
The difference between bilona churning and centrifugal separation affects more than just tradition.
Centrifugal separators:
- Spin at 6,000-10,000 RPM
- Generate significant friction heat
- Forcibly separate fat from other milk components
- Can damage fat globule membranes
- Process in seconds
Bilona churning:
- Rhythmic bi-directional motion
- No significant heat generation
- Gentle separation over 45-60 minutes
- Preserves fat globule structure
- Extracts butter from cultured whole-milk curd, not just cream
The mechanical stress of centrifugal separation can damage the phospholipid membranes surrounding fat globules. These membranes contain nutritionally valuable compounds. While research specifically comparing bilona vs. centrifugal separation is limited, the principle of gentle processing preserving delicate structures is well-established in food science.
What Makes Buffalo Bilona Ghee Nutritionally Distinct
While the Bilona method applies to both cow and buffalo ghee, buffalo ghee offers unique nutritional characteristics worth understanding.
Buffalo Milk Composition
Buffalo milk naturally contains:
| Component | Buffalo Milk | Cow Milk |
|---|---|---|
| Fat content | 7-8% | 3-4% |
| Protein | 4.5-5% | 3-3.5% |
| Calcium | Higher | Lower |
| Magnesium | Higher | Lower |
| Phosphorus | Higher | Lower |
| Vitamin A | Higher | Lower |
How This Translates to Ghee
When this richer milk undergoes the Bilona process, the resulting ghee:
- Denser in fat-soluble vitamins: More vitamin A, D, E per tablespoon
- Higher butyric acid content: Buffalo milk fat contains proportionally more short-chain fatty acids
- Greater mineral traces: While ghee is primarily fat, trace minerals remain
- More CLA per serving: Higher starting fat content means more CLA in the final product
- Superior cooking stability: Higher saturated fat ratio means greater heat stability
The Color Question
Authentic buffalo ghee is naturally creamy white to pale yellow—not golden yellow.
The yellow color in cow ghee comes from beta-carotene, which buffalo convert more efficiently to vitamin A (hence the white color). Yellow color in buffalo ghee often indicates:
- Adulteration with cow ghee
- Added colorants
- Blending with vegetable oils
Pure buffalo Bilona ghee's white color is not a deficiency—it's a marker of authenticity.
→ Learn more about Buffalo Bilona Ghee and how to identify the real thing
How to Identify Authentic Bilona Ghee
Understanding the process helps you identify products that actually follow it.
Authentic Bilona Ghee Characteristics
Texture:
- Dense and grainy, especially when cool
- Not uniformly smooth like industrial ghee
- May show natural variations between batches
Aroma:
- Deep, rich, nutty
- Never bland, flat, or artificially perfumed
- Distinctly different from cream-based commercial ghee
Color:
- Buffalo: Creamy white to pale yellow
- Cow: Light to medium golden yellow
- Never artificially bright or uniform
Taste:
- Complex, layered flavors
- Slightly sweet undertones
- Rich mouthfeel without greasiness
- Leaves no waxy residue on palate
Price:
- Authentic Bilona requires 17-20 litres of milk per litre of ghee
- Industrial methods require only 15-18 litres
- If it's priced like industrial ghee, it probably is industrial ghee
Red Flags to Avoid
Too cheap: Real Bilona ghee costs more because it requires more milk and more time. Suspiciously low prices indicate industrial production or adulteration.
Perfectly uniform: Natural products have natural variation. If every jar looks exactly identical, industrial standardization is likely.
No source information: Authentic producers can tell you exactly where their milk comes from. Vague or missing sourcing information suggests pooled commodity milk.
Added ingredients: Pure ghee needs nothing added. "Fortified," "enriched," or "blended" labels indicate a processed product.
Artificial smell: Chemical or artificial aromas suggest additives or flavoring to mask inferior product.
→ How to test ghee purity at home
Why the Bilona Revival Matters
The resurgence of interest in Bilona ghee isn't just nostalgia—it's a response to what industrial food processing has cost us.
What We Lost
When families switched from traditional ghee to industrial ghee and refined vegetable oils:
- Nutrient-dense traditional fat was replaced with nutrient-poor alternatives
- Complex flavor profiles gave way to bland uniformity
- Local dairy economies were undermined by centralized production
- Traditional knowledge and skills began disappearing
- Authentic products became adulterated or unavailable
What We're Reclaiming
The Bilona revival represents:
- Nutritional wisdom: Recognizing that traditional processing methods often preserved nutrition better than industrial alternatives
- Flavor complexity: Appreciating that real food tastes different from manufactured products
- Agricultural connection: Supporting farmers who raise animals traditionally
- Cultural continuity: Preserving knowledge that might otherwise be lost
- Health autonomy: Choosing nutrient-dense foods over marketed "health" products
Our Commitment to the Bilona Process
At 24 Karat Manthan, the Bilona method isn't a marketing term—it's our operational foundation.
What We Guarantee
Single-origin milk:
- Indigenous buffalo breeds from rural Rajasthan
- Free-grazing animals eating natural fodder
- No synthetic hormones or routine antibiotics
Authentic process:
- Same-day processing—no cold storage delays
- Full fermentation into curd using natural culture (jaman)
- 8-12 hours fermentation time
- Motor-powered wooden bilona churning (bi-directional, traditional motion)
- Small-batch slow-cooking on controlled flame by experienced artisans
- Zero additives, preservatives, or colorants
Complete transparency:
- We can tell you exactly where our milk comes from
- Our process is documented and consistent
- We welcome questions about our methods
Uncompromising quality:
- Every batch meets our nutritional and sensory standards
- Natural batch-to-batch variation is expected and embraced
- If it doesn't meet our standards, it doesn't get packaged
The Result
When you open a jar of 24 Karat Manthan Buffalo Bilona Ghee:
- The texture is dense and grainy—not artificially smooth
- The aroma is deep and nutty—not bland or chemical
- The color is natural creamy white to pale yellow—not artificially colored
- The taste is rich and complex—not flat or greasy
This is what the Bilona process produces. This is what ghee is supposed to be.
→ Experience authentic Bilona ghee for yourself
Conclusion: Process is Preservation
The Bilona method has survived for 5,000 years not because of tradition alone, but because it works.
Every step—from whole milk collection to slow cooking—serves a purpose. Every "inefficiency" compared to industrial methods preserves something that matters: nutrients, flavor, quality.
Modern food science is increasingly validating what traditional cultures knew intuitively: how you make something determines what it becomes.
Industrial ghee and Bilona ghee may share a name, but they are fundamentally different products. The fermentation that develops beneficial fatty acids. The gentle churning that preserves delicate structures. The slow cooking that protects heat-sensitive vitamins. None of this happens in a factory optimized for speed and cost.
When you choose authentic Bilona ghee, you're not just buying a product. You're supporting a process that prioritizes your nutrition over manufacturing convenience.
Your grandmother understood this. Now you do too.
Taste the Difference Process Makes
24 Karat Manthan Buffalo Bilona Ghee is made the way ghee was meant to be made—and you can taste the difference in every spoonful.
→ Shop Buffalo Bilona Ghee Collection
→ Try Our Bestselling 1 Litre Buffalo Bilona Ghee
Have questions about our Bilona process? Contact us or return to our complete guide to Buffalo Bilona Desi Ghee.
