In Indian villages, the Bilona method isn't just a cooking process; it’s a time-honored ritual. Unlike modern commercial ghee, which is often made by heating cream (malai) directly, Bilona ghee is made from cultured curd.
This traditional process preserves the nutritional integrity of the fats and results in a distinctively nutty aroma and grainy texture.
The 5-Step Traditional Process
1. Milking and Boiling
The process starts with high-quality A2 milk from local breeds (like Gir or Sahiwal cows). The milk is boiled in large clay pots over a slow fire, usually using cow dung cakes or wood. This slow heating gives the milk a slightly smoky flavor.
2. Curdling
Once the milk cools to room temperature, a spoonful of existing curd (starter) is added. It is left to sit overnight to transform the entire batch into thick curd. This fermentation step is crucial because it develops healthy probiotics and breaks down lactose.
3. Churning (The "Bilona")
This is the namesake step. The curd is placed in a large earthen or wooden pot. A wooden churner (Ravi or Bilona) is lowered into the pot.
- A rope is wrapped around the churner.
- The person pulls the rope ends back and forth, spinning the churner bi-directionally.
- Cold water is added gradually until the makhana (white butter) separates and floats to the top.
4. Washing the Butter
The hand-churned butter is hand-gathered and washed multiple times with water to remove any remaining buttermilk (chaas). This ensures the final ghee has a long shelf life and doesn't spoil easily.
5. Slow Heating
The butter is placed in a heavy-bottomed pot over a low flame. As it melts, the water evaporates and the milk solids settle at the bottom. Once the liquid becomes golden and transparent and a distinct aroma fills the air, the ghee is ready.