This document summarizes the process for manufacturing ice cream. It involves blending cream and milk products with sugar and flavorings. The mixture is pasteurized, homogenized, cooled, aged, and flavored. It is then frozen while incorporating air, which increases the volume. Bulk flavorings may be added after freezing. The frozen ice cream undergoes quality control testing before being packaged and hardened for storage. The final product is kept at cold temperatures until distribution.
2. Ice cream is a frozen dairy product made
by suitable blending and processing of
cream 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.
What is Ice-Cream?
3. Greater 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
sweeteners
0.2 to 0.5%
stabilizers and
emulsifiers
55% to 64% water
which comes from
the milk or other
ingredients.
6. Manufacturing Steps Of Ice-Cream
Blending the mixture
Pasteurization
Homogenization
Cooling & Aging
Flavouring
Freezing
Addition Of Bulky Flavourings
Quality Control & Packaging
Hardening & Storage
7.
8. 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 .
9. PASTEURIZATION
• Milk and cream are pasteurized to a specific temperature for
a pre-defined duration to kills off the majority of
microorganisms and increases the shelf 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 and cold milk mixture is piped through
on the other side.
• Time-temperature combination for Ice-cream
10. 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 creamier 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 which prevents them
from separating from the rest of the ice cream mixture
11. COOLING AND AGEING
• The ice cream mixture is then transferred to cool down at a
temperature of 0-4°C and moved to aging tanks for getting it
ready for the next step of freezing and aeration. 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 (40°F) under
continuous agitation. During the aging process, the following
occurs:
1. Stabilizer hydrate and takes full effect
2. Milk fat solidies and crystallize
12. FLAVOURING
• The ice cream is pumped to stainless steel vats where
flavorings 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 ingredients can be added prior to freezing,
to make sure the mix flows properly through the
13. FREEZING
• From the flavouring 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 or freon as a freezing agent.
• Continuous freezing facilitates faster freezing leading to very
small ice crystals.
• The increased volume of the ice cream due to incorporation
of the air is called overrun (80 – 100%).
14. ADDITION OF BULKY FLAVOURINGS
• 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.
15. QUALITY CONTROL & PACKAGING
Quality Control:-
• Every mixture is randomly tested during the production
process.
• Butterfat and solid levels are tested.
• The bacteria levels are measured.
• Each batch is also taste-tested before packaging
Packaging:-
• Automatic filling machines extrude ice cream into
16. 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 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
