DESIGN LAB PRESENTATION

PRESENTED BY-MADHUJA MUKHOPADHYAY

DAYEETA DEYSANTOSH KUMAR

PRESENTATION TOPIC

ICE CREAM MANUFACTURING ICE CREAM MANUFACTURING PROCESS DESIGNPROCESS DESIGN

INTRODUCTIONINTRODUCTIONVery little is known about the history of ice

cream. It was first discovered in EUROPE in the back of 4th century .roman emperor Nero ordered to bring some ice from mountain and to combine with fruits.

From europe it was introduced in u.s. countries and in 1776 the first ice cream parlor was opened in America.

NomenclatureNomenclature

• ". The name came from the phrase "iced cream" that was similar to "iced tea". The name was later abbreviated to "ice cream" the name we know today.

What is ice creamWhat is ice cream?• Homogenised dairy emulsions ice cream are

colloids containing fat droplets as disperesed phase.

• The mix emulsion is subsequently foamed .creating dispersed phase of air bubbles

• And finally it is frozen by forming another dispersed layer of ice crystals.

Design and considerationsDesign and considerations• Qualities those to be considered :- Taste – by adding sweetener it can be sweetened or not.

Texture- smooth and creamy texture is influenced by size,distribution,shape and no. of ice crystals and fluffiness is obtained by large amount of air.

Body- by adding proper amount of emulsifier crumbly,gummy body must be avoided.

Melt resistance- acid balance,salt balance and protein composition should be checked to avoid quick melting.

Flavour and colour- food flavour and colour are optional.

IngredientsIngredients• CREAMCREAM• LIQUID SKIMMED MILKLIQUID SKIMMED MILK• POWDERED MILKPOWDERED MILK• CONDENSED MILKCONDENSED MILK• RAW MILKRAW MILK• SUGAR AND SWEETENERSUGAR AND SWEETENER• GELATINGELATIN• YEASTYEAST• FLAVOURFLAVOUR• COLOURCOLOUR• EMULSIFIEREMULSIFIER• VEGETABLE FATSVEGETABLE FATS• FRUITS AND NUTSFRUITS AND NUTS• BUTTERBUTTER

PERCENTAGEPERCENTAGE OF COMPONENT

COMPONENT RANGE(%)

MILK FAT 10 -16

MILK SOLIDS NOT FAT 9-12

SUCROSE 9-12

CORN SYRUP SOLIDS 4-6

EMULSIFIERS /STABILIZERS 0-0.5

TOTAL SOLIDS 36-45

WATER 55-64

USEFULNESSUSEFULNESS OF INGREDIENTSOF INGREDIENTS• MILK FAT- provides creaminess and richness

to ice cream and contributes to its melting characteristics. Minimum fat content is 10%.

• The other milk solids consist of the protein and lactose in milk and ranges from 9 to 12%.

• The nonfat solids include whey which plays an important role in body and texture of ice cream by stabilizing the air.

• Sweeteners are provided to sweetness of icecream and also helps to lower the melting temperature.It helps the ice cream to scoop and eat.

• Stabilizers (alginates,gums)and gelatins are proteins and carbohydrates which add viscosity and control ice crystallization.

• Emulsifiers are used to keep the milk fat evenly dispersed in the ice cream during freezing and storage.it includes egg yolks and mono and di glycerides.

GENERAL MANUFACTURING GENERAL MANUFACTURING PROCESSPROCESS

PRODUCTION PROCESSPRODUCTION PROCESSBLEND &ICE CREAM BLEND &ICE CREAM

MIXTUREMIXTURE

ALL THE RAW SOLID AND ALL THE RAW SOLID AND LIQUID INGREDIENTS ARE LIQUID INGREDIENTS ARE BLENDED AND MIXEDBLENDED AND MIXED

PASTEURIZATION PASTEURIZATION

MIXTURE IS PASTEURIZED MIXTURE IS PASTEURIZED AT 155* F FOR 30 AT 155* F FOR 30

MINUTES TO INCRESE MINUTES TO INCRESE VISCOSITY FROM HIGH VISCOSITY FROM HIGH

FAT,DOLIDS,SWEETENER FAT,DOLIDS,SWEETENER AND EGG YOLKS IN AND EGG YOLKS IN

CUSTARD PRODUCTSCUSTARD PRODUCTS

HOMOGENISERHOMOGENISER

ICE CREAM MIX IS ICE CREAM MIX IS HOMOGENIZED AT 2500 TO HOMOGENIZED AT 2500 TO 3000 psi TO FORM A BETTER 3000 psi TO FORM A BETTER EMULSION AND EMULSION AND SMOOTHER,CREAMIER ICE SMOOTHER,CREAMIER ICE CREAMCREAM

• AGE THE MIX AGE THE MIXAGE THE MIX AT 40* F FOR AT LEAST 4 HOURS OR OVERNIGHT.AGING THE MIX COOLS IT DOWN BEFORE FREEZING

• In The Next Stage flavours are added in continuous stirred tank reactor. Vanilla,fruit,nut flavour,choclate flavour,cake and cookie flavours are mostly common.

FREEZERFREEZER

ICE CREAM MIX ICE CREAM MIX CAN BE FROZEN CAN BE FROZEN IN BATCH OR IN BATCH OR CONTINUOUS CONTINUOUS FREEZERS .FREEZERS .

OVERRUN AND FRUITS MIXINGOVERRUN AND FRUITS MIXING• IN BATCH FREEZER THERE IS A ROTATING

BARREL WHICH IS ONE THIRD TO ONE HALF FULLL OF ICE CREAM,AS THE BARREL TURNS THE AIR IN THE BARREL IS INCORPORATED INTO THE ICE CREAM MIX.THE ADDITION OF AIR IS CALLED OVERRUN WHICH CONTRIBUTES LIGHTNESS OR FLUFFINESS IN ICE CREAM

• AT THE POINT OF DISCHARGE FROM THE FREEZER (DRAW TEMPERATURE),ONLY 50% OF THE WATER IN ICE CREAM IS FROZEN.

FRUITS MIXING FRUITS MIXING

• Fruits,swirls,and any bulky type of flavourings (nuts,candy pieces)are added at this time or they will stop making the ice cream smooth enough.

HARDENINGHARDENING• One method of hardening of ice cream is called a

roller bed process. The ice cream packages are placed on a roller type conveyor in a very cold room of temperature 30°F (-34°C), where cold air is circulated by blowers create wind chill of -60°F (-51°C).

• Second method is Tri-Tray system. It provides moving trays upon which the ice cream is disposed. The trays move within the cold room and cold air is blown around the ice cream. This movement results in decreased hardening time.

PACKAGINGPACKAGING• The cartons are then filled with

premeasured amounts of ice cream at the rate of 70-90 cartons per hour.

• The machine then places a lid on each carton

• A ink jet that spray-paints an expiration date and production code onto each carton

• Then cartons move through the bundler, a heat tunnel that covers each cup with plastic shrink wrapping.

STORAGE AND DISTRIBUTIONSTORAGE AND DISTRIBUTION• The finished product if kept at around -20c to-

25c will have a shelf life of 12-18 months. A distribution temperature of -25c to-30c is recommended as fluctuations around this area cause less danger.

RISKS OF CONTAMINATIONRISKS OF CONTAMINATION• Important source of contamination in ice cream as

they are added after mix is

• Fruits – canned, fresh and frozen and should be of satisfactory in microbiological standards particularly canned fruits pasteurized

• Fresh & frozen fruits – may contain Yeasts. Nuts may be infected with moulds.Coconuts may be contaminated with Salmonellae. Walnuts-Mould and parasitic infection

SAFETY MEASURESSAFETY MEASURES• Tests:

visual inspection,SPC,Coliform,ß-haemolytic streptococci,Yeasts & Moulds.

• Canned / fresh nuts are sterilized in ethylene oxide & CO2 in1:9 or boiling in sugar solution (50%) followed by drying at 2500C for few minutes.

• Coconuts should be heat treated when desiccated

SUPPLIERSSUPPLIERS• BEN AND JERRY• PERRY’S ICE CREAM• BREYER’S• EDDY’S• HAAGEN-DAZS

CONCLUSIONCONCLUSION

• Something seeming so simple and yet still so complex can still be enjoyed as it has been for centuries in pure sweet bliss ,but overall it has become more exciting after knowing the actual process of making.