Ice Cream Processing

Step By Step Production Of Ice Cream

1. I C E - C R EAM P R O C E SSING

2. Ice cream is a frozen dairy product made by suitable blending and processing o f cream and other milk products , together with sugar and flavour, with or without stabilizer or colour, and with t h e incorporation of air during the freezing process. W h a t i s I c e - C r e a m ?

3. G reater than 10% milkfat and usually between 10% and as high as 16% fat in some premium ice creams 9 to 12% milk solids-not-fat : this component, also known as the serum solids, contains the proteins (caseins and whey proteins ) and carbohydrates (lactose) found in milk 12 to 16% sweeteners: usually a combination of sucrose and glucose-based corn syrup sweeten e r s 0.2 to 0.5% stabilizers and emulsifiers 55% to 64% water which comes from the milk or other ingredients . C O M P O S I T I O N

4. FSSAI Standards F or I ce - C ream

5. M a n u f a cturing S t e p s O f I ce - C ream B lending t h e m i x t u re P asteurization H omogenizatio n C o o l i n g & A g i n g F l a v o u r i n g F reezing A d d i t i o n O f B u l k y F l a v o u ring s Q u a l i t y C o n t r o l & P ackaging H ardening & S t o r a g e

6. B L E N D I NG T H E M I X T U R E The milk arrives at the ice cream plant in refrigerated tanker trucks from local dairy farms a r e pumped into storage silos that are kept at 36° F (2°C). Pipes bring the milk in pre-measured amounts to stainless steel double jacketed vats and they have very efficient agitators to facilitate uniform distribution of heat . Premeasured amounts of m i l k p o w d e r , suga r , and additives are blended with the milk for 6 - 8 minutes .

7. P A S T E U R I Z A T I O N Milk and cream are pasteurized to a specific temperature for a pre- defined duration to kills off the majority of microorganisms and increases the she l f life of the product. It also prevents milk fat in the cream from becoming rancid through oxidation. The blended mixture is piped to the pasteurization machine , which is composed of lce Cream of a series of thin stainless steel plates. Hot water, approximately 182°F (83°C), flows on one side of the plates a n d cold milk mixture is piped through on the other side. Time-temperature combination for I ce-cream HTST method - 80 ° C for not less than 25seconds LTHT method -68.5 ° C for not less than 30 min

8. H O M O G E N I Z A T I O N Ice cream mix is homogenized (2500 to 3000 psi) to decrease t h e s i z e o f fat globules from the milk and cream to identical size f o r a d d i t i o n o f more stability to ice cream and d e v e l o p a smooth e r a n d c r e a m i e r ice cream instead of large clumps . By the application of intensive air pressure, homogenizer ensures that the emulsifiers and stabilizers are well blended and evenly distributed w h i c h prevents them from separating from the rest of the i ce cream mix t u r e before it is frozen.

9. C O O L I N G A N D A G E I N G The ice cream mixture is then transferred to cool down at a temperature of 0-4 ° C and m o v e d t o a g i n g t a n k s f o r get t i n g it ready for the next step of freezing and aerat i o n. The mix is cooled fast so that no growth of microorganisms can take place . The mix is aged for between 4-24 hours at 2-5°C ( 4 ° F ) under continuous agitation. During the aging process, the following o c c u r s : 1. Stabilizer h y d r a t e and takes full effect 2. M i l k fat solidies and crystallize 3 .The viscosity of the mix increases and i m p r o ve its whipping quality .

10. F L A V O U R I NG The ice cream is pumped to stainless steel vats w h e r e f lavorings are piped into the vats and blended thoroughly. Flavours are added by experience to obtain pleasing flavour and colours should correspond to the flavour . Only liquid i n g r e dients can be added p r i o r t o freezing, to make sure the mix flows properly through the c o n t i n u ous freezing equipment.

11. F R E E Z ING From the f lavouring tanks, the mix is pumped to the continuous freezer where air is whipped in as it is frozen between the temperatures of -3°C and -6°C using liquid ammonia o r f r e o n a s a freezing agent . Continuous freezing facilitates faster freezing leading to very small ice crystals. The increased volume of the ice cream due to incorporation o f the air is c a l l e d overrun (80 – 100%). When the mixture leaves the freezer, it f o r m s the soft-serve consistency ice cream.

12. A D D I T I O N O F B U L K Y F L A V O U RING S If chunks of food such as strawberry or cookie pieces are to be added to the ice cream, the frozen mixture is pumped to a fruit feeder. The mixture then moves to a blender where the chunks are evenly distributed . Fruits, swirls, and any bulky type of flavorings (nuts, candy pieces, etc.) are added . These ingredients can not be added before freezing or they would interfere with the smooth flow of the mix through the freezer. Mixing in bulky flavorings after freezing also prevents damage to the pieces and allows them to remain whole or in large chunks.

13. Q U A L I TY CONTROL & P A C K A G I N G Quality Control :- Every mixture is randomly tested during the production process . Butterfat and solid levels are tested. The bacteria levels are measured. Each b a t c h is also taste-tested b e f o r e p a c k a g i n g P a c k a ging :- Automatic filling machines e x t r u d e i c e c r e a m i n t o preprinted moulds with different shapes or card board cartons wrapped using glassine (oil resistant paper).

14. H A R D E N I NG & S T O R A G E T he already packaged ice cream is exposed to a temperature range of -20°C to -40°C in the hardening tunnel for between 6 – 8 hours for larger packages and 30 minutes for smaller packages. Hardening completes the ice cream freezing process and stabilizes the product so that it does not melt down too quickly. The hardened ice cream is then stored at temperatures of ≤25°C. The cartons are then stored in refrigerated warehouses until they are shipped to retail outlets. The storage shelf life mosty a v e r age s about 6 - 9 months o f p r o d u ction .

15. M E L T D O W N B E G I N S . . . E n j o y i t b e f o re i t m e l t s