Ice Cream

What is Ice-Cream? 

Ice cream  is a frozen dairy products made by suitable blending and processing and other milk products, together with sugar and flavour,  with or without stabilizer or colour, and with the incorporation of air during the freezing process.

• Stabilizer and emulsifier not more than 

-10% Milk fat

-3.5% protein 

-36% Total solids.

• Starch up to 5 % 

• Air as important ingredient. 

• Provides light texture to it.

• Air make up 30% -50% volume. 

Composition 

– Greater than 10% milkfat and usually between 10% and as high as 16% fat in some Premium ice cream.

– 9 to 12% milk solids -not- fat: This component also known as the serum solids, contains the protein (casein and whey protein) and carbohydrates (lactose) found in milk.

– 12 to 16% sweetener: usually a combination of sucrose and glucose based corn syrup sweeteners.

– 0.2 to 0.5% stabilizer and emulsifier.

– 55% to 64% water which comes from milk or other ingredient. 

    Classification -

No standards classification of ice cream has yet been       adopted by the industry,  even in develop countries. However,  some of the important frozen  dessert can be classified as follows:

1. Plain ice- cream -

An ice cream in which colour and flavour ingredients together amount to less than 5% of the volume of the unfrozen ice cream . Example: vanilla and coffee  Ice-Cream. 

2. Nut and chocolate Ice-Cream -

• Ice cream  flavour with cocoa or chocolate. 

• Nut: ice creamcontaining nuts, such as almonds,  cashewnut, etc. With or without additional flavouring or colour. 

3. Fruits Ice-Cream -

• Ice-Cream  Containing Fruits,  with or with additional fruit flavouring or colour. 

• Fruits such as strawberry,  pineapple, mango, banana etc, may be fresh,  frozen packed,  canned or preserved.

4. Ices Ice-Cream - 

• Made of fruit juice, sugar and stabilizer. 

• With or without additional fruit acid, colour, flavouring or water, and frozen to the consistency of ice cream. 

• Contains  28 % to 30% sugar, 20 to 25% over run and no dairy products. 

Advantage -

1. Milk fat:

 ▪︎Enrich  the flavour and produces characteristics smooth texture and helps give body to the ice cream. 

2. Milk Solid Not Fats: 

▪︎Improve the texture and comparatively cheap source flavour. 

▪︎A higher overrun without snowy flaky texture. 

3. Stabilizer:

▪︎ Very effective in smoothsmoothening  the texture and       giving body to the products. 

4 .Total Solids: 

        ▪︎Makes it smoother and more nutritious.

5. Sugar:

▪︎Cheapest  source of solids  and improve the texture and flavour. 

     Limitations -

1.  Milk fat:

         ▪︎Fat slightly hinders, rather than improve the,  whipping. 

2. Stabilizer -                  

         ▪︎ Excess body and melting resistance. 

3. Total  Solids-

          ▪︎Heavy , soggy or pasty body and Cooling effect  is insufficient high.   

4. Sugar-

         ▪︎  Excessively  sweet and lowers whipping effect.

         ▪︎    Required a lower temperature for proper  hardening. 

               Manufacturing of Ice-Cream-

     Steps of manufacture  ice cream-

● Blending the mixture

●  Pasteurization 

● Homogenization

● Cooling and agent

● Flavouring 

● Freezing 

● Addition of Bulky Flavouring 

● Quality control &  packaging 

● Hardening & Storage 

Blending  the Mixture-

● The milk arrives at the ice cream plant in refrigerated tanker trucks,from local dairy farms, are 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.

Pasteurization -

● Milk and cream are pasteurized to as specific temperature for a pre- defined  duration to kill off the majority of microorganisms and increase shelf life of the product. 

● Hot water, approximately  182° F (83° C), flows on one side of the plates and cold milk mixture is piped through on other side.

● Time temperature combination for ice cream. 

Homogenization -

● Ice cream  mix is homogenized (2500 to 3000 psi) to decrease the size of fat globules  from the milk and cream  to identical size for addition of more stability to ice cream  and develop a smoother and creamer ice cream instead of large  clumps.

● By application of intensive air pressure, homogenized ensures that the emulsifier  and stabilizer  are well blended and evenly distributed  which  prevent  them from  separating from the rest of the ice cream  mixture.

Cooling and Ageing-

● Ice cream mixture is that transfer to cool down at a   temperature of 0-4°C and moved to ageing tanks for getting  it ready for next step of freezing and aeration. 

● Mix is aged between 4- 24 hours at 2- 5°C(40°F) .

  During ageing process, following occurs;

 1 stabilizer hydrate and takes full effect 

 2. Milk fat solidies and crystalize.

Flavouring -

●Flavour added by experience to obtain pleasing flavour.         and   colour should correspond to the flavour. 

● Only liquid ingredient can be added prior to freezing, to        make sure  mix flows properly through the continuous.         freezing  equipment. 

Freezing -

● From  the flavouring tanks, mix is pumped  to the                    continuous where air whipped in it is frozen between.           temperature of -3 °C and  -6°C using liquid ammonia or.          freon as a freezing  agent.

● The increased  volume of the icecream  due to                            incorporate of air is called overrun (80 - 100%).

Addition of Bulky Flavouring -

● If chunks of food such as strawberry  or cookie pieces.        are to be added to the ice cream , dpfrozen mixture  is.      pumped to a fruit feeder.

● Fruits,  swirls,and any Bulky type  of  flavouring  ( nuts,     candy, pieces,etc) are added. Ingredient can not be.             added before freezing or they would interfere with  the smooth flow of the  mix through the freezer.

Quality Control & Packaging -

Quality control-

● Every mixture  is randomly  tested during  the  production  process.

● Butterfat and solid level are tested.

● The bacter level  are measured.

Packaging-

● When ice  cream  is drawn from freezer put into container.     that give it desired form and size for convenient.                       handling during hardening,  shipping and marketing                process.

Hardening & Storage -

● The 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 packaged and 30       minutes for smaller packages.

● Hardening complete  ice cream  freezing  process and.             stabilizer  the product  so that  it does not melt down too       quickly.