Presentation on industrial training at Rollick Ice Cream Manufacturing Plant

1. PRESENTATIONON INDUSTRIAL
TRAINING
AT PRESTIGE ICECREAM PVT. LTD.
(ROLLICK)
NAME- SREEJITA DUTTA
CLASS ROLL NO. 16/FT/14
UNIVERSITY ROLL NO.- 10303416014
REPORT AND SEMINARON INDUSTRIALTRAINING (FT-792)
TRAINING PERIOD- 25.06.2019TO 24.07.2019

2. CONTENTSOF
THE
PRESENTATION
 Ice cream vs. Frozen Dessert
 Products and machines at PIPL
 Flowchart of the manufacturing process
 Mix preparation, packaging and storage/ distribution
 Cleaning in Place
 SomeTechnical Parameters associated with Frozen
Dessert
 Quality Control and Quality Assurance Parameters
 Conclusion

3. ICECREAM &
FROZEN
DESSERT
Ice cream
• Freezing of
pasteurized
milk
• With or
without
addition of
sugar, nuts,
nuts, etc.
• At least 10%
fat content
and 20%
milk solids..
Frozen
Dessert
• Freezing
pasteurized
milk
• Usage of
edible
vegetable
fat.
• 5-8% fat
content

4. PRODUCTS
AND
MACHINESAT
PIPL
STICK MACHINES CONE MACHINES
10k 13k 17k 10k 13k
Rollick Bon
Bon
Rollick Rabdi
Kulfee Stick
Rollick
Chocobar,
Rollipop Litchi,
Mango,
Chatpata Aam,
Orange, HUL
Chocobar,
Mother Dairy
Choco Bar.
Rollick Fruit
and Nut,
Rollick
Sundae,
Mother Dairy
Chillz.
Rollick Choco
Cone, Rollick
Pista Cone,
Rollick Butter
Delight, HUL
Minicones.

5. PRODUCTS
AND
MACHINESAT
PIPL
CUP MACHINES FRUIT FEEDER GALLON
Small Cups BigCups For
Cones
For Cup (Manual
filling)
Rollick
Vanilla,
Rollick
Butter
Delight,
RollickTwo
in One,
Mother
Dairy
Vanilla
Cups
Rollick
Vanilla,
Rollick
Butter
Delight,
RollickTwo
in One,
Mother
Dairy
Vanilla Cups
Rollick
Rabdi
Cone
Rollick
Daab Malai
RollickVanilla,
Chocolate,
Butter Delight,
Butter Scotch.

6. GENERAL
FLOW
DIAGRAM
Selection of
ingredients
Standardization
Mix
preparation
Pasteurization
(80C for 30
mins)
Homogenisation
(2000psi and
500psi)
Cooling and
ageing (4C)
Freezing
Packaging
Hardening
(-25C to -
30C)
Storage in
cold room (-
18C)
Distribution

7. RAW
MATERIALS
COMPONENT INGREDIENT
USED
ROLE REQUIREMENT
Fat Edible vegetable
fat
Enriches and
mellows the ice
cream,
contributes to
the body and
melting
resistance
Min 10.0% milk
fat,
Vegetable fat
contributes to
about 5-8% fat.
Milk SNF Skim milk
powder
Makes compact
and smooth ice
cream, excess
causes
sandiness.
Min. 36.0%
Sugar Granulated sugar Sweetness, to
increase
acceptability.
Max. 15.0%
Stabilizer Prevent
formation of
large ice crystals,

8. PREPARATION
OF MIX
Mix in
pasteurization
vat
Balance tank
(68C)
PHE
Regeneration
(70C)
Homogenization
(2000psi)
Homogenization
(500psi)
PHE Heating
(80C)
FDV open at
80C
PHE Cooling
(40C)
PHE Glycol
(4C)
Ageing Vat (4C
or below)
Ingredients to mix in pasteurization
vat alter as per product specification.
e.g. Stabilizer & emulsifier-
All purpose mix- mono and
diglycerides of fatty acids
Popsicle-Carboxy methyl cellulose

9. FROM
AGEINGVATS
Blending
Vat
Dosing
Machines
To
product
Stick Machine
Cone Machine
Cup Machine
Gallon
Blending vats for
addition of flavours
and colours to plain
mix and citric to
popsicle mix.

10. FROM
AGEINGVATS
Blending
Vat
Dosing
Machines
To
product
Stick Machine
Cone Machine
Cup Machine
Gallon
Mix is transferred
to dosing machines
from which they
are finally dosed
into the respective
products.

11. STICK
MACHINE
(17K)
SPECIFICATIONS
Defrost pump
• 24C to 31C
steam
• For easier lifting of
ice cream from
frozen moulds
Brine (Calcium
chloride solution)
• Specific gravity-
1.27 to 1.28
• pH- around 6
• Temperature is
-38° to -40°C
Continuous Freezer & Molder

12. STICK
MACHINE
(17K)
FLOWCHART
1. FILLING MIX INTO MOULDER 2. STICK INSERTION 3. DIPPING INTO CHOCOLATETANKS
4. STICK ICE CREAMSTO BE PACKED5. PACKAGING

13. STICK
MACHINE
(17k)
TESTING
PARAMETERS
Temperature of liquid chocolate
Weight of product with and without
chocolate
Chocolate consumption per piece
Core temperature of ice cream
Volume and length of final product
Gross and net weight recording

14. CONE
MACHINE
(13K)
Mix in ageing
vat
Blending vat
Addition of
flavour and
colour
Continuous
freezer
Dosing
Topping
(optional)
Nut dispenser
(optional)
Lid loading
Press/
crimper
PrintingExpulsion
Hardener (-
20 to -25C)
Cold storage
(-18C)

15. CONE
MACHINE
(13K)
Temperature of liquid
chocolate
Weight of chocolate
spray in cone
Weight of nuts/ choco
chips in ice cream
Gross and net weight of
product

16. OVER RUN
 Defined as the volume of ice cream obtained in excess to the
volume of mix used.
 Caused due to incorporation of air along with quick freezing.
 Necessary for textural properties of the ice cream.
 DEFECTS-
Excessive
over run
Snowy, flaky
and
unpalatable
Structure will
collapse
Low over
run
Icy and heavy
Standard overrun
maintained in the
industry is 115%
overrrun, i.e., if 100l mix
is prepared, the volume
of mix obtained from
100l mix after air
incorporation will be
215l of ice cream.

17. HARDENER
ANDCOLD
ROOM
PRODUCT TIME (hrs) CORE
TEMPERATURE
(C)
HARDENING
TEMPERFATURE
(C)
Cone or cup 2.5- 3 -12 to -14
-20 to -25Block 18 -16
Gallon 24 -16
The difference between hardener and the
cold room is-
•Temperature in hardener is much lower
than that of cold room.
•The air in the hardener is constantly
circulated so that it reaches the core of the
product in order to properly harden it,
whereas in a cold room constant
temperature is maintained.
(a)
(b)

18. CRITICAL
CONTROL
POINTS (CCPs)
 Operational step in the food production line in which control can
be applied in order to prevent or eliminate a food hazard or at
least reduce it to an acceptable limit.
 The CCPs are maintained in the production line:
a) Pasteurization of mix at 80°C for 30 minutes.
b) Ageing vat temperature should be 4°C or below.
c) Passage of mix through filter and magnetic filter after
pasteurization.
d) Hardener temperature maintained from -20° to -25°C.
e) Cold storage temperature maintained at -18°C.

19. CLEANING IN
PLACE (CIP)
 Method of cleaning the interior surfaces of pipes, vessels, process
equipment, filters and associated fittings, without disassembly
EQUIPMENT CHEMICAL USED
Pasteurizer vat,
venturi, PHE, ageing
vat and blending vat
Pure NaOH flakes
Nitric acid (weekly
twice)
All filling machines Detpol
Continuous freezer SU 157
All stick machine
molds
Satol
All equipments Alstasan Active
(Sanitizing agent)
Fumigation SU 319

20. LABORATORY
TESTING
PARAMETERS
Raw
materials
SMP
Colour
Production
line
Brine
Liquid
chocolate
Final
product
Plain mix
Finished
ice cream

21. QUALITY
CONTROL
PARAMETERS
Viscosity
Specific Gravity
Total Solids
Protein Content
Sensory test is also carried out.

22. QUALITY
CONTROL
PARAMETERS
Viscosity
Specific Gravity
Total Solids
Protein Content
Requirements- B4
cup, stopwatch
and sample.

23. QUALITY
CONTROL
PARAMETERS
Specific Gravity
Viscosity
Total Solids
Protein Content
Requirements-
Hydrometer,
sample.

24. QUALITY
CONTROL
PARAMETERS
Total Solids
Specific Gravity
Viscosity
Protein Content
Requirements-Aluminium Disc,
Hot air oven, Hot plate,
Dessicator, weighing machine
and sample.
Calculating formula-
TS= [(W3-W1)/(W2-W1)]*100
StandardTS of plain mix lies
between 31-33%.
W1= wt. of empty disc
W2= wt. of empty disc+mix before putting into hot air oven(max.=5gm)
W3= wt. of empty disc+mix after taking out from hot air oven

25. QUALITY
CONTROL
PARAMETERS
Protein Content
Total Solids
Specific Gravity
Viscosity
Requirements- Distilled water,
potassium oxalate, 0.1 (N)
NaOH, formaldehyde,
phenolphthalein, burette,
pipette, conical flask and
sample.

26. TESTING
PARAMETERS
OF
PACKAGING
BOXES
Determination of bursting
strength in Digital Bursting
StrengthTester
Determination of dimensions of
boxes according to company
specific guidelines

27. QUALITY
ASSURANCE
PARAMETERS
• Glass policy
• Wood policy
• Drop policy
• Jewellery policy
• Visitors’ policy
Policies
• Trimmed nails
• Usage of head
caps
• Safety shoes
• Clean shave
• Handwash
GHP

28. CONCLUSION
During the training period, I was exposed to an professional
industrial environment that in which I had to finish my daily
allotted task along with learning various conceptual as well as
technical concepts.
I found the training environment comfortable and a good source
to gather knowledge, both from the production floor as well as the
laboratory.
Also, during the duration of the training, I came to know how our
theoretical knowledge correlates the practical application and at
the same, also varies at times.

29. THANKYOU