ice cream manufacturing process and standards.ppt

Ice cream manufacturing

1. Ice cream
Method of manufacture

2. Cream:30%
Skimmilkpowder5-6%
sugar5-10%
Gelatin0.5-1%
Emulsifier0.5%.

3. SELECTION OF INGREDIENTS
↓
CALCULATING THE AMT. OF INGREDIENTS
↓
MIXING OF INGREDIENTS
↓
↓68.5 ºC -30 Min.(or) ; 85 ºC -25 SEC PASTEURIZATION OF MIX
↓
HOMOGENIZING THE -MIX
↓
COOLING AND AGEING THE MIX (0. -5 ºC)
↓
FREEZING (-4 TO -5 ºC]
↓
PACKING OF THE ICE CREAM → HARDENING
AND
STRORAGE (-23 to -29 ºC)

4. Selection of ingredients
 Ice cream ingredients may be grouped into dairy and nondairy
products
Dairy products:
Source of fat:
Sweet cream
Frozen cream
Plastic cream
Unsalted butter
Butter oil.
Source of milk-solids-not fat:
Skim milk
Skim milk powder
Condensed skim milk
Sweet cream buttermilk.
Sources of both fat and solids not fat:
Whole milk.
Whole milk powder
Condensed whole milk
Evaporated milk.

5. Non-dairy products:
Sweetening agents:
Cane sugar or beet sugar.
Corn sugar (dextrose)
Corn syrup solids (dextrose+maltose)
Corn syrup
Invert sugar (glucose +fructose)
Saccharin.

6. Stabilizers
Gelatin-of animal origin
Source-calf, pork skin or bone materials. Its gel
structure is measured by bloom test.
It is used at the rate of 0.25 to 0.5 %
-to form a gel in the mix during the aging periods
and the freezing process
-prevent the formation of large ice crystals in ice
cream
-contribute to the smoothness on texture and
firmness in body of the frozen product.

7. Stabilizers…
Sodium alginate–of vegetable origin
It dissolves properly only when added to the
mix at about 68-71ºC.
Smaller amount is needed to produce the same
stabilizing effect as gelatin.
-This product improves whipping ability
-Leaves a slightly cleaner flavour in the mouth.

8. Stabilizers…
Guar gum –of Indian origin.
Carageenan
Agar agar:
Carboxy methyl cellulose
Pectin

9. Emulsifiers
They are substances which help to form
emulsions.
Mono and Di glycerides
This product improves whipping ability
-Smoother body and texture of the frozen
product.

10. Flavours
Vanilla-this is the most popular flavour all over
the world. Vanilla flavouring is obtained from the
perennial climbing plant Vanilla Planifolia
Chocolate and cocoarank second only to vanilla
as flavoring of ice cream
Straw berry
Pine apple
Lemon
Banana
Mango
Orange

11. Colour
Yellow
Green
Pink

12. Fruits and nuts:
Apple
Banana
Mango
Pine apple
Grape
Almond
Pistachio
Cashew nut
Walnut
Groundnut

13. Figuring the mix
Ice cream mix may be divided into two groups,
namely simple and complex.
Complex mixes require the use of the Pearson’s
square, algebraic methods
algebraic method → symbols such as X,Y, Z is
used to represent the weights of dairy
ingredients required for a 100 kg batch of mix

14. Making the mix
All liquid ingredients are placed in a jacketed vat provided
with a power stirrer
skim milk powder, sugar, and stabilizers are added while
the liquid material is agitated before the temperature
reaches 49ºC.
If use
-gelatin----before the liquid material reaches
49ºC
-sodium alginate ----until liquid material has reached at
least 66ºC
-butter, plastic cream, frozen cream ----cut into small pieces
and melting

15. Pasteurization
The ISI specification for pasteurization
temperature for ice cream mix
Batch system-68.5ºCfor not less than 30min.
HTST method -80 ºCfor not less than 25 sec.

16. Homogenization of mix
The advantages of homogenization are
It prevents fat separation during ageing.
Produces more uniform ice cream with a smoother
texture.
Improves whipping ability
Shortens ageing period.
Decreases the risk of churning occurring in the
freezer

17. Cooling and ageing of mix
Cooling the mix immediately after
homogenization to 0-5ºCis essential
Ageing refers to holding the mix at a low
temperature for a definite time before freezing
The ageing temperature should not exceed 5 ºC.
The ageing time ---range from 3 to 4 hours

18. Ageing
Improves the body and texture of ice cream
Improves the whipping capacity
Increases maximum overrun
Increases melting resistance.